JP2001322193A - Constituent member for trimming vehicle interior and interior trimming material for vehicle using the constituent member - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an interior trimming material for a vehicle which maintains satisfactory acoustical properties and resin part recycleabilities, without fear about the possible contamination or generation of an extraordinary sound due to an air current. SOLUTION: This constituent member for trimming a vehicle interior comprises a hot melt film with 80-150 deg.C melt point, 1-100 MFR and 20-70 μm thickness and a non-woven fabric with a higher melt point by 20 deg.C than that of the hot melt film and 0.25-0.90 g/cm3 average apparent density, both being joined together, and also shows 50-500% breaking extension at 100 deg.C and 50"/100 deg.C or more air permeability at 100 deg.C and during 20% extension. In addition, the interior trimming material for a vehicle made up of a skin material, a base material and a back material is of such a construction that the back material is constituted of the described constituent member and is laminated and molded so as to position the face of the hot melt film on the base material side. Especially the interior trimming material is characterized in that the nonwoven fabric and the hot melt film which constitute the skin material, the base material and the back material are entirely made of the same material.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior component which can be used as a member constituting an interior material for a vehicle, and an interior material for a vehicle which uses the interior component as a back surface material.

[0002]

2. Description of the Related Art Various types of vehicle interior materials are used. As characteristics required for vehicle interior materials, their decorativeness and contact feeling to passengers are indispensable, but recently low air permeability is also required. If air permeability is high, a phenomenon in which indoor air permeates through the interior material due to a pressure difference and may move toward the body may occur, but at this time, fine particles such as tobacco tar floating in the indoor air may adhere to the interior material surface. It is trapped and becomes dirty and adheres to the interior material. Therefore, it is necessary to eliminate this air flow, and as a countermeasure, an interior material has been provided with an air-permeable blocking layer. Generally, a plastic film is used for the air-permeable barrier layer.

[0003] Japanese Patent Application Laid-Open No. Hei 7-117571 discloses an interior material for a vehicle comprising a skin material (with a cushion material) / multilayer film / base material. The multilayer film includes a low-melting-point resin layer having thermal adhesiveness and a high-melting-point resin layer between them, and this high-melting-point layer functions as an air-permeable barrier layer. However, although this invention is effective against the problem of contamination of the ceiling skin material, the sound from the indoor side is reflected by this air-permeable barrier layer because the air-permeable barrier layer is directly behind the thin skin material. As a result, there is a problem that the sound absorbing function as an interior material is impaired. Further, Japanese Utility Model Laid-Open No. 5-65532 discloses a structural material composed of a skin material / substrate / back surface material (hot melt + impermeable film). In this configuration, since this structural material has a resin layer on the rearmost surface side in contact with the body of the vehicle, noise occurs due to friction between the resin layer and the metallic body due to vibration of the vehicle, etc., and discomfort to the occupant is caused. give. In addition, as a backing material,
That is, it is necessary to use multilayer films having different compositions,
The structure becomes complicated and the recyclability is reduced, so that it is not possible to sufficiently meet social demands.

[0004]

SUMMARY OF THE INVENTION The present invention is free from the above-mentioned problems, that is, it has good sound absorbing properties, is less liable to be stained by airflow in a room, and has no abnormal noise.
It is still another object of the present invention to provide an interior material for a vehicle which is excellent in recyclability of a resin portion when disassembling the vehicle.

[0005]

According to the present invention, a melting point of 80 to 1 is used.
A hot melt film having a temperature of 50 ° C., an MFR of 1 to 100 and a thickness of 20 to 70 μm, a melting point higher than that of the hot melt film by 20 ° C. or more, and an apparent density of 0.25 to 0.90 g
/ Cm is ³ joining the nonwoven elongation at break 50 to 500 percent of the temperature 100 ° C., air permeability at 20% elongation at a temperature 100 ° C. is a vehicle interior component is 50 seconds / 100 cc or more. Further, the present invention provides a vehicle interior material comprising a skin material, a base material, and a back material, wherein the back material is formed of the above-described constituent members, and the hot melt film surface of the back material is laminated so as to be located on the base material side. And a molded vehicle interior material. In particular, the present invention relates to the above vehicle interior material, in which the nonwoven fabric and the hot melt film constituting the skin material, the base material, and the back surface material are all made of the same material.

A feature of the present invention is that a hot-melt film having a specific property which functions as a hot-melt adhesive and also functions as a ventilation barrier to some extent, and has a low air permeability due to a higher apparent density than a normal nonwoven fabric. In addition, a specific nonwoven fabric having excellent moldability is combined with a specific nonwoven fabric to form a constituent member. As a result, the object of the present invention can be achieved, and the simplicity of the configuration can simplify the manufacturing process, reduce the cost, and facilitate the selection of recyclable materials. . That is, by using a nonwoven fabric having a higher apparent density than a generally used nonwoven fabric (usually, an apparent density of 0.2 g / cm ³ or less) as a backing material, a relatively thin hot melt film is used. Even so, the air permeability of the back material can be reduced.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION The vehicle component according to the present invention is a composite sheet formed by joining a thin hot melt film and a specific nonwoven fabric having low air permeability and moldability. The member for vehicle configuration of the present invention is molded using a mold while being heated to a temperature of 80 to 150 ° C. Since it is easily deformed during the molding process, the molding process can be performed favorably, which is one of the features of the vehicle component of the present invention. Conditions as preferred configuration member is 20% elongation stress when heated to molding temperature 70 kg / cm ² or less, preferably 0.1~50kg / cm ^2. The 20% elongation stress is obtained by converting the strength at the time of elongation of 20% into the stress per cross-sectional area. And elongation at break when heated to a molding temperature is 50 to 500%, preferably 70 to 4%.
It is 50%, and the vehicle component according to the present invention also satisfies the condition. Further, the air permeability at 20 ° C. elongation at a temperature of 100 ° C. is 50 seconds / 100 cc or more, preferably 70 seconds / 100 cc or more. 20% at 100 ° C here
If the air permeability during elongation is 50 seconds / 100 cc or more,
This is the value obtained when the sample was cooled at room temperature while being stretched at 00 ° C. by 20%, and thereafter the air permeability was measured. 20% elongation stress is 70
If it exceeds kg / cm ² and the elongation at break is less than 50%, conformity to a mold during molding is poor, and deformation becomes difficult.
Then, the air permeability when extended by 20% is 50 seconds / 100
If it is less than cc, problems such as poor air blocking properties and easy staining of the skin material and the like arise.

[0008] The nonwoven fabric constituting the vehicle component of the present invention is selected in consideration of moldability and air permeability that can be integrally formed. Therefore, a nonwoven fabric in which the apparent density, the breaking elongation at the time of forming, and the like are selected within a specific range is used for a component for a vehicle interior having the formability which is the object of the present invention.

As the nonwoven fabric suitable for the present invention, a nonwoven fabric manufactured by a known spun bonding method, thermal bonding method, needle punching method or the like can be used. The fibers constituting the nonwoven fabric are polyethylene, polyolefin fibers such as polypropylene, polyethylene terephthalate, polyester fibers such as polybutylene terephthalate,
Polyamide fibers such as nylon-6 and nylon-66,
Copolyester fiber, copolyamide fiber,
Single or two or more kinds of short fibers and long fibers such as a composite fiber such as a core-sheath type or a side-by-side type are mixed or laminated.

The fiber diameter of the fibers constituting the nonwoven fabric is preferably 0.6 to 11 dtex, more preferably 1 to 7 dtex.
dtex. In addition, a fiber having a circular cross section and various irregular cross sections can be used. As the fiber constituting the nonwoven fabric, a polyester long fiber nonwoven fabric having a birefringence of 0.02 to 0.07 by a spun bond method is particularly preferable from the viewpoint of moldability and air permeability.

The values of the elongation at break and the initial elongation stress at the molding temperature of the nonwoven fabric are important because they affect the moldability.
That is, the high elongation at break and the small value of the initial elongation stress can be easily deformed with a small force, and therefore, the ease of deformation, the conformability to a mold such as a deep uneven shape or a complicated shape, etc. This leads to excellent moldability. The nonwoven fabric used in the present invention preferably has a breaking elongation of 50 to 500.
%, More preferably 70 to 450%. Also preferably, as the initial elongation stress, the elongation stress at 20% elongation is 7%.
0 kg / cm ² or less, more preferably 0.1 to 50 kg /
cm ² . If the elongation at break is less than 50% and the elongation stress at 20% elongation exceeds 70 kg / cm ² , deformation is difficult and the conformability to the mold is poor. On the other hand, when the elongation at break exceeds 500%, problems such as the occurrence of fusion to the mold and the susceptibility to thermal degradation occur.

The apparent density of the nonwoven fabric is 0.25 to 0.90 g
/ Cm ³ , preferably 0.30 to 0.65 g / cm ³ , and such an apparent density is necessary for moldability, air permeability, and the like that can be integrally molded. When the average apparent density is less than 0.25 g / cm ³ , the moldability is good but the air permeability is high. On the other hand, if it exceeds 0.90 g / cm ³ , the air permeability can be suppressed low, but the moldability decreases. In addition, since the nonwoven fabric must not change its shape and physical properties even when bonded to a hot melt film, its melting point needs to be 20 ° C. or more higher than the melting point of the hot melt film to be bonded.

A hot-melt film, which is another component constituting a vehicle component, has a melting point of 80 to 150 ° C.
Those having an MFR of 1 to 100 and a thickness of 20 to 70 μm are preferred. When the melting point is lower than 80 ° C., the heat resistance of the interior material for a vehicle is insufficient. On the other hand, when the temperature is higher than 150 ° C., melting and bonding become extremely difficult during molding. A more preferable melting point range is 90 to 145 ° C. MF of hot melt film
When R is less than 1, the melt viscosity during molding is high, and the melt does not sufficiently penetrate into the adherend, and thus a sufficient adhesive strength cannot be obtained. On the other hand, if it is higher than 100, the melt viscosity of the resin at the time of molding is too low, so that it penetrates only to the lower side at the time of bonding of the upper and lower adherends, for example, only the base material, and still has a sufficient adhesive force. Is difficult to obtain. Use of a material having an excessively high MFR adversely affects heat resistance as an interior material for an automobile. A more preferred range of MFR is 3 to 90.
It is.

If the thickness of the hot melt film is less than 20 μm, it does not sufficiently penetrate into the base material during molding, so that a sufficient adhesive strength cannot be obtained. Further, when used as a component (back surface material) of a molded ceiling in combination with a nonwoven fabric, if it is less than 20 μm, it is not possible to exhibit sufficient air-permeability to stop ventilation of the molded ceiling. Further, the thicker the thickness, the better the air permeability, but on the other hand, it is disadvantageous in terms of economic efficiency.
Exceeding 0 μm results in excessive quality. A more preferred thickness is 30 to 60 μm. The hot melt film is 2
Although it may be used as a multilayer film having more than one layer, a single layer is more preferable in terms of cost, simplicity of the manufacturing process, and particularly in terms of recyclability.

As the material of the hot melt film, ethylene-acrylic acid copolymer, ethylene-methacrylic acid copolymer, various polyethylene resins (low density, medium density, high density, linear low density, branched low density) Or these acid-modified resins; ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, ethylene-methyl acrylate copolymer, ethylene-butyl acrylate copolymer,
Ethylene-methyl methacrylate copolymer, ethylene-
Butyl methacrylate copolymer, ethylene- (meth) acrylate copolymer, ethylene-maleic acid copolymer,
Ethylene-itaconic acid copolymer, ethylene-α-olefin copolymer, ethylene-acrylate-methacrylic acid terpolymer, ethylene-acrylate-maleic anhydride terpolymer, or acid-modified thereof Resins; ionomers obtained by ion-crosslinking a copolymer of ethylene and acrylic acid or methacrylic acid; atactic polypropylene or acid-modified resins thereof; copolymer polyamides; terephthalic acid, ethylene glycol and 1,4-
Examples thereof include copolymers of butanediol and copolymer polyesters containing other components. These resins may be used alone or as a mixture. In addition, various additives such as a filler such as calcium carbonate and talc and a tackifier may be mixed with these.

The specific nonwoven fabric and hot-melt film constituting the vehicle interior component of the present invention can be freely selected as long as the above-mentioned required characteristics of the vehicle interior component are satisfied. For example, when the density of the nonwoven fabric is relatively small within a predetermined range, the thickness of the hot melt film can be increased. When the density of the nonwoven fabric is relatively large within the predetermined range, the thickness of the hot melt film can be reduced.

The present invention also relates to a vehicle interior material using the above vehicle interior component as a back surface material. The vehicle interior material is a member provided on the indoor side surface of the vehicle body panel, and is composed of a skin material, a base material, and a back material.
Consists of components. The back material constitutes the body panel side, while the skin material is arranged to be inside the vehicle, and the base material is constituted as an intermediate layer between the skin material and the back material. In the present invention, by using the vehicle interior component as the back surface material and by setting the skin material and the base material as described below, good sound absorption is maintained, and the skin material is stained by the airflow in the room. An object of the present invention is to provide an interior material for a vehicle, which generates less noise and does not generate noise.

In the vehicle interior material according to the present invention, the base material is preferably a material which can be shaped by heating and pressing and has air permeability. Examples of such a substrate include a nonwoven fabric in which inorganic fibers, organic fibers, or a fiber mixture thereof are bonded to each other with a thermoplastic resin, or a knitted or woven fabric made of these fibers. In the above, glass fibers and carbon fibers are used as the inorganic fibers, and various natural fibers such as cotton and hemp are used as the organic fibers; polyester fibers, polyamide fibers, acrylic fibers, polypropylene fibers, polyvinyl alcohol fibers, and acetate fibers. Various synthetic or regenerated fibers such as system fibers and rayon can be exemplified. As the substrate, a foamed urethane sheet or a sheet reinforced with glass fibers or the like can be used.

The material that can be used as the skin material of the vehicle interior material is selected from those having air permeability. In particular,
Non-woven fabrics or woven fabrics made of polyester fiber, polypropylene fiber, or the like, knits, brushed knits, and those backed with foamed urethane or non-woven fabric can be used.

One feature of the present invention is that excellent recyclability is achieved because all of the vehicle interior materials can be made of the same resin. The interior material for vehicles can be collected and reused by using polyester as the nonwoven fabric and the hot melt film constituting the skin material, the base material, and the back material which are the constituent components.

[0021]

The present invention will be described below more specifically and in detail with reference to examples. Example 1 [Preparation of Interior Component] ^On a polyester non-woven fabric having a melting point of 260 ° C. and an apparent density of 0.40 g / cm ³ , an extruder was used. Extrude the united hot melt resin,
The two components were integrated by an extrusion lamination method to produce an interior component. 100 ° C of the obtained interior component
Table 1 shows the elongation at break at 20 ° C. and the air permeability at 20% elongation at 100 ° C.

[Preparation of Interior Material for Vehicle] A base material made of polyester fiber mat (basis weight: 800 g / m ² )
Heat at 20 ° C, take out and immediately superimpose the back material and the skin material on both sides, 4m thick in a press set at 60 ° C
Pressing was performed for 40 seconds using the m spacer to prepare a vehicle interior material in which the skin material / substrate / back surface material was integrally laminated. As the backing material, the interior component prepared above was used, and as the skin material, a web-like polyamide hot melt 30 was previously prepared.
g / m ² and laminated with a basis weight of 180 g / m ² of polyester needle-punched nonwoven fabric was used, respectively. In the lamination with the base material, the hot melt side of the back surface material and the skin material was used as the base material side. The adhesive strength and air permeability of the obtained laminate were measured and are shown in Table 1.

The air permeability (components for interior and interior materials for vehicles) and adhesive strength of the laminate were measured as follows. (1) Measurement of air permeability: Measured according to JIS P-8117. (2) Measurement of adhesive strength between back material nonwoven fabric and base material The laminate is cut into a 25 mm width, and an interface (an interface between the back material nonwoven fabric and the base material) for which the adhesive strength is to be measured is partially peeled off, and both are separated. The piece was grasped and pulled through an Instron tensile tester. The peel strength was defined as the adhesive strength. Tensile test condition: 23 ° C, 180 ° peeling, Tensile speed 200mm / min

Examples 2 to 4 [Preparation of Interior Components] The interior components of Examples 2 to 4 were produced using the hot melt resin and the nonwoven fabric shown in Table 1. 100 ° C of the obtained interior component
Table 1 shows the elongation at break at 20 ° C. and the air permeability at 20% elongation at 100 ° C.

[Preparation of vehicle interior material] Vehicle interior materials of Examples 2 to 4 were produced in the same manner as in Example 1 except that the above-mentioned interior components were used as the back surface material. The adhesive strength and air permeability of the obtained laminate were measured and are shown in Table 1.

Comparative Example 1 [Preparation of Interior Components] The interior components of Comparative Example 1 were produced using the hot melt resin and the nonwoven fabric shown in Table 1. Table 1 shows the elongation at break at 100 ° C. and the air permeability at 20% elongation at 100 ° C. of the obtained interior component.

[Preparation of Vehicle Interior Material] A vehicle interior material of Comparative Example 1 was prepared in the same manner as in Example 1 except that the above-mentioned interior component member was used as a back surface material. The adhesive strength and air permeability of the obtained laminate were measured and are shown in Table 1.

[0028]

[Table 1]

[0029]

According to the present invention, when the interior material for a vehicle is formed by using the interior component having the ventilation-preventing layer of the present invention as the back material, the flow of indoor air from the surface layer to the back surface is eliminated, so that dirt adheres to the skin material. It can be prevented from being soiled, and there is no unpleasant feeling that the indoor sound reverberates at the barrier layer. In addition, since the back surface material in contact with the vehicle body is not exposed, no abnormal noise (squeaking noise) due to friction occurs. In addition, since the back material or the entire interior material can be made of the same kind of resin, there is an advantage that the recyclability of the material is excellent.

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Noriaki Matsumura, Inventor Maeda Kasei Co., Ltd. 5-2-2, Uehonmachi, Chuo-ku, Osaka-shi, Osaka (72) Hirofumi Iwasaki 1, Dojimahama, Kita-ku, Osaka-shi, Osaka No.2 Asahi Kasei Kogyo Co., Ltd. (72) Inventor Norio Ise 2-4-1, Kutaro-cho, Chuo-ku, Osaka City, Osaka Prefecture Kurashiki Spinning Co., Ltd. Osaka Head Office (72) Inventor Masashi Nakano Osaka, Osaka, Japan 2F 4-31, Kutaro-cho, Chuo-ku, Kurashiki-Shinbo Co., Ltd. F-term (reference) 3D023 BA01 BB01 BC01 BD01 BD02 BE04 BE06 BE31 4F100 AK41A AK41B AK41C AK41D AR00A AT00C AT00D BA02 BA04 BA07 BA10B BA10 DG33 JA04B JA06A JD02 JL08 JL12A YY00 YY00A YY00B

Claims (4)

[Claims] 1. Melting point: 80 to 150 ° C., MFR: 1 to 10
0, a hot melt film having a thickness of 20 to 70 μm and a nonwoven fabric having a melting point higher than that of the hot melt film by 20 ° C. or more and an apparent density of 0.25 to 0.90 g / cm ³ at a temperature of 100 ° C. Elongation at break is 50-500
%, Air permeability at 20% elongation at a temperature of 100 ° C. is 50 seconds / 1
A vehicle interior component that is at least 00 cc. 2. An interior material for a vehicle comprising a skin material, a base material and a back material, wherein the back material comprises the interior component according to claim 1, and the hot melt film surface of the back material is on the base material side. An interior material for a vehicle which is laminated and molded so as to be positioned. 3. The vehicle interior material according to claim 2, wherein the nonwoven fabric and the hot melt film constituting the skin material, the base material, and the back surface material are all made of the same material. 4. The vehicle interior material according to claim 2, wherein the nonwoven fabric and the hot melt film constituting the skin material, the base material, and the back surface material are all made of a polyester material.