CN115869905A - Interior material for vehicle and method for manufacturing interior material for vehicle - Google Patents
Interior material for vehicle and method for manufacturing interior material for vehicle Download PDFInfo
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- CN115869905A CN115869905A CN202211006372.6A CN202211006372A CN115869905A CN 115869905 A CN115869905 A CN 115869905A CN 202211006372 A CN202211006372 A CN 202211006372A CN 115869905 A CN115869905 A CN 115869905A
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Images
Abstract
The object is to provide an interior material for a vehicle and a method for manufacturing the interior material for a vehicle, which can effectively remove unpleasant odor and VOC. The interior material for a vehicle according to the present invention is characterized by comprising an interior base material and a fibrous active carbon sheet laminated on the surface of the interior base material through a hot-melt film, wherein at least one of a through hole and a slit is provided in the hot-melt film, and the interior base material and the fibrous active carbon sheet are integrated by welding the hot-melt film.
Description
Technical Field
The present invention relates to an interior material for a vehicle and a method for manufacturing the interior material for a vehicle.
Background
Conventionally, in a vehicle cabin or the like, countermeasures have been taken against unpleasant odors such as exhaust odor, fuel odor, tobacco odor, body odor, rotten odor of food waste, and the like including material odor generated from an interior resin member such as a seat cushion or the like. In addition, measures against VOC (volatile organic compound) generated from coated parts such as instrument panels and door trims are also required.
As a measure against unpleasant odor and VOC, a method of using an adsorbent such as an activated carbon sheet for an interior material for a vehicle is known. In the conventional method of using an activated carbon sheet for a vehicle interior material, after a base material of the vehicle interior material is molded, the activated carbon sheet is attached to the base material by means of sewing, attaching with a transparent tape, or the like, and processing after molding is required. In addition, conventional activated carbon sheets have a specification in which powdered activated carbon is impregnated in a nonwoven fabric or the like, and have no followability, and therefore, it is difficult to form the activated carbon sheets integrally with a base material.
In order to cope with these problems, for example, as an interior material for a vehicle occupant deodorizing described in patent document 1, an interior material for a vehicle is known, A flexible fibrous activated carbon sheet is used as an activated carbon sheet, and a laminate is obtained by laminating the activated carbon sheet on the surface of a substrate with an adhesive layer interposed therebetween, and the laminate is integrally molded. Such an interior material for a vehicle can be manufactured by using a conventional molding die and existing equipment used in a molding process of each interior material for a vehicle such as a floor mat (carpet, skin) and a roof lining, and therefore, additional equipment investment is not required and post-processing after molding such as sewing and attaching is not required. Therefore, countermeasures against bad smell and VOC can be achieved at low cost.
Documents of the prior art
Patent document 1: japanese patent laid-open publication No. 2002-126511
Disclosure of Invention
In a conventional vehicle interior material in which a laminate obtained by laminating an activated carbon sheet on a surface of a base material with an adhesive is integrally molded, the adhesive surface of the activated carbon sheet is covered with the adhesive, and therefore, the air permeability is reduced. As a result, there is a fear that bad smells and VOCs cannot be effectively absorbed by the activated carbon sheet.
The present invention has been made in view of the above problems, and an object thereof is to provide an interior material for a vehicle and a method for manufacturing the interior material for a vehicle, which can effectively remove unpleasant odor and VOC.
In order to solve the above problems, an interior material for a vehicle according to the present invention includes an interior base material and a fibrous active carbon sheet laminated on a surface of the interior base material through a hot-melt film, wherein the hot-melt film is provided with at least one of through holes and slits, and the interior base material and the fibrous active carbon sheet are integrated by welding of the hot-melt film.
The method for producing an interior material for a vehicle according to the present invention is a method for producing an interior material for a vehicle in which an interior base material and a fibrous active carbon sheet are integrated, and is characterized by comprising a lamination step of laminating a fibrous active carbon sheet on a surface of an interior base material through a hot-melt film to obtain a laminate, the hot-melt film being provided with at least one of through holes and slits, and an integration step of press-molding the laminate and integrating the interior base material and the fibrous active carbon sheet of the laminate by welding the hot-melt film.
According to the present invention, offensive odors and VOCs can be effectively removed.
Drawings
Fig. 1 (a) is a schematic sectional view showing a vehicle interior material according to embodiment 1, and fig. 1 (b) is a schematic plan view showing a hot-melt film welded to an outer surface of an interior base material in the vehicle interior material according to embodiment 1.
Fig. 2 (a) to 2 (f) are schematic process sectional views showing a method for producing a vehicle interior material according to embodiment 1.
Fig. 3 (base:Sub>A) isbase:Sub>A schematic plan view of the fibrous active carbon sheet and the hot-melt film of the laminate obtained in the lamination step of the method for producingbase:Sub>A vehicle interior material according to embodiment 1 from the hot-melt film side, and fig. 3 (b) isbase:Sub>A schematic sectional view of the laminate taken along the linebase:Sub>A-base:Sub>A in fig. 3 (base:Sub>A).
Fig. 4 (base:Sub>A) isbase:Sub>A schematic plan view of the fibrous active carbon sheet and the hot-melt film of the laminate obtained in the lamination step of the method for producing an interior material forbase:Sub>A vehicle according to the modification example of embodiment 1, as viewed from the hot-melt film side, and fig. 4 (b) isbase:Sub>A schematic sectional view of the laminate taken along the linebase:Sub>A-base:Sub>A in fig. 4 (base:Sub>A).
Fig. 5 (a) to 5 (d) are photographs showing another example of the vehicle interior material according to the embodiment.
Fig. 6 (a) and 6 (b) are photographs showing another example of the hot melt film of the embodiment.
Fig. 7 (a) to 7 (c) are photographs showing a through-hole of another example of the hot-melt film according to the embodiment.
Fig. 8 (a) is a photograph showing the appearance of the fibrous active carbon sheet side of the storage tray (package tray) manufactured in the example. Fig. 8 (b) is a graph showing the average values of the evaluation results of the odor intensity and the unpleasant feeling (degree of unpleasant odor) of the storage tray of the example (with activated carbon) and the built-in base material of the comparative object (without activated carbon) and the odor intensity of the unique odor.
Fig. 9 (a) is a graph showing an average value of evaluation results of odor intensity of the unique odor of the activated carbon-integrated floor covering of the reference example and the normal floor covering of the comparative target. Fig. 9 (b) is a graph showing the amounts of aldehydes in each test piece in the air bag measured for the activated carbon-integrated floor covering of the reference example and the normal floor covering of the comparative target, and fig. 9 (c) is a graph showing the amounts of other hydrocarbons in each test piece in the air bag measured for the activated carbon-integrated floor covering of the reference example and the normal floor covering of the comparative target.
Description of the reference numerals
2. Built-in base material
2s outer surface
2sa upper surface of the surface convex portion
2sb side surface of the surface convex part
4. Hot melt film
4h through hole
4n gap
4d crack
6. Fibrous active carbon sheet
10. Interior material for vehicle
10p laminate
Detailed Description
Embodiments of a vehicle interior material and a method for manufacturing the vehicle interior material according to the present invention will be described below.
First, a vehicle interior material and a method for manufacturing the vehicle interior material according to the embodiment will be described by exemplifying the vehicle interior material and the method for manufacturing the same according to embodiment 1.
(vehicle interior material according to embodiment 1)
Fig. 1 (a) is a schematic sectional view showing a vehicle interior material according to embodiment 1, and fig. 1 (b) is a schematic plan view showing a hot-melt film welded to an outer surface of an interior base material in the vehicle interior material according to embodiment 1.
As shown in fig. 1 (a) and 1 (b), a vehicle interior material 10 according to embodiment 1 is a floor covering, and includes: the interior base material 2 and the fibrous activated carbon sheet 6 formed by laminating the outer surface 2s of the interior base material 2 with the hot-melt film 4 interposed therebetween. The outer surface 2s of the interior base material 2 has concave portions and convex portions. The hot melt film 4 has a notch 4n in the outer edge 4e and a through hole 4h in the inner side. The hot-melt film 4 is welded to the upper surface 2sa and the side surface 2sb of the convex portion of the outer surface 2s of the interior base material 2. The hot-melt film 4 is welded to the inner surface 6r of the fibrous active carbon sheet 6. The internal base material 2 and the fibrous active carbon sheet 6 are integrated by fusion of the hot-melt film 4.
In the vehicle interior material 10 according to embodiment 1, the hot-melt film 4 in which the interior base material 2 and the fibrous active carbon sheet 6 are welded is provided with the notch 4n and the through hole 4h. Therefore, the air permeability between the interior base material 2 and the fibrous active carbon sheet 6 can be ensured by the notches 4n and the through holes 4h of the hot-melt film 4. Thus, in addition to the unpleasant odor and VOC generated in the interior base material 2, the fibrous active carbon sheet 6 can effectively absorb the unpleasant odor and VOC and the like that reach the hot-melt film 4 from the outside through the interior base material 2. Thus, bad smells, VOCs, etc. can be effectively removed.
(method for manufacturing vehicle interior Material according to embodiment 1)
Fig. 2 (a) to 2 (f) are schematic process sectional views showing a method for producing a vehicle interior material according to embodiment 1. Fig. 3 (base:Sub>A) isbase:Sub>A schematic plan view of the fibrous active carbon sheet and the hot-melt film of the laminate obtained in the lamination step of the method for producing an interior material forbase:Sub>A vehicle according to embodiment 1, viewed from the hot-melt film side, and fig. 3 (b) isbase:Sub>A schematic sectional view of the laminate taken along the linebase:Sub>A-base:Sub>A in fig. 3 (base:Sub>A).
In the method for manufacturing the vehicle interior material according to embodiment 1, first, as shown in fig. 2 (a), the interior base material 2 is prepared by unwinding from the roll R (preparation step). Further, a predetermined fibrous active carbon sheet 6 integrated with the interior base material 2 and a hot-melt film 4 for integrating both are prepared. Next, as shown in fig. 2 (b), a fibrous active carbon sheet 6 is laminated on the outer surface 2s of the internal base material 2 through the hot-melt film 4 to obtain a laminated body 10p (laminating step).
As shown in fig. 3 (a) and 3 (b), the hot-melt film 4 is a multilayer film in which an inner weld layer 4a, a heat-resistant layer 4b, and an outer weld layer 4c are laminated in this order. In the laminate 10p, the inner surface 4ar of the inner fusion layer 4a (the inner surface 4r of the hot-melt film 4) is in contact with the outer surface 2s of the inner base material 2, and the outer surface 4cs of the outer fusion layer 4c (the outer surface 4s of the hot-melt film 4) is in contact with the inner surface 6r of the fibrous active carbon sheet 6. As shown in fig. 3 (a), when the fibrous active carbon sheet 6 and the hot-melt film 4 of the laminate 10p are viewed from the hot-melt film side in plan, the outer edge 6e of the fibrous active carbon sheet 6 is rectangular, and the outer edge 4e of the hot-melt film 4 overlaps the outer edge 6e of the fibrous active carbon sheet 6 except for the portion of the notch 4 n. As the hot melt film 4, a plurality of partially circular notches 4n are arranged in a row at the outer edge 4e, and a plurality of circular through holes 4h are arranged in a row at the inner side in the longitudinal direction and the lateral direction.
Next, as shown in fig. 2 (c) and 3 (b), after the laminate 10p is put into a heating furnace, the laminate 10p is heated in the heating furnace to a temperature at which the inner fusion layer 4a and the outer fusion layer of the hot-melt film 4 melt and exhibit adhesion, but not to a temperature at which the heat-resistant layer 4b of the hot-melt film 4 melts and exhibits adhesion (heating step).
Next, as shown in fig. 2 (d), the heated laminate 10p is placed between an upper die and a lower die of a molding die, and press-molded by the molding die (molding step). Thereby, the interior base material 2 of the laminate 10p is molded into a mold surface shape, and the outer surface 2s and the inner surface 2r of the interior base material 2 are formed into shapes having concave portions and convex portions. At the same time, the fibrous active carbon sheet 6 and the hot-melt film 4 are compressed between the upper die of the molding die and the interior base material 2, and deformed into a shape along the convex portion of the outer surface 2s of the interior base material 2. Then, the inner fusion-bonded layer 4a (shown in fig. 3 b) and the outer fusion-bonded layer 4c (shown in fig. 3 b) of the hot-melt film 4 are fused to the convex portion of the outer surface 2s of the inner base material 2 and the inner surface 6r of the fibrous active carbon sheet 6, respectively. At this time, the inner fusion-bonded layer 4a and the outer fusion-bonded layer 4c are also fused to the heat-resistant layer 4b (shown in fig. 3 b) located therebetween. In this way, the internal base material 2 and the fibrous active carbon sheet 6 of the stacked body 10p are integrated by welding of the hot-melt film 4 (integration step).
Next, as shown in fig. 2 (e), the integrated laminated body 10p is placed between the upper die and the lower die of the punching die, and cut by the punching die so that the outer edge becomes a desired shape when viewed from the laminating direction (cutting step). Thereby, as shown in fig. 2 (f), the vehicle interior material 10 is manufactured. The vehicle interior material 10 shown in fig. 2 (f) is the same as the vehicle interior material 10 shown in fig. 1, but if necessary, as shown in fig. 2 (f), the sound absorbing material 20 is disposed on the outer surface side of the vehicle interior material 10 and is installed in the vehicle.
In the method for manufacturing the vehicle interior material according to embodiment 1, the notch 4n and the through-hole 4h are provided in the hot-melt film 4 interposed between the interior base material 2 and the fibrous active carbon sheet 6 of the stacked body 10 p. Therefore, when the fibrous active carbon sheet 6 and the hot-melt film 4 are compressed between the upper die of the molding die and the interior base material 2 and deformed into a shape of a convex portion along the outer surface 2s of the interior base material 2 by press-molding the heated laminated body 10p, the followability of the hot-melt film 4 can be improved, and the formation of wrinkles and welding unevenness of the hot-melt film 4 can be suppressed. Further, the interior material 10 for a vehicle, which can effectively remove unpleasant odor and VOC, can be manufactured.
(modification example)
Fig. 4 (base:Sub>A) isbase:Sub>A schematic plan view of the fibrous active carbon sheet and the hot-melt film of the laminate obtained in the lamination step of the method for producing an interior material forbase:Sub>A vehicle according to the modification example of embodiment 1, as viewed from the hot-melt film side, and fig. 4 (b) isbase:Sub>A schematic sectional view of the laminate taken along the linebase:Sub>A-base:Sub>A in fig. 4 (base:Sub>A).
As shown in fig. 4 (a) and 4 (b), in the laminate 10p obtained in the laminating step of the modification, the hot-melt film 4 is a single-layer film composed of a single welded layer. In the laminate 10p, the inner surface 4r of the hot-melt film 4 is in contact with the outer surface 2s of the interior base material 2, and the outer surface 4s of the hot-melt film 4 is in contact with the inner surface 6r of the fibrous active carbon sheet 6. As shown in fig. 4 (a), when the fibrous active carbon sheet 6 and the hot-melt film 4 are viewed from the hot-melt film side, the outer edge 6e of the fibrous active carbon sheet 6 is rectangular, and the outer edge 4e of the hot-melt film 4 overlaps the outer edge 6e of the fibrous active carbon sheet 6 except for the portion of the notch 4 n. The hot melt film 4 has a notch 4n at the corner 4g and a cross-shaped slit 4d on the inner side. The laminate 10p shown in fig. 4 is the same as the laminate 10p shown in fig. 3 except for the hot melt film 4.
In a modification of embodiment 1, a laminate 10p shown in fig. 4 is obtained, and an interior material for a vehicle is manufactured in the same manner as in embodiment 1, except for heating and press forming. Therefore, since the notches 4n and the slits 4d are provided in the hot-melt film 4, when the heated laminate 10p is press-molded, the following property of the hot-melt film 4 can be improved as in embodiment 1, and the formation of wrinkles and welding unevenness in the hot-melt film 4 can be suppressed. Further, it is possible to manufacture an interior material for a vehicle, which can secure air permeability between the interior substrate 2 and the fibrous active carbon sheet 6 by the notches 4n and the slits 4d of the hot-melt film 4.
(Effect)
Therefore, according to the vehicle interior material of the embodiment, the unpleasant odor and VOC can be effectively removed as in embodiment 1. Further, according to the method for manufacturing the vehicle interior material of the embodiment, the vehicle interior material capable of effectively removing the unpleasant odor and VOC can be manufactured as in embodiment 1 and the modification thereof. Further, by setting the conditions such as the shape, size, and arrangement position of the through-holes or slits of the hot-melt film to appropriate conditions, when the fibrous active carbon sheet and the fibrous active carbon sheet are deformed into shapes along the concave portions, convex portions, and the like on the surface of the interior base material by press-molding the heated laminate in the integration step, the followability of the hot-melt film can be improved, and the formation of wrinkles and welding unevenness of the hot-melt film can be suppressed.
Further, according to the embodiment, the interior base material and the fibrous carbon sheet can be integrated by press molding in the conventional mass production process of the vehicle interior material, and therefore, there is no need to change the conventional mass production process for mass production of the vehicle interior material provided with the activated carbon sheet, and no new cost for additional equipment investment or the like is incurred. Therefore, mass production can be performed with minimal additional cost. Further, according to the embodiment, the fibrous carbon sheet can be integrated with any shape portion including the concave portion, the convex portion, and the like on the surface of the interior base material, and therefore, the installation area of the fibrous carbon sheet required for sufficiently removing the unpleasant odor and the VOC can be secured. Further, according to the embodiment, since the area of the fibrous carbon sheet can be changed when the fibrous carbon sheet is laminated on the surface of the interior base material, restrictions on the installation position of the vehicle interior material, the molded component, and the like can be alleviated.
Hereinafter, each configuration of the vehicle interior material and the method of manufacturing the vehicle interior material according to the embodiment will be described in detail.
1. Interior material for vehicle
The interior material for a vehicle includes an interior base material and a fibrous active carbon sheet laminated on a surface of the interior base material via a hot-melt film, wherein the hot-melt film is provided with at least one of through holes and slits, and the interior base material and the fibrous active carbon sheet are integrated by welding the hot-melt film.
(1) Hot melt film
The hot-melt film is not particularly limited as long as at least one of the through-holes and slits is provided, and only one of the through-holes and slits may be provided as shown in fig. 2 (b), or both of them may be provided. The through-holes and slits of the hot-melt film correspond to those of the hot-melt film after fusion bonding between the internal base material and the fibrous active carbon sheet in the lamination step of the production method of the embodiment, and therefore, description thereof is omitted here.
The hot-melt film is not particularly limited as long as it is fused to the internal base material and the fibrous active carbon sheet, and may have a single-layer structure, as in the case where the hot-melt film shown in fig. 4 to be described later is fused to the internal base material and the fibrous active carbon sheet by heating, or a single fusion-bonded layer may be fused to the internal base material and the fibrous active carbon sheet by heating. Further, for example, as in the case of the hot-melt film shown in fig. 3, the hot-melt film may be fused to the internal base material and the fibrous active carbon sheet by heating, or may have a multilayer structure in which at least both ends in the stacking direction are formed of fusion-bonded layers, and the fusion-bonded layers at both ends in the stacking direction are fused to the internal base material and the fibrous active carbon sheet by heating, respectively.
As the hot-melt film having a multilayer structure, for example, like the hot-melt film in the vehicle interior material according to embodiment 1, it is preferable to dispose a heat-resistant layer between the weld layers at both ends in the laminating direction. This can surely obtain the effects of improving the following property and suppressing the formation of wrinkles and weld unevenness at the time of production.
The component of the fusion-bonded layer is not particularly limited as long as it can exhibit adhesion by heating and melting, and examples thereof include Ethylene Vinyl Acetate (EVA) based resins, polyamide based resins, polyester based resins, polyolefin based resins, and polyurethane based resins. The heat-resistant layer is not particularly limited as long as it is a component that does not melt at a temperature at which the fusion-bonded layer can be melted, and examples thereof include polyamide resins such as nylon, polyolefin resins, ethylene vinyl alcohol copolymers, and polyester resins.
The thickness of the hot-melt film is not particularly limited, and is preferably in the range of 30 μm to 100 μm, for example, in the case of a single-layer structure in which the hot-melt film is composed of a fusion-bonded layer. When the film thickness is not less than the lower limit of the range, sufficient strength can be obtained in the film itself, and when the film thickness is not more than the upper limit of the range, sufficient followability can be obtained. When the heat-resistant layer is disposed between the fusion layers at both ends of the hot-melt film in the laminating direction, the thickness of the fusion layer is preferably in the range of 10 μm or more and 50 μm or less, and the thickness of the heat-resistant layer is preferably in the range of 10 μm or more and 50 μm or less. When the thickness of the weld layer is not less than the lower limit of the range, sufficient strength can be obtained in the film itself, and when the thickness of the weld layer is not more than the upper limit of the range, sufficient conformability can be obtained. When the thickness of the heat-resistant layer is not less than the lower limit of the range, the film itself can have sufficient strength and can sufficiently maintain the shape, and when the thickness of the heat-resistant layer is not more than the upper limit of the range, sufficient conformability can be obtained.
(2) Fibrous active carbon sheet
The fibrous active carbon sheet is not particularly limited as long as it is formed into a sheet shape by using fibrous active carbon (active carbon fiber) as a main component, and examples thereof include a sheet shape formed by mixing a certain amount of thermoplastic synthetic fiber into fibrous active carbon by a dry or wet method, and a sheet shape formed by stacking a plurality of the sheets and heating the stacked sheets.
The material of the fibrous active carbon is not particularly limited, and examples thereof include pitch-based, phenol-based, cellulose-based, and acrylic-based materials. The thermoplastic synthetic fibers are not particularly limited, and for example, binder fibers made of polyester, polyamide, polyolefin, or the like can be used, and particularly, polyester binder fibers sold under the trademark melaty by UNITIKA corporation are preferable.
The thickness of the fibrous active carbon sheet is not particularly limited, and is preferably in the range of 600 μm to 1600 μm, for example. When the thickness is not less than the lower limit of the range, sufficient strength can be obtained, and when the thickness is not more than the upper limit of the range, sufficient flexibility and followability can be obtained.
(3) Built-in base material
The interior material is not particularly limited, and a material generally used for an interior material for a vehicle can be used, and examples thereof include a material obtained by mixing a thermoplastic resin with a fibrous material and molding the mixture into a plate shape.
Examples of the fibrous material include cotton, hemp, kenaf fiber, bamboo fiber, wool, silk, glass fiber, carbon fiber, metal fiber, and a mixed fiber thereof. Examples of the thermoplastic resin include polypropylene (PP), polyethylene (PE), polyethylene terephthalate (PET), nylon (PA), polystyrene, acrylonitrile-styrene copolymer, acrylate-styrene-acrylonitrile copolymer, and acrylonitrile-butadiene-styrene copolymer.
The thickness of the interior base material is not particularly limited, and is preferably in the range of, for example, 100 μm or more and 8000 μm or less. When the thickness is not less than the lower limit of the range, sufficient strength can be obtained, and when the thickness is not more than the upper limit of the range, cost can be sufficiently suppressed.
(4) Interior material for vehicle
Fig. 5 (a) to 5 (d) are photographs showing another example of the vehicle interior material according to the embodiment. As shown in fig. 5 (a), the interior material for a vehicle may be a floor covering, which includes: a face-protecting sheet (inner base material), and a fibrous activated carbon sheet laminated on the inner surface of the face-protecting sheet at a region facing the front sheet via a hot-melt film. As shown in fig. 5 (b) to 5 (d), the vehicle interior material may be a roof lining, a door trim, an instrument panel muffler, or the like, and includes: an interior base material, and a fibrous active carbon sheet laminated on the surface of the interior base material with a hot-melt film interposed therebetween.
The interior material for a vehicle is not particularly limited as long as it includes an interior base material and a fibrous carbon sheet laminated on the surface of the interior base material with a hot-melt film interposed therebetween, and the fibrous carbon sheet may be laminated directly on the surface of the interior base material with the hot-melt film interposed therebetween, or may further include another functional layer provided on the surface of the interior base material and serving a predetermined function, and the fibrous carbon sheet may be laminated on the surface of the other functional layer with the hot-melt film interposed therebetween. The vehicle interior material is generally produced by the production method according to the embodiment.
2. Method for manufacturing interior material for vehicle
A method for producing an interior material for a vehicle, which is a method for producing an interior material for a vehicle, in which an interior base material and a fibrous active carbon sheet are integrated, comprises a lamination step for laminating a fibrous active carbon sheet on the surface of an interior base material through a hot-melt film to obtain a laminate, the hot-melt film being provided with at least one of through holes and slits, and an integration step for integrating the fibrous active carbon sheet and the interior base material of the laminate by welding the hot-melt film.
(1) Lamination step
The hot-melt film interposed between the internal base material and the fibrous active carbon sheet in the lamination step is not particularly limited as long as at least one of the through-holes and the slits is provided, and only one of the through-holes and the slits may be provided as shown in fig. 3 (a), or both of them may be provided as shown in fig. 4 (a). The "through hole" refers to a hole or a notch penetrating the hot-melt film in the lamination direction. The "slit" refers to a cut that penetrates the hot-melt film in the lamination direction and is seen as a straight line when viewed from above in the lamination direction.
Fig. 6 (a) and 6 (b) are photographs showing another example of the hot-melt film according to the embodiment. As the hot melt film, through-holes may be provided by punching as shown in fig. 3 (a) and 6 (a), or through-holes may be provided by honeycomb processing as shown in fig. 6 (b). Fig. 7 (a) to 7 (c) are photographs showing a through-hole of another example of the hot-melt film according to the embodiment. The arrangement of the through-holes in the hot melt film is not particularly limited, and examples thereof include a circular hole parallel type shown in fig. 1 (b), fig. 7 (a) and fig. 7 (b), a circular hole staggered type shown in fig. 6 (a) and fig. 7 (c), and a honeycomb structure type shown in fig. 6 (b). The shape of the through-hole of the hot melt film is preferably, for example, a circular hole. This is a point of view in view of ease of processing and facility limitation in production. The size of the through-hole in a plan view of the hot melt film is preferably in a range of, for example, 1mm to 10mm in equivalent circle diameter. When the size is not less than the lower limit of the range, sufficient air permeability can be obtained, and when the size is not more than the upper limit of the range, the shape can be sufficiently suppressed from being unable to be held during punching. The area ratio of the through-holes in a plan view of the hot-melt film is preferably in a range of, for example, 3% to 20%. Since the area ratio passing through the through-hole is not less than the lower limit of this range, a sufficient air permeability can be obtained and, when the area ratio of the through-hole is equal to or less than the upper limit of the range, the shape of the punched hole is sufficiently suppressed from being unable to be held.
The hot-melt film is not particularly limited as long as it exhibits adhesion to the interior base material and the fibrous active carbon sheet by being melted by heating in the integration step, and may be a single-layer film composed of a fusion-bonded layer exhibiting adhesion by being melted by heating in the integration step, as shown in fig. 4, for example, or may be a multilayer film composed of a fusion-bonded layer exhibiting adhesion by being melted by heating in the integration step at least at both ends in the stacking direction, as shown in fig. 3, for example.
As a hot melt film having a multilayer structure, for example, a heat-resistant layer that is not melted by heating in the integrating step is preferably arranged between the weld layers at both ends in the laminating direction, like the hot melt film used in the manufacturing method of embodiment 1. In the integration step, when the hot-melt film is fused by press-molding the laminate, only the fusion-bonded layer can be melted without melting the heat-resistant layer, and therefore the through-holes and cracks of the hot-melt film can be maintained in the initial state, and as a result, the effects of improving the followability and suppressing the formation of wrinkles and fusion unevenness can be reliably obtained. Examples of such a hot-melt film include a three-layer hot-melt film having holes, which is manufactured by Elektrise plastics industries, ltd.
The components of the weld layer are the same as those described in the item "1. Vehicle interior material (1) hot-melt film", and therefore, the description thereof is omitted here. The components of the heat-resistant layer are the same as those described in the item "1. Vehicle interior material (1) hot-melt film", and therefore, the description thereof is omitted here.
The thickness of the hot-melt film is not particularly limited, and is preferably in the range of 30 μm to 100 μm, for example, when the hot-melt film has a single-layer structure including a fusion-bonded layer. When the film thickness is not more than the lower limit of the range, the film itself can have sufficient strength, and when the film thickness is not more than the upper limit of the range, sufficient followability can be obtained. When the heat-resistant layer is disposed between the weld layers at both ends of the hot-melt film in the laminating direction, the thickness of the weld layer is preferably in the range of 10 μm to 50 μm, and the thickness of the heat-resistant layer is preferably in the range of 10 μm to 50 μm. When the thickness of the weld layer is not less than the lower limit of the range, sufficient strength can be obtained in the film itself, and when the thickness of the weld layer is not more than the upper limit of the range, sufficient conformability can be obtained. When the thickness of the heat-resistant layer is not less than the lower limit of the range, the film itself can have sufficient strength and can sufficiently maintain the shape, and when the thickness of the heat-resistant layer is not more than the upper limit of the range, sufficient conformability can be obtained.
The fibrous active carbon sheet used in the lamination step is the same as the fibrous active carbon sheet described in the item "1. Fibrous active carbon sheet as interior material for vehicle (2)", and therefore, description thereof is omitted here.
The interior base material used in the laminating step is the same as the interior base material described in the item "1. Interior base material for vehicle (3): interior base material", and therefore, the description thereof is omitted here.
(2) Integrated process
The integration step is not particularly limited as long as the step of integrating the internal base material of the stacked body and the fibrous active carbon sheet by fusion of the hot-melt film is performed by press molding the stacked body, and for example, as in embodiment 1, a heating step of heating the stacked body and a molding step of press molding the heated stacked body may be provided. In addition, the integration step may be a step of press-molding the laminate with a heated molding die. In such an integration step, the laminate is heated by a press mold during press molding, whereby the hot-melt film is heated and melted and can be welded to the interior base material and the fibrous active carbon sheet.
The heating temperature of the hot-melt film is not particularly limited as long as it is a temperature at which the fusion-bonded layer melts and exhibits adhesion, and is set according to the composition of the fusion-bonded layer and the like. For example, it is preferably in the range of 110 ℃ to 160 ℃. In the case where the heat-resistant layer is disposed between the weld layers at both ends in the laminating direction, the heating temperature of the hot-melt film is preferably in a range of not less than the temperature at which the weld layers melt to exhibit adhesion and less than the temperature at which the heat-resistant layer melts, for example, in a range of not less than 110 ℃ and not more than 200 ℃.
(3) Method for manufacturing interior material for vehicle
The method for producing the interior material for a vehicle is not particularly limited as long as it includes a lamination step and an integration step, and in the lamination step, a method may be employed in which a fibrous active carbon sheet is laminated directly on the surface of the interior substrate through a hot-melt layer to obtain a laminate and the laminate is press-molded in the integration step, or a method may be employed in which a fibrous active carbon sheet is laminated through a hot-melt layer on the surface of another functional layer provided on the surface of the interior substrate to perform a predetermined function in the lamination step to obtain a laminate and the laminate is press-molded in the integration step.
Examples
Hereinafter, the vehicle interior material and the method for producing the vehicle interior material according to the present invention will be described in more detail by referring to examples and reference examples.
[ examples ]
As the interior material for a vehicle of the present invention, a storage tray is manufactured. Hereinafter, the description will be specifically made.
First, an interior base material, a fibrous active carbon sheet, and the following members as a hot-melt film are prepared (preparation step).
(built-in base material)
The product is as follows: built-in base material for storage tray manufactured by Takehiro corporation
The method comprises the following steps: substrate made of polyamide and polyethylene
Thickness: 5000 mu m
(fibrous active carbon sheet)
Product name: fibrous activated carbon sheet FMS-AC112T6 manufactured by UNITIKA corporation
Thickness: 1080 μm
(Hot melt film)
Product name: aizhi plastic industry corporation three-layer hot melt film with holes
Shape and size of the outer edge: except the gap part, the shape and the size of the fibrous active carbon sheet are the same as those of the fibrous active carbon sheet
Thickness: 50 μm (thickness of heat-resistant layer: 12 μm, thickness of weld layer: 19 μm)
Shape and arrangement of through-holes in plan view: the circular holes are arranged in parallel
Equivalent circle diameter of through hole in plan view: 2.5mm
Area ratio of through hole in plan view: 9 percent of
Next, a laminate is obtained by laminating a fibrous active carbon sheet on one surface of the interior substrate with a hot-melt film interposed therebetween (lamination step). At this time, the outer edge of the hot-melt film overlaps the outer edge of the fibrous active carbon sheet except for the notch portion.
Next, the laminate is put into a heating furnace, and the laminate is heated in the heating furnace (heating step). At this time, the surface temperature of the fibrous active carbon sheet of the laminate was maintained at 120 ℃ for 20 seconds to heat the laminate.
Next, the heated laminate is placed between an upper die and a lower die of a molding die, and press-molded by the molding die (molding step). Thus, the interior base material of the laminate is molded into a mold surface shape, and one side surface of the interior base material is formed into a shape having a concave portion and a convex portion. At the same time, the fibrous active carbon sheet and the hot-melt film are compressed between the upper die of the molding die and the interior base material, and deformed into shapes along the concave portions and convex portions on the one-side surface of the interior base material. Then, the fusion-bonded layers at both ends in the lamination direction of the hot-melt film are fused to the concave and convex portions on the one surface of the interior base material and the surface of the fibrous active carbon sheet, respectively. In this way, the internal base material of the stacked body and the fibrous active carbon sheet are integrated by welding of the hot-melt film (integration step).
Next, the integrated laminate is placed between an upper die and a lower die of a punching die, and cut by the punching die so that the outer edge when viewed from the laminating direction in a plan view has a desired shape (cutting step), thereby manufacturing a tray (vehicle interior material).
[ Observation of appearance ]
FIG. 8 (a) is a photograph showing the appearance of the fibrous active carbon sheet side of the storage tray manufactured in the example. As shown in fig. 8 (a), in the storage tray manufactured in the example, wrinkles and welding unevenness were not observed from the appearance of the fibrous active carbon sheet. It is considered that the formation of wrinkles and welding unevenness of the hot-melt film can be suppressed. In fig. 8 (a), the interior base material appears behind the tray.
[ sensory test for odor-removing Properties ]
The deodorizing performance of the trays manufactured in the examples was evaluated by sensory tests. Specifically, the odor intensity and the unpleasant odor of the storage trays manufactured in the examples were evaluated by a plurality of testers on the basis of the following criteria. In addition, the odor intensity of the unique odor (solvent odor, amine odor, bitter taste, sour taste, pungency, and fishy odor) of the storage tray was also evaluated by a plurality of testers according to the following criteria. Further, as a comparative object, the interior base materials used in the examples were also evaluated in the same manner. Then, the odor intensity and the unpleasant feeling of the storage tray of example (with activated carbon) and the built-in base material of the comparison object (without activated carbon) and the odor intensity of the unique odor were averaged to obtain the evaluation results of all the testers.
(odor intensity)
4.0: strong smell
3.0: smell easily perceived
2.0: faint smell
1.0: secret and knowable smell
0.0: is tasteless
(uncomfortable feeling)
0.0: without discomfort
-1.0: slight discomfort
-2.0: discomfort
-3.0: is very uncomfortable
(odor intensity of unique odor)
4.0: strong smell
3.0: smell easily perceived
2.0: faint smell
1.0: secret and knowable smell
0.0: is tasteless
Fig. 8 (b) is a graph showing the average values of the evaluation results of the odor intensity and the unpleasant feeling of the built-in base material of the storage tray of example (with activated carbon) and the comparative object (without activated carbon) and the odor intensity of the unique odor. As shown in fig. 8 (b), the average values of the evaluation results of the odor intensity and the unpleasant feeling of the example (with activated carbon) and the odor intensity of the unique odor were lower than the comparative object (without activated carbon).
[ reference example ]
As a vehicle interior material of a reference example, a floor covering (hereinafter, may be simply referred to as an activated carbon-integrated floor covering) is prepared which includes an interior base material and a fibrous carbon sheet laminated on the surface of the interior base material via a hot-melt film, and in which the interior base material and the fibrous carbon sheet are integrated by welding of the hot-melt film. Then, sensory tests for odor removing performance and sensory tests for VOC removing performance were performed on the activated carbon-integrated floor covering of the reference example.
[ sensory test for odor-removing Properties ]
The odor removing performance of the activated carbon-integrated floor covering of the reference example was evaluated by a sensory test. Specifically, the odor intensity of the unique odor (solvent odor, amine odor and sour odor) of the activated carbon-integrated floor covering of the reference example was evaluated by a plurality of testers according to the following criteria. As a comparative object, a general floor covering, which was composed of an interior base material used in the activated carbon-integrated floor covering of the reference example and did not include an activated carbon sheet, was also evaluated in the same manner. Then, the odor intensity of the unique odor of the activated carbon-integrated floor covering of the reference example and the odor intensity of the unique odor of the general floor covering of the comparative example were averaged to obtain the evaluation results of all the testers.
(odor intensity of unique odor)
4.0: strong smell
3.0: smell easily perceived
2.0: faint smell
1.0: secret and knowable smell
0.0: is tasteless
Fig. 9 (a) is a graph showing an average value of evaluation results of odor intensity of the unique odor of the activated carbon-integrated floor covering of the reference example and the normal floor covering of the comparative target. As shown in fig. 9 (a), the evaluation results of the odor intensity of the unique odor of the activated carbon-integrated floor covering of the reference example were all much lower in average value than the ordinary floor covering of the comparative example.
[ sensory test for VOC removing Properties ]
The VOC removing performance of the activated carbon-integrated floor covering of the reference example was evaluated. Specifically, a plurality of test pieces prepared by cutting the activated carbon-integrated floor covering in the stacking direction were put into an air bag having a capacity of 300 liters together with 250 liters of pure air, and heated at 65 ℃ for 2 hours. Next, according to the JASO-M902 method, aldehydes were collected in a DNPH cartridge, and other hydrocarbons were collected in a Tenax tube, and then the VOC amount [ μ g/piece ] of each test piece in the bladder was measured using a high-performance liquid chromatograph and a gas chromatograph mass spectrometer. Further, as a comparative object, VOC removing performance was similarly evaluated also for a general floor covering composed of the interior base material used in the reference example and not provided with the activated carbon sheet.
Fig. 9 (b) is a graph showing the amount of aldehydes in each test piece in the air bag measured for the activated carbon-integrated floor covering of the reference example and the normal floor covering of the comparative target. Fig. 9 (c) is a graph showing the amounts of other hydrocarbons measured for each test piece in the air bag for the activated carbon-integrated floor covering of the reference example and the normal floor covering of the comparative example.
As shown in fig. 9 (b), all of the VOC amounts of aldehydes in each test piece in the air bag measured with respect to the activated carbon-integrated floor covering of the reference example were much lower than those of the comparative ordinary floor covering. As shown in fig. 9 (c), the VOC amounts of other hydrocarbons measured for each test piece in the air bag with respect to the activated carbon-integrated floor covering of the reference example were also all much lower than those of the comparative ordinary floor covering.
While the embodiments of the vehicle interior material and the method for manufacturing the vehicle interior material according to the present invention have been described above in detail, the present invention is not limited to the above embodiments, and various design changes may be made without departing from the scope of the claims.
Claims (2)
1. An interior material for a vehicle, characterized in that,
comprising an interior base material and a fibrous active carbon sheet laminated on the surface of the interior base material with a hot-melt film interposed therebetween,
at least one of a through hole and a slit is provided on the hot melt film,
the internal base material and the fibrous active carbon sheet are integrated by welding the hot-melt film.
2. A method for producing an interior material for a vehicle, which comprises integrating an interior base material and a fibrous active carbon sheet, characterized by comprising a lamination step and an integration step,
a laminating step of laminating a fibrous activated carbon sheet on a surface of an interior base material via a hot-melt film, wherein at least one of a through-hole and a slit is provided in the hot-melt film,
the integration step is a step of press-molding the laminate, and integrating the internal base material and the fibrous active carbon sheet of the laminate by welding the hot-melt film.
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| JP2021-158159 | 2021-09-28 | ||
| JP2021158159A JP2023048699A (en) | 2021-09-28 | 2021-09-28 | Interior material for vehicle, and manufacturing method of interior material for vehicle |
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| Publication Number | Publication Date |
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| CN115869905A true CN115869905A (en) | 2023-03-31 |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2002126511A (en) * | 2000-10-26 | 2002-05-08 | Unitika Ltd | Deodorizing sheet and deodorizing vehicle interior furnishing |
| CN1521055A (en) * | 2003-01-14 | 2004-08-18 | �����֯��ʽ���� | Interior trim material for vehicle and manufacturing method thereof |
| JP2007083859A (en) * | 2005-09-21 | 2007-04-05 | T S Tec Kk | Interior material for vehicle, roof trim for vehicle and manufacturing method of interior material for vehicle |
| JP2010036553A (en) * | 2008-08-08 | 2010-02-18 | Nissan Motor Co Ltd | Interior material and method for manufacturing the same |
| CN103998228A (en) * | 2011-12-16 | 2014-08-20 | 仓敷纺绩株式会社 | Fibre-reinforced resin moulding, and vehicle interior material using same |
| CN105307749A (en) * | 2013-06-07 | 2016-02-03 | 东洋纺株式会社 | Filtering medium for deodorizing filter |
-
2021
- 2021-09-28 JP JP2021158159A patent/JP2023048699A/en active Pending
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2022
- 2022-08-22 CN CN202211006372.6A patent/CN115869905A/en active Pending
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2002126511A (en) * | 2000-10-26 | 2002-05-08 | Unitika Ltd | Deodorizing sheet and deodorizing vehicle interior furnishing |
| CN1521055A (en) * | 2003-01-14 | 2004-08-18 | �����֯��ʽ���� | Interior trim material for vehicle and manufacturing method thereof |
| JP2007083859A (en) * | 2005-09-21 | 2007-04-05 | T S Tec Kk | Interior material for vehicle, roof trim for vehicle and manufacturing method of interior material for vehicle |
| JP2010036553A (en) * | 2008-08-08 | 2010-02-18 | Nissan Motor Co Ltd | Interior material and method for manufacturing the same |
| CN103998228A (en) * | 2011-12-16 | 2014-08-20 | 仓敷纺绩株式会社 | Fibre-reinforced resin moulding, and vehicle interior material using same |
| CN105307749A (en) * | 2013-06-07 | 2016-02-03 | 东洋纺株式会社 | Filtering medium for deodorizing filter |
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