CN102218866B - Manufacturing method of vehicular interior decorating material - Google Patents

Abstract

The invention discloses a manufacturing method of vehicular interior materials. The method comprises the steps of preparing stampable sheets (1) having thermoplastic resin, reinforced fiber and heat-expansibility particles in a dispersed way; placing cuticle materials (2) on the stampable sheets and heating as well as compressing the cuticle materials through a flat type hot press (21); pressing the cuticle material on the surfaces of the stampable sheets to manufacture a pasting material (3) formed by pasting the cuticle material on the stampable sheets; opening the hot press and making the heat-expansibility particles of the stampable sheets of the pasting material expand and form an expanding pasting material (4) with a set thickness; placing the expanding pasting material in a cold press for pressurization and shaping; and thus forming a vehicular interior decorating material. By the method, an attaching material which has a increased thickness due to the heat-expansibility particles contained in the stampable sheets when sheet materials are expanded and can fully ensure the rigidity of the pasting material formed by the stampable sheets and the cuticle materials and the caking property between the stampable sheets and the cuticle material is obtained.

Description

The manufacture method of vehicular interior decorating material

Technical field

The present invention relates to the manufacture method of a kind of rigidity and all good vehicular interior decorating material of caking property, particularly about in the manufacture method by can the base material that formed of punching press sheet material (stampable sheet) be fitted surface layer material and the vehicular interior decorating material formed.

Background technology

Can punching press sheet material be a kind of composite formed by the fortifying fibre such as glass fibre, carbon fiber and thermoplastic resin etc., and be the fine sheet being suitable for being formed adding the laggard row punching press of thermal expansion large-scale shaping material.Thisly can be configured as complicated shape by punching press sheet material, and its formed products has very high intensity and lighter in weight, thus this just can be committed to practicality in fields such as automobile interior trim materials by punching press sheet material in recent years.Because this can contain the fortifying fibre to almost ultimate fibre state of fibrillation by punching press sheet material, if so be again heated to more than the fusing point of resin and do not arrive the temperature of decomposition point, then will be produced resilience by the fortifying fibre that pitch pocket binds, and become the intumescent sheets of more than the several times being expanded to original thickness.This intumescent sheets is supplied to compression-molding apparatus, vacuum forming device or air-pressure forming device etc., and the light weight that just can complete regulation shape can the shaping of punching press sheet material.That is, make die clearance during shaping be greater than theoretic throat (thickness when voidage of product is zero) by regulating, just can obtain that density ratio is above-mentioned can the little and expansion-molded product in the more much higher hole of face rigidity (patent document 1) of punching press sheet material.

Above-mentioned expansion-molded product are that a kind of fortifying fibre with disordered orientation is wrapped around one another, and thermoplastic resin adhesion by melting and solidification, the porous body of three-dimensional mesh structure that is combined into.Because the rigidity of these expansion-molded product and elastic modelling quantity and thickness cube product be directly proportional, so in order to improve its rigidity, the method improving elastic modelling quantity or increase its thickness is effective.The method increasing expansion-molded product thickness has: increase become fine sheet can punching press sheet material thickness method and improve can the expansile method of punching press sheet material.But, increase and can the thickness of punching press sheet material self weight can be caused to increase, thus unsatisfactory.Further, because the dilatancy of punching press sheet material the rebound effect of fortifying fibre can will be relied on, so its expansile raising is limited.

For this reason, propose and a kind ofly there is heating to being mixed in punching press sheet material and after the thermal expansivity particle of the character of expansions, making it to expand to its heating, do not force the technology (such as, patent document 2) of increase sheet thickness with not gaining in weight thus.At this, above-mentioned thermal expansivity particle generally refers to the particle that diameter is the coreshell type structure of about tens of μm.The following particle of many uses, that is: core is liquid hydrocarbon, and shell is formed by the thermoplastic resin with gas barrier property, if to its heating, hydrocarbon will vaporized expanding, and thermoplastic resin can deliquescing, thus to expand into diameter be about hundreds of μm spherical.

When above-mentioned expansion-molded product are used for the roof material etc. needing to have ornamental decoration material such as automobile, general being formed in by above-mentioned expansion-molded product above-mentionedly punching press sheet material (or intumescent sheets) can overlap the laminating material (such as, patent document 3,4) being fitted with decoration surface layer material.Be strict with the automotive trim material formed by this laminating material and not only will have high rigidity, but also will high bond strength can be had between punching press sheet material or intumescent sheets (below, can punching press sheet material and intumescent sheets be all called " base material ") and surface layer material.

The coating technique of this laminating material expected now is: do not allow sticker between intumescent sheets and decoration surface layer material, realizes laminating integration by means of only heating press molding.But, there is not the simple coating technique of tack coat between intumescent sheets and surface layer material under, contact area between the intumescent sheets that voidage is larger and surface layer material is less, and adhesion composition during laminating is only the thermoplastic resin being present in intumescent sheets top layer, and the swelling state limit maintaining intumescent sheets in order to limit forms laminating material, forming pressure during laminating is less, reduce from the inner resin soaking into (supply) to surface of intumescent sheets for this reason, enough be close to intensity so cannot expect to have between intumescent sheets and surface layer material.When particularly containing thermal expansivity particle in intumescent sheets, because this thermal expansivity particle can become to hinder between intumescent sheets and surface layer material form good close-burning main cause, if so it is generally acknowledged and do not use sticker just cannot be committed to practicality.

For this reason, general way allows tack coat be positioned at intumescent sheets realize integrated with the chien shih of surface layer material.Such as, in patent document 3, under the state allowing hot melt adhesive adhesion formulation sticker between intumescent sheets and surface layer material, carry out press molding, the technology improving the close property of intumescent sheets and surface layer material is thus known.Under this prior art, heating furnace is put into after punching press sheet material can arranging hot melt adhesive adhering agent layer, thermal expansivity particle is allowed to bubble and become intumescent sheets and hot melt adhesive sticker is melted, then take out from heating furnace, hot melt adhesive sticker on intumescent sheets is still set up surface layer material for the situation of molten state is transferred, then puts into cold stamping die and form.Under the prior art, although surface layer material is fitted on base material with hot melt adhesive sticker, but because the hot melt adhesive sticker melted is impregnated in the space of base material and porous intumescent sheets, thus this hot melt adhesive sticker does not remain between intumescent sheets and surface layer material, is not namely formed so-called effective containing adhering agent layer.For this reason, exist between intumescent sheets and surface layer material and not there is enough close property, and the problem of poor air permeability.Therefore, hot melt adhesive adhesion formulation sticker will be increased, or allow other film between intumescent sheets and surface layer material.In this case, weight can be caused to increase and cost raising, thus unsatisfactory.Also have, this thermal expansivity particle hinders by forming good close-burning main cause, even if therefore use as mentioned above hot melt adhesive adhesion formulation sticker also cannot obtain enough adhesion strengths between the intumescent sheets that expands of punching press sheet material and surface layer material owing to can become.

Patent Document 4 discloses a kind of technology base material being implemented to following technique, that is: such as can when punching press sheet material in making, thermal expansivity particle is allowed to concentrate on one side side in advance, can carry out heating and make thermal expansivity particle expansion and after becoming intumescent sheets by punching press sheet material again to thermal expansivity particle uneven distribution, surface layer material is placed on the unconcentrated surface that there is the side of thermal expansivity particle of this intumescent sheets, then carries out press molding with mould.

A kind of method manufacturing expansion-molded product is Patent Document 4 discloses at this.That is: allotment allow fortifying fibre, thermoplastic resin and thermal expansivity uniform particle be dispersed in containing micro-bubble containing surfactant aqueous medium in and formed bubble liquid, this bubble liquid is manufactured paper with pulp, form net (web), making after then heating this net, pressurize and cool can punching press sheet material.When the expansion-molded product of manufacture, this can be heated by punching press sheet material, make above-mentioned thermal expansivity particle expansion and become intumescent sheets, press molding is carried out with cold stamping die after this intumescent sheets places surface layer material, then cooled, thus just produced the expansion-molded product being provided with surface layer material at one of intumescent sheets on the surface.Also disclose following technology especially.That is: when carrying out above-mentioned manufacturing paper with pulp, by attracting to carry out deaeration, make thermal expansivity particle set in any surface side of net, just produce thus thermal expansivity particle set in one side side can punching press sheet material, when through heating make this can punching press sheet material expand manufacture intumescent sheets when, make thermal expansivity particle set in any surface side of intumescent sheets.Further, make surface layer material be layered in the side side that there is thermal expansivity particle hardly of intumescent sheets, then carry out press molding with mould, thus obtain the expansion-molded product being fitted with surface layer material on base material.But, under this technology, in order to allow thermal expansivity particle set in one direction, need to adopt special method for making, and in order to make it concentrate in one direction, will be restricted in raising rigidity.

Patent document 1: Japanese Laid-Open Patent Publication JP 60-179234 publication

Patent document 2: Japanese Laid-Open Patent Publication JP 2000-328494 publication

Patent document 3: Japanese Laid-Open Patent Publication 02-045135 publication

Patent document 4: Japanese Laid-Open Patent Publication JP 2006-342437 publication

Summary of the invention

-invent technical problem to be solved-

Under the prior art disclosed in patent document 3,4, because adopt following operation, that is: net being made in advance can punching press sheet material, this can be heated by punching press sheet material, allowing can thermal expansivity particle expansion in punching press sheet material and produce intumescent sheets, then press molding is carried out with mould after placing surface layer material on this intumescent sheets, so likely cause the bonding between intumescent sheets and surface layer material not firm.Further, if increase the weight of base material, though rigidity can be guaranteed, lightweight cannot be realized.That is, when can punching press sheet material included thermal expansivity particle, caking property between base material and surface layer material is not enough, and thus obtained shaping material cannot meet rigid requirements.At present, utilize and can include thermal expansivity particle and achieve light-weighted sheet material by punching press sheet material, be difficult to obtain by fully guaranteeing the vehicular interior decorating material that the rigidity of base material and the close-burning laminating material between base material and surface layer material are formed.

The object of the invention is to: solve the problem, particularly obtain a kind of due to thermal expansivity particle can be included and can increase thickness when sheet material expands by punching press sheet material, and can fully guarantee by can the rigidity of laminating material that formed of punching press sheet material and surface layer material and can close-burning laminating material between punching press sheet material and surface layer material.

-in order to technical solution problem technical scheme-

To achieve these goals, the starting point is placed on by the present inventor: whether can change existing allowing can thermal expansivity particle expansion in punching press sheet material and after forming intumescent sheets, then surface layer material is bonded in the operation on intumescent sheets.

Further, attempt the test having carried out process sequence to reverse.That is, whether can punching press sheet material on if to first can be attached to by surface layer material before thermal expansivity heating particulates expands, allow again and can the problem that expands of punching press sheet material be studied after laminating.If because can infer can punching press sheet material and surface layer material be bonded after allow thermal expansivity particle expansion again, then fitting part between the two will be peeled off, so the present inventor once thought that the method was not proper because of this expansion process.But, existing method, namely in order to surface layer material is fitted in make can punching press sheet material expand and formed intumescent sheets on, then need not compress the swelling state of intumescent sheets, thus bonding process will be restricted.For this reason, make its method expanded not proper again although the present inventor thinks first to fit at first, but still be devoted to the research of said method with working with perseverance.

In practical study, first the surface of punching press sheet material only can arrange adhering agent layer, then placing surface layer material on this adhering agent layer, with adhering agent layer, both are being bonded together.It is made to expand through heating in this condition.But, result shows that the bonding force of surface layer material is not enough.That is, when having carried out heating, adhering agent layer melt infiltration, in base material, thus just there will be the result of bonding force deficiency, and thermal expansivity particle expansion and the bonding force weakened between the two result also in bonding force deficiency.

For this reason, more deep research has been carried out.Identical with above-mentioned viewpoint, can on punching press sheet material it is considered that first surface layer material is bonded at, and then allow thermal expansivity particle expansion, attempt having carried out various test based on this idea.In the middle of this, seeking that can a kind of bonding disobeyed by above-mentioned sticker be just pasted onto surface layer material can method on punching press sheet material.In this course, attempt ground carry out can through add hot compression surface layer material is pasted onto can test on punching press sheet material.

At this, inventor worries: make to comprise thermal expansivity particle can punching press sheet material overlapping with surface layer material after carry out adding hot compression again way likely can hinder can thermal expansivity particle in punching press sheet material dilatancy (expansion below in operation) or damage thermal expansivity particle itself.But, in the process of concentrating on studies, carry out with hot press punching press sheet material and surface layer material adding the test of hot compression.Now, as long as suitably setting hot press carries out the condition (keeping the stipulated time with set point of temperature, authorized pressure) adding hot compression, thermal expansivity particle would not be damaged, and can carry out adding hot compression under the expansile condition retaining thermal expansivity particle, both are fit together, and when open hot press, utilizing the heating-up temperature of this hot press just can make can thermal expansivity particle expansion in punching press sheet material.That is, know: as long as carry out adding hot compression under suitable heating contractive condition, both just can be made to fit together, and utilize this heating-up temperature just can allow thermal expansivity particle expansion after removing compressive state, make to become intumescent sheets by punching press sheet material, fit-state between the two can also be maintained simultaneously.

The main cause obtaining above-mentioned desired result is because when being placed on by surface layer material and punching press sheet material can carrying out adding hot compression again, can the thermoplastic resin of welding fortifying fibre in punching press sheet material be crushed, the surface area of thermoplastic resin increases, contact area between fortifying fibre and thermoplastic resin is increased, even if then allow thermal expansivity particle expansion, also can not peel off between punching press sheet material (intumescent sheets) and surface layer material, fit-state between the two can be maintained.

Particularly, if first the surface of punching press sheet material can arrange adhesive film layer, then be pasted onto by surface layer material on this adhesive film layer, then effect of fitting can be better.That is, allow the resin film formed by hot melt adhesive resin between punching press sheet material and surface layer material, then can suitably set heating contractive condition, just can guarantee firm pasting, and also can not hinder expansion when thermal expansivity particle expansion, can fit-state be maintained and swelling state is good.

Specifically, the feature of the invention of first aspect involved in the present invention is: prepare dispersion containing thermoplastic resin, fortifying fibre and thermal expansivity particle can punching press sheet material, surface layer material is placed on this can on punching press sheet material after carry out adding hot compression with plate hot press, being pressed in by surface layer material can on the surface of punching press sheet material, produce after punching press sheet material can posting the stickup material of surface layer material, open hot press, what make warmed-up stickup material can thermal expansivity particle expansion in punching press sheet material, material is pasted in the expansion forming specific thickness, then, this expansion stickup material is put into cold press and carries out press molding, thus form the interior trim material of automobile.

The invention of second aspect is such, in the manufacture method of the vehicular interior decorating material involved by the invention of first aspect, it is characterized in that: this can punching press sheet material placement surface layer material side surface on, the resin flake formed by hot melt adhesive resin is set, this resin flake is placed with surface layer material.

The invention of the third aspect is such, in the manufacture method of the vehicular interior decorating material involved by the invention of first aspect, it is characterized in that: can between punching press sheet material and this surface layer material at this, the resin flake formed by the spun bond nonwoven fabric (spunbonded nonwoven) of skin-core structure is set, this resin flake is placed with surface layer material.

The invention of fourth aspect is such, in the manufacture method of the vehicular interior decorating material involved by the invention of the third aspect, it is characterized in that: the core of this skin-core structure is formed by pet resin, the skin zone of this skin-core structure is formed by olefine kind resin.

The invention of the 5th aspect is such, in the manufacture method of the vehicular interior decorating material involved by the invention of the either side in first to fourth, it is characterized in that: in hot press, can punching press sheet material and surface layer material with 160 ~ 210 DEG C of heating, and can the thickness reduction of punching press sheet material be more than 0.9 times of the thickness before compression, and keep for 5 ~ 30 seconds.

-invention effect-

According to the invention of first aspect, can be easy to obtain the rigidity with interior trim material and can close-burning light weight automobile interior trim material between punching press sheet material and surface layer material.

According to the invention of second aspect, positively caking property can be ensured further.

According to the invention of the third aspect, can obtain and not produce concavo-convex hollow phenomenon at surface layer material, there is the interior trim material of good appearance.

According to the invention of fourth aspect, the interior trim material that caking property between surface layer material and base material is excellent can be obtained.

According to the invention of the 5th aspect, can be easy to obtain the rigidity of effectively having given play to interior trim material and can close-burning light weight automobile interior trim material between punching press sheet material and surface layer material.

Accompanying drawing explanation

Fig. 1 relates to the figure of embodiments of the present invention, and schematically illustrating can punching press sheet material and the overlapping state be placed in hot press of surface layer material.

Fig. 2 relates to the figure of embodiments of the present invention, schematically illustrates to carry out adding hot compression to manufacture the state of laminating material with hot press.

Fig. 3 be operation shown in Fig. 2 after process chart, schematically illustrate open hot press relief can thermal expansivity particle expansion in punching press sheet material and define the state of the laminating material that expands.

Fig. 4 be operation shown in Fig. 3 after process chart, schematically illustrate, with cold press, the state of press molding carried out to the laminating material that expands.

Fig. 5 relates to the figure of embodiments of the present invention, schematically illustrates and to be placed on by surface layer material and on the base material of punching press sheet material, can not yet to carry out the state adding hot compression.

Fig. 6 relates to the enlarged drawing of embodiments of the present invention, schematic illustration carry out with hot press before adding hot compression can the distribution of thermoplastic resin, fortifying fibre and thermal expansivity particle in punching press sheet material.

Fig. 7 relates to the enlarged drawing of embodiments of the present invention, schematic illustration carried out with hot press when adding hot compression can the distribution of thermoplastic resin, fortifying fibre and thermal expansivity particle in punching press sheet material.

Fig. 8 is the figure of the layer-by-layer state be schematically illustrated in embodiments of the invention 6 between base material and surface layer material.

Fig. 9 is arranged in order to illustrate the generalized section that base material gets final product the skin-core structure of the spun bond nonwoven fabric between punching press sheet material and surface layer material in example 6 in accordance with the invention.

Figure 10 is the curve map of the relation between the absorptivity of the test piece that embodiments of the present invention and comparative example are shown and frequency.

-description of reference numerals-

1 can punching press sheet material

2 surface layer materials

3 laminating materials

31 fortifying fibres

32 thermoplastic resins

33 thermal expansivity particles

4 expansion laminating materials

5 hot melt adhesive resin films

8 base materials

21 hot presses

22 cold presses

Detailed description of the invention

Below, with reference to accompanying drawing, embodiments of the present invention are described in detail.In addition, the illustrative in nature done preferred embodiment is below only example, intention is not limited the present invention, application of the present invention or its purposes.

Fig. 1 to Fig. 9 relates to the figure of embodiments of the present invention, and Fig. 1 to Fig. 4 is the figure of each procedure schematically illustrated in the manufacturing process of interior trim material.Fig. 1 schematically illustrates punching press sheet material and surface layer material overlap to be placed on the figure of the state in hot press.Fig. 2 schematically illustrates to carry out adding hot compression to manufacture the figure of the state of laminating material with hot press.Fig. 3 be schematically illustrate after open that hot press allows can thermal expansivity particle expansion in punching press sheet material and produce the figure of the state of the laminating material that expands.Fig. 4 illustrates the figure with cold press, the laminating material that expands being carried out to the state of press molding.Fig. 5 schematically illustrates to be placed on by surface layer material and on punching press sheet material and base material, can not yet to carry out the figure of the state adding hot compression.

First, to net involved in the present invention, can punching press sheet material, surface layer material is bonded at can punching press sheet material be formed stickup material, this stickup material is expanded and the expansion laminating material that formed and the interior trim material that forms the laminating material that expands and obtain are described.

In simple terms, net of the present invention is formed by fortifying fibre, thermoplastic resin and thermal expansivity particle, makes by the method for manufacturing paper with pulp.This net is heated, pressurize after cooled again, just can obtain tabular can punching press sheet material.This can be configured to by punching press sheet material: the thermoplastic resin through heating, cooling and melting and solidification forms parent, is dispersed with fortifying fibre and thermal expansivity particle (unswollen state) wherein.In the present invention, as shown in Figure 1, punching press sheet material 1 can be furnished with the surface layer material 2 with good appearance at this.In addition, hereinafter by can the laminated construction of punching press sheet material be described.

As shown in Figure 2, with hot press 21 to punching press sheet material 1 and surface layer material 2 hot compression can be added, formed and to be fitted material 3 by the tabular of both laminatings.Thermal expansivity particle in this laminating material 3 expands under the heating-up temperature of hot press 21, forms the laminating material 4 (with reference to Fig. 3) that expands.Carrying out pressurization with cold press 22 to expansion laminating material 4 makes it be formed as regulation shape, just can obtain vehicular interior decorating material (with reference to Fig. 4) thus.

Then, to net of the present invention, can punching press sheet material and can fortifying fibre, thermoplastic resin and thermal expansivity particle in punching press sheet material being described.Particularly, be described with reference to the bond state of Fig. 6 and Fig. 7 to fortifying fibre, thermoplastic resin and thermal expansivity particle.

Fig. 6 be schematically illustrated in produce can punching press sheet material 1 time the dispersity of fortifying fibre, thermoplastic resin and thermal expansivity particle.31 represent bar-shaped fortifying fibre, and 32 represent the thermoplastic resin that fortifying fibre 31 is bonded to one another, and 33 represent the spherical thermal expansivity particle (unswollen state) be dispersed between fortifying fibre 31.Fig. 7 is schematically illustrated in the dispersity of having carried out fortifying fibre 31, thermoplastic resin 32 and thermal expansivity particle 33 when adding hot compression with hot press.Fortifying fibre 31 and thermal expansivity particle (unswollen state) 33 have almost no change, but thermoplastic resin 32 is squeezed its surface area is increased.Thus, the area got up by thermoplastic resin 32 bonding between fortifying fibre 31 increases, and adhesion strength improves.Hereinafter this adhesion strength is described in detail.

The present invention's fortifying fibre used can use any one fiber in inorfil and organic fiber, also can use both compounds or the fiber that mixes.As spendable fiber, can list: such as, glass fibre, carbon fiber, boron fibre, stainless steel fibre, other inorfil such as metallic fiber and mineral fibres, and the natural fiber such as aramid fibre, polyester fiber, Fypro, fiber crops etc. organic fiber.Can also by the one in these fibers or the two or more use that combines.In addition, from the angle of giving the higher stiffening effect of interior trim material, inorfil is better than organic fiber, wherein when paying attention to intensity, preferably uses carbon fiber.On the other hand, from the viewpoint of cost, preferably use glass fibre.Even if also can not leave recuperation of heat (Thermal Recycle) angle of residue from burning, then preferably have organic fiber.

From fully guarantee can the stiffening effect of punching press sheet material and expansile viewpoint, the average diameter of preferred above-mentioned fortifying fibre is more preferably this average diameter is by using the fortifying fibre of average diameter in above-mentioned scope, the content of thermal expansivity particle when manufacturing paper with pulp just can be improved.In addition, when post to be contemplated for by the resilience of fortifying fibre and the expansile effect that is multiplied of thermal expansivity particle to increase swell increment, also can be by average diameter fortifying fibre and play and to the average diameter of the effect of filling between this fiber be fortifying fibre mix and used.From the angle fully guaranteeing stiffening effect, dilatancy, formability, the average length of preferred fortifying fibre is in the scope of 3 ~ 100mm.From the previous stage of the operation in net of manufacturing paper with pulp, allow the angle that thermoplastic resin and fortifying fibre disperse more equably, the average length of more preferred fortifying fibre is in the scope of 3 ~ 50mm.In addition, above-mentioned average diameter and average length refer to the fortifying fibre before about 50 being used with microscope etc. or net, can the mean value of measured value that is measured of punching press sheet material, the diameter of about 50 fortifying fibres in interior trim material and length.In addition, also can with the temperature of about 600 DEG C to net, punching press sheet material, interior trim material can observe fortifying fibre with microscope etc. again after curing.

Preferred the present invention above-mentioned fortifying fibre used has carried out surface-treated fiber with coupling agent or sizing agent.Particularly, in order to improve wettability between fortifying fibre and thermoplastic resin and caking property, preferably process with silane coupler.As above-mentioned silane coupler, the coupling agents such as vinyl silanes class, amino silicone alkanes, epoxy radicals silicone hydride class, methylpropenyl silanes, chlorosilane, hydrosulphonyl silane class can be used.Limit can be adopted to stir the method for fortifying fibre limit spraying silane coupler solution or fortifying fibre be immersed in the known method silane couplers such as method in coupling agent solution and carry out surface treatment to fortifying fibre.In addition, for the quality of fortifying fibre to be dealt with, the addition of preferred above-mentioned silane coupler is 0.001 ~ 0.3mass%.This is because when discontented 0.001mass%, the effect of silane coupler is less, cannot obtain enough adhesion strengths between fortifying fibre and thermoplastic resin; On the other hand, if more than 0.3mass%, the effect of silane coupler will reach capacity former.This addition more preferred is in the scope of 0.005 ~ 0.2mass%.

Can the intensity of punching press sheet material and dilatancy in order to improve, preferred the present invention fortifying fibre used is that fibrillation has been filamentary fiber, preferably processes above-mentioned fortifying fibre with water-soluble sizing agent for this reason.As this sizing agent, polyethylene glycol oxide class, polyvinyl alcohol water-soluble resin etc. can be used.For the quality of fortifying fibre to be dealt with, the addition of preferred sizing agent at below 2mass%, more preferably at below 1mass%.If this is because more than 2mass%, the event of difficulty will be become in the fibrillation of fiber in operation of manufacturing paper with pulp.In addition, the minimum of addition is limited to about 0.05mass%.If addition very little, operability will be deteriorated.

Below, the thermoplastic resin used in the present invention is described.

As the thermoplastic resin that the present invention is used, can by the such as polyolefin resin such as polyethylene, polypropylene, polystyrene, polyvinyl chloride, PETG, Merlon, polyamide, polyacetals etc., or the one or more kinds of resin combination in the thermoplastic elastomer (TPE) such as ethylene-vinyl chloride copolymer, ethene-vinyl acetate copolymer, Acrylnitrile-Butadiene-Styrene, EPM (EPM), EPDM (ethylene propylene diene rubber) etc. get up to be used.In these resins, the polyolefin resin such as polyethylene, polypropylene is all very excellent because of intensity, rigidity and formability, so be preferred resin.Particularly polypropylene is because above-mentioned characteristic is balanced and cheap, so be more preferred resin.And then, in polypropylene, and the MFR that preferably measures under the condition of JISK6921-2:1997 defined (melt flow rate (MFR), wherein, 230 DEG C, 21.17N) polypropylene in the scope that 1 ~ 200g/10 divides, more preferred polypropylene in the scope that 10 ~ 150g/10 divides.

Further, the caking property in order to improve thermoplastic resin and fortifying fibre, can use simultaneously having carried out the thermoplastic resin of modification and unmodified thermoplastic resin with multiple compounds such as the acid such as unsaturated carboxylic acid, unsaturated carboxylic acid anhydrides, epoxides.Can by such as the methods of graft copolymerization on polypropylene such as maleic acid, maleic anhydride, acrylic acid being carried out modification.Particularly from the angle improving intensity, preferably through the thermoplastic resin of modification, there is in its molecule the modification such as anhydride group, carboxyl base.

The shape of thermoplastic resin can be particle shape or the threadinesss such as powder, particle, thin slice.From improving the operability of net, the content of thermal expansivity particle and manufacturing and can the thermoplastic resin that melted and fortifying fibre be made to be intertwined fully during punching press sheet material, the viewpoint improving intensity and rigidity is set out, and preferably uses fibrous thermoplastic's resin and particle shape thermoplastic resin simultaneously.At this, when using particle shape thermoplastic resin, preferably use mean particle diameter is thermoplastic resin, can angle in punching press sheet material from allowing thermoplastic resin be evenly dispersed in, more preferably mean particle diameter is thermoplastic resin.On the other hand, when using fibrous thermoplastic's resin at the same time, preferably use average diameter is and average length is the thermoplastic resin of 1 ~ 50mm, from allowing thermoplastic resin be evenly dispersed in the angle of steeping in liquid, more preferably average length is the thermoplastic resin of 1 ~ 30mm.

Below, the thermal expansivity particle used in the present invention is described.

Thermal expansivity particle used in the present invention has when being heated to more than a certain temperature, the pressure that the shell of deliquescing produces due to core vaporized expanding and the characteristic expanded.Of the present invention one is characterised in that greatly: with this thermal expansivity particle as form net, can punching press sheet material and expand laminating material material.With only improve compared with the situation of swell increment by the rebound effect of fortifying fibre, by using this thermal expansivity particle, larger swell increment can be guaranteed, therefore, it is possible to realize low-density further, thus can light weight be obtained and there is the expansion laminating material of rigidity.

In the present invention, thermal expansivity particle can use known thermal expansivity particle, but particularly preferably to be core be liquid hydrocarbon, and in the shell formed by the thermoplastic resin with gas barrier property, contain the hud typed thermal expansivity particle of this core.In general, the hydrocarbon that the hydrocarbon as core uses boiling point lower than the softening point of the thermoplastic resin of shell, the hydrocarbon class having the boiling points such as such as iso-butane, pentane, hexane below 150 DEG C that can list and ethers.As the thermoplastic resin forming shell, what can list has: the polyolefin resins such as such as polyethylene, polypropylene, ethylene-propylene copolymer, polystyrene, polyvinyl chloride, polyvinylidene chloride, methacrylic resin, ABS (acrylonitrile-butadiene-styrene terpolymer) resin, ethene-vinyl acetate copolymer, polyamide, PETG, polybutylene terephthalate (PBT), polyurethane, polyacetals, polyphenylene sulfide, the known thermoplastic resin such as fluororesin.Particularly preferably be core to be formed by liquid hydrocarbons such as iso-butane, pentane, hexanes and the thermal expansivity particle that formed by the thermoplastic resin such as acrylonitrile copolymer, polyvinylidene chloride of shell.

The average diameter of preferred thermal expansivity particle is before adding thermal expansion more preferred above and discontented and then more preferred above and below.If this is because expand before particle diameter less than when manufacturing paper with pulp, thermal expansivity particle just easily comes off through the gap of fortifying fibre, and thus particle content reduces; On the other hand, if exceed the size of the thermal expansivity particle after expansion will be excessive, thus the thickness of expansion-molded product just becomes uneven or can cause the event of surface quality deterioration.In addition, the average diameter of preferred thermal expansivity particle when expanding is more be preferably if the average diameter of thermal expansivity particle after expanding is too small, then in order to allow can punching press sheet material expand required for thermal expansivity particle weight (quantity) will increase.On the other hand, if the average diameter after expanding is excessive, will produce concavo-convex on the surface of expansion-molded product, and make surface texture deterioration.In addition, the average diameter of the thermal expansivity particle after above-mentioned expansion is the mean value observed with light microscope etc. and calculate after measuring the diameter of about 50 the thermal expansivity particles in expansion-molded product.

As mentioned above, thermal expansivity particle is once be heated to more than a certain temperature, and the shell of deliquescing will start to expand due to the pressure of core vaporized expanding generation.In the present invention, this temperature is called beginning expansion temperature, this starts expansion temperature and refers to that the particle diameter of thermal expansivity particle starts the temperature sharply increased when making thermal expansivity particle carry out intensification with 10 DEG C/minute.The beginning expansion temperature of preferred thermal expansivity particle used in the present invention is more than 120 DEG C, more preferred at 130 ~ 230 DEG C.This is because when starting expansion temperature less than 120 DEG C, the heat resistance of thermal expansivity particle itself is not good enough, and the baking temperature of the net of manufacturing paper with pulp drops to extremely low by needs, thus dry required time increases, thus unsatisfactory; On the other hand, if start expansion temperature more than 230 DEG C, the heating-up temperature expanded in order to make it will be too high, thus likely cause the event of thermoplastic resin deterioration.

The beginning expansion temperature of preferred above-mentioned thermal expansivity particle is less with the difference of the fusing point of the thermoplastic resin of formation parent.If this is because the beginning expansion temperature of thermal expansivity particle is more much lower than the fusing point of thermoplastic resin, then after thermoplastic resin fusing at fortifying fibre ambient dynamic, before adhesion, thermal expansivity particle will excessive expansion, thus unsatisfactory; On the other hand, if beginning expansion temperature is too high, then just needs to be heated to very high temperature to obtain enough expanded thickness, thus likely making the event of thermoplastic resin deterioration.Therefore, the beginning expansion temperature of preferred thermal expansivity particle and the difference of the fusing point of the thermoplastic resin of formation parent are within ± 30 DEG C.

The maximum swelling temperature of preferred above-mentioned thermal expansivity particle is higher than the fusing point of thermoplastic resin, and both temperature difference more preferred is within 50 DEG C.At this, above-mentioned maximum swelling temperature refers to that, when allowing thermal expansivity particle carry out intensification with 10 DEG C/minute, the particle diameter of thermal expansivity particle reaches maximum temperature.If why preferably both temperature differences are because maximum swelling temperature is more a lot of than the fusing point height of thermoplastic resin within 50 DEG C, then in order to obtain enough dilatancy, just need to be heated to very high temperature, thus likely causing the event of thermoplastic resin deterioration.

Below, to the weight per unit area of net of the present invention and form net, can the compounding ratio of punching press sheet material, the fortifying fibre of interior trim material, thermoplastic resin and thermal expansivity particle be described.

First, the weight per unit area of preferred net of the present invention etc. is at 100 ~ 1000g/m ²scope in.If this is because the weight per unit area of net is less than 100g/m ², then when it can be used as interior trim material, do not reach enough thickness, rigidity also can decline; On the other hand, if more than 1000g/m ², be then difficult to realize the event of lightweight of expansion-molded product.Preferred weight per unit area is at 100 ~ 700g/m ²scope in, and then more preferably at 100 ~ 500g/m ²scope in.

Secondly, although it is different from the content of the proportion of used fortifying fibre and thermoplastic resin and other additive, colouring agent to form the fortifying fibre of net of the present invention etc. and the compounding ratio of thermoplastic resin, but in order to obtain the higher interior trim material of the mechanical strength such as bending strength (bending strength) and the modulus of elasticity in static bending (elasticity slope (elastic slope)), the mass ratio of preferred fortifying fibre and thermoplastic resin is in the scope of 3/97 ~ 60/40.

For the fortifying fibre amounting to 100 mass parts and thermoplastic resin, the content preferably forming the thermal expansivity particle of net of the present invention etc. is 1 ~ 40 mass parts.If discontented 1 mass parts, expansile raising effect just cannot embody; On the other hand, if more than 40 mass parts, expansile raising effect will be excessive, and not only the inside of interior trim material is even the density of superficial layer also can reduce, and thus rigidity and flexing resistance decline.

In addition, nets of the present invention etc., except comprising above-mentioned thermoplastic resin, fortifying fibre, thermal expansivity particle, can also comprise additive and colouring agent, the organic binder bonds etc. such as antioxidant, resistance to light stabilizer, matal deactivator, fire retardant, carbon black, VOC (volatile organic compound) adsorbent, VOC distintegrant, deodorant as required.Can such as by carrying out coating to fortifying fibre and thermoplastic resin in advance or coordinating when mixing, adding above-mentioned additive and colouring agent to the method for net spraying again or with sprayer etc., thus make net etc. containing this additive and colouring agent.

Surface layer material of the present invention plays decoration and protection, and what preferably formed by the natural fiber such as string, animal origin or acetate fiber class, polyamide-based, polyesters, polyacrylic, PP type synthetic fibers etc. weaves cotton cloth or non-woven fabrics.Fiber-like surface layer material due to penetrate into surface layer material after sticker and thermoplastic resin fusing fiber between anchoring effect remarkable, so its adhesion strength improves.Also have, if can realize and bonding between sticker and thermoplastic resin, then such as by advance the blister sheet of continuous like that for polyurethane foam generation bubble is arranged on weave cotton cloth or non-woven fabrics the face of fitting with core on, just can eliminate the concavo-convex of core, improve the aesthetic appearance on surface layer material surface, can also resiliency be obtained.Such as, polyurethane foam (urethane foam) thin slice fitted knitted fabric (knit) and the surface layer material that formed can be used in.

Below, to manufacturing net involved in the present invention, can the method for punching press sheet material and interior trim material being described.

The manufacture method of net involved in the present invention is such, that is: to allowing fortifying fibre, thermoplastic resin and thermal expansivity particle dispersion namely manufacture paper with pulp containing the bubble liquid formed in the aqueous medium of surfactant that contains of micro-bubble at dispersion liquid, thus this net is produced.Also above-mentioned raw materials can not be made to be dispersed in this bubble liquid, and this stock dispersion is blended in the water not containing tackifier and flocculant.In addition, if use bubble liquid, fortifying fibre, thermoplastic resin, thermal expansivity particle will remain on foam surface and be dispersed in bubble liquid, so have the advantage that also can not produce separation in the process of transporting dispersion liquid.Net is manufactured in the present invention by following method.The method be by comprise fortifying fibre, thermoplastic resin, thermal expansivity particle dispersion liquid (bubble liquid) be poured on the such porous support of copy paper net, carry out attracting from the below of porous support again and after deaeration, the solid constituent in dispersion liquid be deposited on porous support.

As surfactant used in manufacturing paper with pulp method at above-mentioned foam, any one in anionic species, nonionic class, cationic based surfactants can be used.Particularly, owing to making with dispersed in media as well satisfactory for result of fortifying fibre and the thermoplastic resin raw material that is main component, so preferably neopelex, cocoanut fatty acid diethanolamide etc. can be used.

Under the condition (temperature and time) that thermal expansivity particle does not produce maximum swelling, the net obtained to manufacturing paper with pulp through above-mentioned foam carries out drying.That is, if this is because allow the thermal expansivity particle in net reach maximum swelling at drying stage, then not only the operability of net declines, and manufacture can compress when punching press sheet material time thermal expansivity particle can be crushed, thus when manufacturing interior trim material can the dilatancy of punching press sheet material likely occur not enough therefore.

In order to make thermal expansivity particle reach maximum swelling, need certain heat.Therefore, in order to not allow thermal expansivity particle reach maximum swelling, just needing to control acid extraction, making input heat during drying less than this certain heat.Specifically, preferably in order to carry out temperature difference between dry heating-up temperature and maximum swelling temperature within 30 DEG C.Preferably when heating-up temperature is below maximum swelling temperature, the heat time is within { 2 × (maximum swelling temperature-beginning expansion temperature) } divides; When heating-up temperature is higher than maximum swelling temperature, the heat time is within { 300/ (heating-up temperature-maximum swelling temperature) } divides and within { 2 × (maximum swelling temperature-beginning expansion temperature) } divides.

In addition, utilizing sprayer spraying process or print roll coating method the emulsion or the aqueous solution that comprise organic binder bond be coated in and manufacture paper with pulp and in obtained net through above-mentioned foam, when this emulsion or the aqueous solution being penetrated into above-mentioned net from its opposing face side vacuum attraction etc. again, because the fortifying fibre when dry net, thermoplastic resin, thermal expansivity particle efficiency is attached in this net well, so not only their content improves, and operability and production efficiency are also improved, thus this sprayer spraying process and print roll coating method are preferred methods.

Below, tabular of the present invention can the manufacture method of punching press sheet material be described.

Of the present invention can punching press sheet material be produced like this.That is: more than the softening point or fusing point of thermoplastic resin and thermal expansivity particle does not produce after net obtained to manufacturing paper with pulp through above-mentioned foam under the condition (temperature and time) of maximum swelling heats, pressurizes, carry out cooling curing again, thermoplastic resin is made to melt and form parent thus, utilize the thermoplastic resin of melting and solidification to make the fortifying fibre of dispersion bond securely with thermal expansivity particle, combine, so just producing can punching press sheet material.At this, the above-mentioned condition (temperature and time) not producing maximum swelling is identical with condition described above.Reason temperature being set in more than the fusing point of thermoplastic resin is: if less than fusing point, then thermoplastic resin welding on fortifying fibre and thermal expansivity particle, and would not cannot obtain required intensity securely.On the other hand, the reason of carrying out heating do not produce the condition of maximum swelling at thermal expansivity particle under is: if make thermal expansivity particle reach maximum swelling in this heating process, then not only can punching press sheet material operability decline, and thermal expansivity particle can due to manufacture can punching press sheet material time the compression carried out and being crushed, manufacture the dilatancy required for expansion-molded product after thus sometimes cannot obtaining.

Preferably net is being heated, carry out again pressurizeing after thermoplastic resin is melted manufacturing can punching press sheet material time pressurized conditions be: compress, make the proportion of punching press sheet material to reach more than 0.3.If this is because discontented 0.3, the mobility of thermoplastic resin is just insufficient, cannot be formed in the event of the structure being dispersed with fortifying fibre and thermal expansivity particle in parent and thermoplastic resin.More preferably proportion is more than 0.4.But, if excess compression, just likely lose fortifying fibre or the weight per unit area of thin slice is reduced (thin slice area increases, lower thickness), so preferably compress below the pressure that voidage is zero.

In addition, in the manufacture method of punching press sheet material, can carry out again after making thermoplastic resin melt the pressurization of above-mentioned net, also can carry out with heating simultaneously of the present invention.Pressure method has batch-type intermittent pressurized method, the continuous pressure method using teflon (registration mark) or steel band and roll-type pressurization etc., can use any one method wherein.Can the operability of punching press sheet material in order to improve, in the process of thermoplastic resin fusing, can pressurizeing, then making it expand except unloading, then cool under the state thick when Thickness Ratio pressurizes.And then, carry out drying and the heating of net simultaneously, then carry out the method for pressurizeing not only economy but also there is very high manufacture efficiency again.

In addition, can on punching press sheet material in order to surface layer material is bonded in more securely, preferably being arranged on by the resin flake (in the present invention, below resin film, nonwoven fabric sheet being all called resin flake at interior thin slice) of the tens of micrometers thick formed by hot melt adhesive resin can between punching press sheet material and surface layer material.

This resin flake is impregnated into punching press sheet material face side can to form the dipping tack coat with adequate thickness in punching press sheet material side, and by its anchoring effect, play that improve can the resin flake of caking property effect between punching press sheet material and surface layer material, preferably by have with can the same or similar structure of thermoplastic resin in punching press sheet material, and fusing point or melt viscosity is roughly the same with above-mentioned thermoplastic resin or resin more than it is formed.

The polyolefin resin such as polyethylene, polypropylene that the preferred working strength of the resin flake formed by the thermoplastic resin as this hot melt adhesive resin, rigidity and formability are all very excellent, particularly polypropylene is because above-mentioned characteristic is balanced and cheap, so be more preferred resin.And then, in polypropylene, and the MFR that preferably measures under the condition of JISK6921-2:1997 defined (melt flow rate (MFR), wherein, 230 DEG C, 21.17N) polypropylene in the scope that 1 ~ 200g/10 divides, more preferred polypropylene in the scope that 10 ~ 150g/10 divides.

As nonwoven fabric sheet, the spun bond nonwoven fabric of preferably spun bond nonwoven fabric, particularly skin-core structure.In this case, the core of skin-core structure preferably can not because of the heat during heating materials such as the PET (PETG) that melt.The skin zone of skin-core structure preferably uses the material that can melt because of heat during heating, and the polyolefin resin such as acrylic resin, polyvinyl resin is all applicable material.Particularly, skin zone preferably uses the acrylic resin good with the conformability of the acrylic resin as base material.

Particularly, when surface layer material is the double-decker of polyurethane foam and knitted fabric, preferably use the spun bond nonwoven fabric of this skin-core structure.That is, when resin film is formed by hot melt adhesive resin, this hot melt adhesive resin melts because heat during heating produces, penetrate into the polyurethane foam in surface layer material, therefore after forming because the difference etc. of os-motic state will produce tiny concavo-convex at epidermal area, namely produce so-called hollow phenomenon, just likely make the aesthetic appearance on surface impaired.For this reason, when surface layer material is the double-decker of polyurethane foam and knitted fabric, preferably use the nonwoven fabric sheet formed by the spun bond nonwoven fabric of skin-core structure, but not resin film.It is generally acknowledged: if use the spun bond nonwoven fabric of this skin-core structure, although then skin-core structure skin zone can be shaped time heating-up temperature under fusing and infiltrate in polyurethane foam, but core can not melt and can maintain original shape, so above-mentioned hollow phenomenon can be prevented.In addition, the situation forming resin flake with the spun bond nonwoven fabric of skin-core structure is not limited to the double-deck surface layer material with above-mentioned knitted fabric and polyurethane foam, also goes for other surface layer materials such as such as non-woven fabrics.

In order to improve flexing resistance, rigidity equal strength characteristic, sound absorption characteristics and air impermeability further, interior trim material of the present invention also can form high-density resin layer in the side side of the surface layer material of not fitting of interior trim material.It is lower than the internal layer portion of expansion-molded product or there is not the resin bed in space that above-specified high density resin bed refers to voidage, also requires that this high-density resin layer has and base material and the bonding caking property of other high-density resin layer.As the method forming high-density resin layer, existing known technology can be used.Preferred: such as, the liquid immersion making to comprise the resin forming high-density resin layer to net, can punching press sheet material a surface method, the high-density resin melted is squeezed into flake after carry out lamination method and resin flake lamination that high-density resin is made get up to be formed the method etc. of high-density resin layer.Wherein, the method for being got up by this high-density resin stack of sheets is in net with either party in punching press sheet material can carry out lamination, easily so be preferred method.In order to suppress weight to increase, the thickness of high-density resin thin slice is preferably below 200 μm, more preferred between 20 ~ 150 μm.At this, above-specified high density resin flake can be the thin slice that polypropylene, nylon, straight linear polyethylene etc. are formed, or the plural layers formed more than making this stack of sheets two-layer.Further, sound absorption properties in order to obtain, through hole can be formed with fine needle drift, hole cutting machine etc. on above-specified high density resin flake.

In addition, Fig. 5 illustrates can the resin flake 5 that formed by hot melt adhesive resin of lamination respectively on the two sides of punching press sheet material 1, then arranges the embodiment of high-density resin layer in the face side of a resin flake 5.That is, to show on the surface of a resin flake 5 lamination surface layer material 2, the embodiment of lamination polyamide 6, spun bond nonwoven fabric 7 successively on the surface of another resin flake 5.In addition, Fig. 5 shows the example of lamination above-specified high density resin bed, but is not must these high-density resin layers of lamination, also can omit at least one deck in high-density resin layer.

Below, by simple can punching press sheet material monomer, formed by hot melt adhesive resin at the both sides superimposed layer of this monomer resin flake can punching press sheet material and on a resin flake, be also provided with high-density resin layer can all be called base material 8 by punching press sheet material.

Then, the manufacture method of interior trim material involved in the present invention is described.

Interior trim material of the present invention is made like this.First, as shown in Figures 1 and 2, surface layer material 2 being placed on the tabular of making according to the method described above can on the surface of this base material of punching press sheet material 1.In this condition, carry out adding hot compression under defined terms with hot press 21.In this heating compression section, can flatten to expand its surface area by the thermoplastic resin in punching press sheet material 1, the contact area between itself and fortifying fibre is increased, thus the bonding force between fortifying fibre and thermoplastic resin is strengthened.Meanwhile, surface layer material 2 is close to be bonded on punching press sheet material 1, laminating material 3 can be produced thus.Then, as shown in Figure 3, open rapidly hot press 21 and make it keep the spacing distance specified, utilizing the heating-up temperature of hot press 21 to make can thermal expansivity particle expansion in punching press sheet material 1.Thus, the laminating material 4 that expands just is produced.Afterwards, as shown in Figure 4, with cold press 22, press molding is carried out to expansion laminating material 4, so just define vehicular interior decorating material.

To in this manufacture method, the heating contractive condition of hot press is described.

Heating temperature condition is that need to be heated to can be more than the softening temperature of thermoplastic resin in punching press sheet material or the beginning expansion temperature of fusing point and thermal expansivity particle, makes the softening or fusing of above-mentioned thermoplastic resin.If temperature is too low, can the softening or fusing of thermoplastic resin in punching press sheet material will be insufficient, can adhesion strength between punching press sheet material and surface layer material not enough.To can the heating of punching press sheet material insufficient, thermal expansivity particle would not expand as imagination.On the contrary, if heating-up temperature is too high, fractional melting can be crossed by the thermoplastic resin in punching press sheet material, just significantly can move between fortifying fibre, thus the engaging force between fortifying fibre will be not enough.Further, the possibility that the aesthetic appearance on surface layer material surface is impaired improves, thus unsatisfactory.

If heating-up temperature is too high, will, to heating excessively by punching press sheet material, make thermal expansivity particle damaged.Therefore, the heating-up temperature of preferred hot press is 160 ~ 210 DEG C.In addition, also according to the kind of surface layer material, can make slightly there is temperature difference between the mold temperature of the mold temperature of surface layer material side and substrate backside side.That is, the mold temperature of face side can be made lower than the temperature of substrate backside side 20 ~ 30 DEG C.

The contractive condition compressing base material with hot press is such.If to base material excess compression, thermal expansivity particle will be pressed excessively flat, thus manufactures the dilatancy of laminating required for material that expand after cannot obtaining.Further, significantly can move by the thermoplastic resin that fortifying fibre is bonded to each other in punching press sheet material, likely occur that the bonding force between fortifying fibre is not enough.On the contrary, if insufficient to the compression of base material, just fully thermoplastic resin cannot be flattened to expand its surface area, thus the contact area between fortifying fibre can not be increased.Consequently, fully can not guarantee the bonding force between fortifying fibre and thermoplastic resin, cause rigidity not enough.Therefore, preferably carry out controlling making the thickness of punching press sheet material to be compressed to more than 0.9 times of the thickness before compression.And then, be preferably compressed to 0.8 ~ 0.3 times.At this, why selected can the thickness of punching press sheet material be because the material of the surface layer material that can use has non-woven fabrics, fabric, braid etc., and the sandwich construction that the structure of this surface layer material has single layer structure and lamination to get up, so there is larger difference in surface layer material in proportion and weight per unit area.Therefore, in the present invention when having carried out adding hot compression with hot press, can there is sizable difference due to the difference of shrinkage degree and proportion in the thickness of surface layer material.For this reason, inventor think only with can the thickness of punching press sheet material to specify that above-mentioned contractive condition is advisable, so as mentioned above only so that the thickness of punching press sheet material this contractive condition can be defined.

Change an angle, if from the proportion of base material (can punching press sheet material), then be about for the base material of 0.6 ~ 0.7 relative to the proportion of base material (can punching press sheet material), preferably control to make the proportion of this base material to become 0.8 ~ 1.2 to compression stress.And then, preferably improve compression ratio when thickness increases, by proportion be such as 0.6 base material to be compressed to proportion be 0.8, make its compression ratio be 0.8/0.6 ≈ 1.33, by proportion be 0.7 base material to be compressed to proportion be 1.2, make its compression ratio be 1.2/0.7 ≈ 1.71.If compared, preferably in the scope of 1.05 ~ 2.5, particularly preferably in the scope of 1.2 ~ 2.0 with the ratio of the proportion of the base material of compression rear (before expansion) before compressing.

In addition, if the thickness of base material is 2.0 ~ 3.5mm, the thickness of surface layer material is 0.5 ~ 1.5mm, then preferred gross thickness is compressed to 1.3 ~ 4.0mm, particularly preferably gross thickness is compressed to about 1.7 ~ 2.5mm.Preferred compressed rate is 40 ~ 80%, is more preferably 50 ~ 70%.Such as, if the thickness of base material is 0.6 ~ 1.0mm, surface layer material is non-woven fabrics and its thickness is 1.0 ~ 2.0mm, then preferred gross thickness is compressed to about 1.3 ~ 2.0mm.Such as, if the thickness of base material is 0.6 ~ 1.0mm, surface layer material is made up of knitted fabric, and its thickness is 2.0 ~ 4.0mm, then preferred gross thickness is compressed to about 1.2 ~ 2.0mm.

But, in the job management that reality is carried out hot press, because determine that the method that the spacing distance of hot press carries out managing is simple, so be scarcely according to proportion and compression ratio, but manage according to the method for above-mentioned decision spacing distance.Such as, can the thickness of punching press sheet material be 2.5mm, the thickness of surface layer material be 1.0mm, both thickness and be 3.5mm when, set interval when pressurizeing with hot press, make both thickness and reach 2.3mm.Can the thickness of punching press sheet material be 0.7mm, the thickness of surface layer material be 1.2mm, both thickness and be 1.9mm when, set interval when pressurizeing with hot press, make both thickness and reach 1.6mm.As mentioned above, according to material and their thickness, obtain suitable thickness by rule of thumb, be easy to management with the way controlling thickness when pressurizeing.

How many compression times there are differences according to the composition of material and thickness etc.If compression time is oversize, the thermoplastic resin melted in base material will ooze out, and the appearance of surface layer material just can be damaged; On the contrary, if compression time is too short, the softening or fusing of thermoplastic resin will be insufficient, thus cause caking property to decline.For this reason, compression time is preferably 5 ~ 30 seconds, is particularly preferably 7 ~ 15 seconds.

In the present invention, carry out adding hot compression with hot press, can flatten to expand its surface area by the thermoplastic resin in punching press sheet material, improve the engaging force between fortifying fibre thus, and allowing surface layer material and can after punching press sheet material is close to securely, utilize this heating-up temperature to heating by punching press sheet material, making can thermal expansivity particle expansion in punching press sheet material.So, by punching press sheet material and surface layer material hot compression can be added with hot press to what be piled up, just can will be able to flatten to expand its surface area by the thermoplastic resin in punching press sheet material, thus the engaging force improved between fortifying fibre, surface layer material can also be made simultaneously and can be close together securely by punching press sheet material, and then, because can heat by punching press sheet material whole with hot press, so when opening hot press, wholely can be also subject at short notice almost heating uniformly by punching press sheet material, thus thermal expansivity particle can be opened by expansion equably.

In the interior trim material formed like this, when with the resin flake that by hot melt adhesive resin formed of resin film as both sides, because resin flake fusing when carrying out adding hot compression with hot press, so when finally making interior trim material with cold press, likely can not become the independent stratum that can distinguish base material and surface layer material clearly, this situation is also contained in the present invention.In addition, when making resin flake with the spun bond nonwoven fabric of skin-core structure, core can remain between surface layer material and base material, therefore mostly can recognize in this interior trim material when finally making interior trim material and have resin flake.

In addition, the surface of the hot press that also can contact at surface layer material forms corrugated pattern.In this case, the hair down phenomenon of surface layer material will be not obvious, thus have the effect that can maintain surface layer material aesthetic appearance.

[embodiment]

Below, according to embodiment, the present invention is specifically described.

(embodiment 1)

Can punching press sheet material

Thermoplastic resin: (weight average molecular weight 200,000, MFR65g/10 divide polypropylene particles, mean particle diameter fusing point 165 DEG C)

Fortifying fibre: glass fibre (length 25mm, average diameter 13 μm)

Thermal expansivity particle:

Surface layer material

Polyester organic fiber non-woven fabrics (thickness 1.2mm)

Resin flake (resin film)

Thickness is the polypropylene (MFR65, fusing point 160 DEG C) of 40 μm

Polyamide-based fiber

Thickness is the nylon 6 (fusing point 215 DEG C) of 25 μm

Spun bond nonwoven fabric

Polyester fiber spun bond nonwoven fabric (weight per unit area 13g/m ², thickness 0.08mm)

Dispersion liquid is made like this, that is: stir add the surfactant of 0.5g/L and neopelex in 1.5 premium on currency after, mix the bubble liquid containing micro-bubble, be mixed in this bubble liquid again by dry weight percentage be 40% polypropylene particles and dry weight percentage be 60% the raw material that formed of glass fibre, and then drop into thermal expansivity particle, stir 10 minutes, make it disperse, just obtain dispersion liquid thus.Then, make this bubble liquid deaeration and make it dry, the weight per unit area sum of the weight per unit area and thermoplastic resin of producing fortifying fibre is 400g/m ², the weight per unit area of thermal expansivity particle is 30g/m ²net.Observe with the section of microscope to this net, result is as expression illustrated in Figure 6, and fortifying fibre 31, thermoplastic resin 32 and thermal expansivity particle 33 scatter.

On the two sides of the net obtained, lamination is polypropylene (MFR65, the fusing point 160 DEG C) resin film of 40 μm as the thickness of resin flake, and then on the surface of a resin film film (thickness is the nylon 6 (fusing point 215 DEG C) of 25 μm) of multi-layer polyamide fiber, then on the surface of this film lamination polyester fiber spun bond nonwoven fabric (weight per unit area 13g/m ², thickness 0.08mm), then with 210 DEG C, preheating is carried out to this laminated body, between the cooler pan laminated body be preheated being placed on 25 DEG C, with 5kgf/cm ²pressure pressurize, thus have cured by the method for manufacturing paper with pulp make very fine and closely woven can punching press sheet material (thickness: 1.0mm).As shown in Figure 5, producing can the punching press sheet material superimposed layer base material of other resin bed at this.Observe with the section of microscope to this laminated body, result, as expression illustrated in Figure 6, presents fortifying fibre 31 and is bondd by the particle of thermoplastic resin 32, and the scattered structure of unexpanded thermal expansivity particle 33.

Then, prepare the polyester organic fiber non-woven fabrics (thickness 1.2mm) being used as surface layer material, by this polyester organic fiber nonwoven fabric laminate on the surface of the resin film of above-mentioned base material, thus just obtain the laminated body of 2.2mm.This laminated body of being got up by lamination puts into hot press, has carried out adding hot compression according to following condition.

Heating-up temperature: 200 DEG C

Decrement: 73% (2.2mm → 1.6mm)

Heat time: 10 seconds

After heating with hot press, observe with the section of microscope to this laminated body, result is as expression illustrated in Figure 7, present the thermoplastic resin 32 that fortifying fibre 31 makes surface area add by being crushed to bond securely, and the scattered structure of unexpanded thermal expansivity particle 33.Then, as shown in Figure 3, make the gap of hot press 21 be opened to 30mm, allow thermal expansivity particle expansion, just produce the laminating material 4 that expands thus.

Further, as shown in Figure 4, with cold press 22, this expansion laminating material 4 is formed, thus just obtain interior trim material.

(embodiment 2)

Except the length of fortifying fibre and glass fibre is 25mm, its average diameter be 11 μm of this point different from embodiment 1 beyond, other condition is all identical with embodiment 1.

(embodiment 3)

Except the length of fortifying fibre and glass fibre is 25mm, its average diameter be 7 μm of this point different from embodiment 1 beyond, other condition is all identical with embodiment 1.

(embodiment 4)

Except can the thickness of punching press sheet material be 1.0mm, the thickness of the surface layer material that knitted fabric is made be 3.0mm, their heating are compressed to 1.7mm this point different from embodiment 1 beyond, other condition is all identical with embodiment 1.

(embodiment 5)

Identical with embodiment 1, the length of fortifying fibre and glass fibre is 25mm, and its average diameter is 13 μm.And the difference of embodiment 1 is: can not arrange hot melt adhesive resin and resin flake between punching press sheet material and surface layer material, and be directly placed on by surface layer material can on punching press sheet material, and other condition is identical with embodiment 1.

(embodiment 6)

This embodiment 6 has carried out the example of special provision to the combination of surface layer material and resin flake.Specifically, be with the difference of embodiment 1: as can be seen from figures 8 and 9, prepare the spun bond nonwoven fabric 501 (core 502: fusing point is the PET resin of 260 DEG C that thickness is the skin-core structure of 30 μm, skin zone 503: fusing point is the polyvinyl resin of 110 DEG C) make resin flake, and prepare polyurethane foam 203 (thickness: 2.5mm, density: 40kg/m ³) surface layer material be fitted on knitted fabric 202 makes surface layer material 201.The resin flake formed by above-mentioned non-woven fabrics is stacked in can punching press sheet material face side face on, thus produce base material, then on the spun bond nonwoven fabric overlapping the skin-core structure on base material, surface layer material is placed, polyurethane foam side is contacted with this non-woven fabrics, so just obtains the laminated body of 3.5mm.This laminated body that lamination gets up is put into hot press, has carried out adding hot compression according to following condition.

Heating-up temperature: 180 DEG C

Decrement: (3.5mm → 1.6mm)

Heat time: 10 seconds

Subsequently, interior trim material is produced according to the method identical with embodiment 1.

(comparative example 1)

Identical with embodiment 1, prepare at the base material that the both sides of punching press sheet material can be provided with resin bed.Then, with far-infrared heater, the heater setpoint temperatures heating of 250 DEG C × 2 minutes is carried out to this base material, make thermal expansivity particle expansion, produce tabular expansion base material.The surface of this expansion base material arranges hot-melt adhesive layer, and places the surface layer material identical with embodiment 1, just produce laminated body thus.With gap being set as that the cold press of 6.5mm to compress this laminated body and to cool, surface layer material being pasted onto on base material and forming, so just obtaining interior trim material.

(comparative example 2)

Comparative example 2 shows to obtain the elasticity slope identical with embodiments of the invention 1, and adds the example of the weight per unit area of base material.

Respectively the interior trim material obtained in embodiment 1 ~ embodiment 6 and comparative example 1, comparative example 2 is made into that length is 150mm, width is the test piece of 50mm, and implement to be 100mm and crosshead speed executes loaded three point bending test under being the condition of 50mm/min in span to this test piece, thus determine elasticity slope.This elasticity slope be according to JISK7171 in span: carry out under the condition of 100mm, test speed: 50mm/min.Show the result of this test in Table 1.Also checked the stripping state of surface layer material relative to base material.Disbonded test uses the test piece that width is 25mm, peels off surface layer material, make this surface layer material overturn 180 ° with the draw speed of 200mm/min.In addition, the material breakage of surface layer material refers to that surface layer material does not peel off from the interface of base material, but the material of surface layer material is destroyed and produces and peels off.

[table 1]

As shown in Table 1: in example of the present invention (embodiment 1 ~ embodiment 6), the elasticity slope of high value can be obtained.On the other hand, the result of comparative example 1 is that elasticity slope is lower, and rigidity is not enough.Further, as comparative example 2, although can obtain the elasticity slope equal with the present invention, just need the weight per unit area increasing considerably base material in the case, thus weight increases, and cannot obtain desirable result from realizing light-weighted viewpoint.

To the result that the caking property of surface layer material checks be: at the material breakage of embodiment 1 ~ embodiment 4 and embodiment 6 mesocuticle, the close-burning interior trim material fully meeting surface layer material can be obtained.In embodiment 5, adhesion strength is 3N, and result to meet required caking property.On the other hand, in comparative example 1, adhesion strength is 2N, and bonding force is not enough.Therefore, if the level making bonding force reach identical with the present invention, as comparative example 2, increase the weight per unit area of base material, although then enough bonding forces can be obtained, weight can be caused to increase.

The measurement result of absorptivity in the pipe that figure 10 illustrates embodiment 1 ~ embodiment 3, embodiment 6 and comparative example 1, comparative example 2.In this pipe, the mensuration of absorptivity according to JISA1405-2, sound wave is impinged perpendicularly on not have the side side of surface layer material and the surface of side, high density face, determines absorptivity in pipe under the state that air layer is 0mm rearward.As can be seen from Figure 10: embodiments of the invention 1 ~ embodiment 3, embodiment 6 and comparative example 2 have excellent sound absorption characteristics, but the sound absorption characteristics of comparative example 1 are very poor.In addition, although do not compared embodiment 4, embodiment 5, think that these two embodiments also can obtain the result identical with embodiment 1 ~ 3, thus omit and they are described.

-industrial applicability-

The present invention can be advantageously applied to expectation and realize the vehicular interior decorating material such as light-weighted such as roof material and rear foreign material dish (rearpackage tray) material.

Claims (4)

1. a manufacture method for vehicular interior decorating material, is characterized in that:

Prepare dispersion containing thermoplastic resin, fortifying fibre and thermal expansivity particle can punching press sheet material,

Surface layer material is placed on this can on punching press sheet material after with plate hot press by can punching press sheet material and surface layer material and the thickness reduction of punching press sheet material can be less than 0.9 times of thickness before compression and keep the mode in 5 ~ 30 seconds to carry out adding hot compression with 160 ~ 210 DEG C of heating, being pressed in by surface layer material can on the surface of punching press sheet material, produce after punching press sheet material can posting the laminating material of surface layer material

Open hot press, make by the warmed-up laminating material of this hot press can thermal expansivity particle expansion in punching press sheet material, form the expansion laminating material of specific thickness,

Then, this expansion laminating material is put into cold press and carries out press molding, thus form vehicular interior decorating material.

2. the manufacture method of vehicular interior decorating material according to claim 1, is characterized in that:

This can punching press sheet material placement surface layer material side surface on, the resin flake formed by hot melt adhesive resin is set, this resin flake is placed with surface layer material.

3. the manufacture method of vehicular interior decorating material according to claim 1, is characterized in that:

This surface layer material is formed by the knitted fabric of polyurethane foam with the face side being fitted in this polyurethane foam, can between the surface of side of placement surface layer material of punching press sheet material and this polyurethane foam at this, the resin flake formed by the spun bond nonwoven fabric of skin-core structure is set, this resin flake is placed with surface layer material.

4. the manufacture method of vehicular interior decorating material according to claim 3, is characterized in that:

The core of this skin-core structure is formed by pet resin, and the face side of this core is formed by olefine kind resin.