JP2002210856A - Interior material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an interior material abounding in moldability and sound absorbing properties. SOLUTION: Powder 16 of a hot-melt adhesive is scattered on an adherent surface of a fibrous sheet 15 and a skin material 6 is adhered by the medium of the powder 16 of the hot-melt adhesive. Thereby air permeability is ensured.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior material used for a ceiling material of an automobile and the like.

[0002]

2. Description of the Related Art Conventionally, for example, in the case of a ceiling material of an automobile, as shown in FIG.
Glass fiber mat with urethane adhesive on both sides
(3,4) is bonded and reinforced, and the surface side is made of non-woven fabric through hot-melt film (5).
(6) glued, and on the back side, the glass fiber mat
To cover (4), an interior material (1) to which a nonwoven fabric (8) is adhered via a hot melt film (7) is used.

[0003]

The above-mentioned conventional interior materials
In the case of (1), since the skin material (6) is adhered via the hot melt film (5), the air circulation is hindered by the hot melt film (5), and the sound absorption is poor. There is a point.

[0004]

According to the present invention, as a means for solving the above-mentioned conventional problems, a hot melt adhesive powder (16) is scattered on the bonding surface of a fiber sheet (15), The present invention provides an interior material (11) in which a skin material (6) is adhered via a melt adhesive powder (16). Further, the present invention provides an interior material (11) in which a glass fiber sheet (3) is adhered to the back surface of a fiber sheet (15) having hot melt adhesive powder (16) interspersed on the adhesion surface, and a porous substrate ( 2) Fiber sheet lined with glass fiber sheet (3) with adhesive
(15), and a skin material (6) via hot melt adhesive powder (16) scattered on the surface of the fiber sheet (15).
To provide an interior material (11) to which is adhered. A glass fiber sheet is adhered to the back surface of the porous substrate (2) with an adhesive.
It is desirable that the laminated sheet (9A, 9B) of (4) and the fiber sheet be bonded. The skin material (6) desirably has air permeability. Further, it is desirable that the laminated sheets (9A, 9B) are impregnated with an initial condensate of a thermosetting synthetic resin.

[0005]

In the present invention, in order to bond the skin material (6), a fiber sheet (15) having hot melt adhesive powder (16) scattered on the bonding surface is used instead of the conventional hot melt film. On the other hand, if the skin material (6) is air permeable, air permeability is ensured up to the position of the base material (2), and sound absorption is improved.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described with reference to one embodiment shown in FIGS. 1 and 2. As a porous base material (2) of an interior material (11) used as a ceiling material of an automobile, a semi-finished material is used. A porous base material (2) such as a rigid urethane foam resin sheet, a soft urethane foam resin sheet impregnated with a polyvalent isocyanate or a urethane prepolymer, a rigid fiber mixed polypropylene foam sheet, and a rigid fiber mixed polystyrene foam sheet is used. Such a porous substrate (2) is lightweight and has a sound absorbing property. However, since the porous substrate (2) has poor rigidity, a glass fiber sheet (3) is adhered to the surface of the porous substrate (2) with an adhesive for reinforcement.
The glass fiber sheet (3) is a glass fiber nonwoven fabric (glass fiber mat), a glass fiber knitted fabric (glass cloth) or the like, and the adhesive is, for example, a urethane resin adhesive, a melamine resin adhesive, an acrylic resin adhesive. Agents, vinyl acetate resin adhesives and the like are used. The glass fiber nonwoven fabric may be bonded to the back surface of the porous substrate (2). On the front side, a fiber sheet in which hot melt adhesive powder (16) is dotted on the bonding surface on the glass fiber sheet (3).
The skin material (6) is bonded through (15).

The fiber sheet (15) is made of, for example, synthetic fibers such as polyester fiber, polyethylene fiber, polypropylene fiber, polyamide fiber, acrylic fiber, urethane fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, acetate fiber, pulp, cotton, and the like. Consisting of one or more natural fibers such as wool, coconut fiber, hemp fiber, bamboo fiber, kenaf fiber, or regenerated fibers obtained by defibrating scraps of textile products using these fibers It is a knitted or woven fabric.

In order to disperse the hot-melt adhesive powder on the surface of the fibrous sheet (15), the powder may be sprayed directly. However, the hot-melt adhesive is prepared by dispersing the hot-melt adhesive powder in water. It is preferred to apply a powder dispersion. The hot melt adhesive powder dispersion further prevents the hot melt adhesive powder from settling, and further prevents the hot melt adhesive powder from entering between the fuzz of the fibrous sheet and the surface of the fibrous sheet. It is desirable to thicken with a thickener in order to fix the toner.

The hot melt adhesive used in the present invention is, for example, a polyolefin resin such as polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, or a modified product of the polyolefin resin, A single or a mixture of two or more of vinyl chloride, polyurethane, polyester, polyester copolymer, polyamide, polyamide copolymer and the like, and the powder of the hot melt adhesive is usually 50 to 3
The size is about 00 mesh.

The thickener used in the present invention includes, for example, alkali metal salts such as sodium, potassium and lithium such as polyacrylic acid, polymethacrylic acid and alginic acid; water-soluble synthetic polymers such as polyethylene oxide; A stringy thickener such as a water-soluble natural polymer composed of a vegetable mucilage such as biloba oil and Norrysia is used, and an alkali thickening type acrylic copolymer emulsion is particularly preferable. Examples of the alkali thickening type acrylic copolymer include a copolymer of an acrylic ester and an α, β-unsaturated carboxylic acid, and another vinyl copolymerizable with the acrylic ester and the acrylic ester. A multi-component copolymer of a monomer and an α, β-unsaturated carboxylic acid or the like can be used.

The acrylates include methyl acrylate, ethyl acrylate, n-propyl acrylate, isopropyl acrylate, n-butyl acrylate, isobutyl acrylate, t-butyl acrylate, 2-ethylhexyl acrylate, cyclohexyl acrylate, tetrahydrofurfuryl acrylate, Methyl methacrylate, ethyl methacrylate, n
-Propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, 2-ethylhexyl methacrylate, cyclohexyl methacrylate, tetrahydrofurfuryl methacrylate, stearyl methacrylate, lauryl methacrylate, β-hydroxyethyl acrylate, β-hydroxyethyl methacrylate, β-hydroxyethyl Methacrylate, β-hydroxypropyl acrylate,
β-hydroxypropyl methacrylate, dimethylaminoethyl acrylate, dimethylaminoethyl methacrylate, glycidyl acrylate, glycidyl methacrylate and the like.

Examples of the α, β-unsaturated carboxylic acid include acrylic acid, methacrylic acid, maleic acid, itaconic acid, crotonic acid, atropic acid and citraconic acid.

Examples of other vinyl monomers copolymerizable with the acrylate include ethers such as methyl vinyl ether, ethyl vinyl ether, n-propyl vinyl ether, n-butyl vinyl ether, isobutyl vinyl ether, styrene, α- Styrenes such as methylstyrene, cyano group-containing monomers such as (meth) acrylonitrile, (meth) acryloyl isocyanate, m
Isocyanate group-containing monomers such as -isopropenyl-α, α-dimethylbenzyl isocyanate; amide group-containing monomers such as diacetone acrylamide, N-vinylformamide and N-vinylacetamide; styrene p-sulfonate; Monomers containing a sulfone group such as (acryloylamino) -2-methylpropanesulfonic acid, and mercapto group-containing monomers such as mercaptopropyltrimethoxysilane, mercaptopropyltrimethoxysilane, mercaptopropyltriethoxysilane, and mercaptopropyltrimethoxysilane Body and the like.

In the above acrylic copolymer emulsion, when the α, β-unsaturated carboxylic acid is converted into a salt with an alkali, the acrylic copolymer becomes water-soluble. Is contained in the acrylic copolymer in an amount sufficient to obtain The amount of the α, β-unsaturated carboxylic acid varies depending on the type of the acrylate ester, other vinyl monomer or the α, β-unsaturated carboxylic acid, but is usually 20 to 60 in the copolymer. %, Preferably 30 to 50% by weight.

The above acrylic copolymer may be crosslinked to such an extent that the water solubility is not adversely affected. In this case, a polyfunctional vinyl monomer such as divinylbenzene, methylenebisacrylamide, ethylene glycol dimethacrylate, polyethylene glycol dimethacrylate, trimethylolpropane dimethacrylate, trimethylolpropane methacrylate, or diallyl phthalate is used in the copolymer. Introduce.

In order to prepare the hot melt adhesive powder dispersion of the present invention using the above acrylic copolymer emulsion as a thickener, first, the above acrylic copolymer emulsion and hot melt adhesive are prepared. The powder is preferably added to water and stirred to form a dispersion. At this stage,
Since the acrylic copolymer emulsion is not thickened, it is very easy to uniformly disperse it in water. The hot melt adhesive powder need not be added to water at the same time as the acrylic copolymer emulsion, and may be added to water at any stage, but is preferably added before thickening.

The hot melt adhesive powder is usually dispersed in water in the range of 1 to 60% by weight, and the acrylic copolymer emulsion has a viscosity of the hot melt adhesive dispersion after alkali thickening. 50-2000 cps / 25 ° C
Is added to the water so that For example, when using a 30% by weight emulsion of a copolymer obtained by copolymerizing ethyl acrylate and methacrylic acid at a weight ratio of 6: 4,
The addition amount of the emulsion is about 0.1 to 10% by weight.

As described above, the acrylic copolymer emulsion and the powder of the hot melt adhesive are added to water, and after mixing uniformly, an alkali is added. Then, the carboxylic acid derived from the α, β-unsaturated carboxylic acid contained in the acrylic copolymer becomes a salt, and the copolymer becomes water-soluble and thickens the dispersion.

Examples of the alkali include ammonia and amines; hydroxides of alkali metals and alkaline earth metals such as sodium hydroxide, potassium hydroxide, barium hydroxide and calcium hydroxide; and oxidation of alkaline earth metals such as lime. object;
Sodium carbonate, sodium sulfite, sodium acetate,
Weak acid salts of alkali metals such as sodium phosphate can be used. The amount of the alkali to be added is usually determined with reference to the pH of the dispersion being about 6 to 9.

As described above, the hot melt adhesive powder dispersion using the alkali thickening type acrylic copolymer emulsion as a thickener exhibits plastic flow, and the hot melt adhesive powder is substantially precipitated. Is prevented.

In the hot melt adhesive powder dispersion,
For example, higher alcohol sulfate (Na salt or amine salt), alkyl allyl sulfonate (Na salt or amine salt), alkyl naphthalene sulfonate (Na salt or amine salt), alkyl naphthalene sulfonate condensate, alkyl phosphate, dialkyl Sulfosuccinate,
Rosin soap, anionic surfactant such as fatty acid salt (Na salt or amine salt), polyoxyethylene alkyl ether, polyoxyethylene alkyl phenol ether,
Nonionic surfactants such as polyoxyethylene alkyl ester, polyoxyethylene alkylamine, polyoxyethylene alkylolamine, polyoxyethylene alkyl amide, sorbitan alkyl ester, polyoxyethylene sorbitan alkyl ester, octadecylamine acetate, imidazoline derivative acetate , One or more surfactants such as cationic surfactants such as polyalkylene polyamine derivatives or salts thereof, octadecyltrimethylammonium chloride, trimethylaminoethylalkylamide halogenide, alkylpyridinium sulfate, and alkyltrimethylammonium halide. May be added as a dispersant.

As a method for applying the hot-melt adhesive powder dispersion to the surface to be coated, a method in which a high pressure is directly applied to the dispersion and the dispersion is air-sprayed is preferable. According to this method, even when the viscosity of the hot melt adhesive powder dispersion is high, the dispersion can be spray-applied efficiently. At this time, the hot melt adhesive powder dispersion does not necessarily need to be stirred, but may be. The coating amount is usually 1 to 100 g / m ² as a solid content.
It is. Incidentally, the hot melt adhesive powder dispersion,
It may be manufactured in advance at a high concentration, and diluted with water to a desired concentration before use.

The hot-melt adhesive powder dispersion spray-applied as described above has structural viscosity and is not dispersed in a mist form but adheres to the surface to be coated in the form of nodules. Such nodular droplets do not enter between the fuzz even if the fuzz is applied to the surface to be coated of the fiber sheet, adhere to the surface of the fuzz, and after drying, adhere to the surface of the surface to be coated by hot melt. A state in which the agent powder adheres efficiently can be obtained. Also,
Since the hot melt adhesive powder dispersion is applied without precipitation, the hot melt adhesive powder can uniformly adhere to the surface to be coated.

The skin material (6) used in the present invention includes:
Desirably, a nonwoven fabric or a knitted fabric of the same fiber as the synthetic fiber or the natural fiber used in the fiber sheet (15) or a breathable nonwoven fabric, such as a non-woven nonwoven fabric, is used. Leather or the like may also be used.

On the back side of the substrate (2), a reinforcing material (9) is adhered by an adhesive. The reinforcing material (9) is a laminated sheet of a glass fiber sheet (9A) and a fiber sheet (9B), and the glass fiber sheet (9A) is a nonwoven fabric or knitted fabric of glass fiber, and the fiber sheet (9B ) Is a fiber sheet
A nonwoven fabric or knitted fabric of the same fiber as in (15).

The reinforcing material (9) is impregnated with an initial condensate of a thermosetting synthetic resin. That is, the above reinforcing material
In the case of (9), the glass fiber sheet (9A) has a poor impregnating adhesion of the liquid, and the glass fiber sheet (9A) alone cannot sufficiently impregnate and adhere the precondensate. Therefore, in the present invention, the fiber sheet (9B) is laminated on the glass fiber sheet (9A), and the fiber sheet (9B) is mainly impregnated with the above-mentioned initial condensate and carried thereon. In the reinforcing material (9), the bonding between the glass fiber sheet (9A) and the fiber sheet (9B) is performed by an impregnated initial condensate, but may be separately bonded by an adhesive. The reinforcing material (9) coated and impregnated with the initial condensate may be cured by heating and drying if desired.
It is desirable that the initial condensate is slightly condensed to a B state.

The precondensate impregnated in the reinforcing material (9) is
By setting it in the state, the curing time of the initial condensate can be shortened, and the interior material is
Good formability can be imparted to (11), and the reinforcing material (9) can be stored for a long period of time. Such reinforcement
In (9), since the thermosetting synthetic resin in the B state is completely cured by hot pressing, an interior material (11) having excellent shape retention and heat resistance can be obtained. In addition, the reinforcing material (9) is a glass fiber sheet even if the fiber sheet (9A) comes to the base material (2) side.
(9B) may come to the substrate (2) side.

As the initial condensate of the thermosetting synthetic resin, it is preferable to use a phenolic initial condensate which is an initial condensate of a monohydric phenol and / or a polyhydric phenol with an aldehyde. The above monohydric phenol and / or
Alternatively, the polyhydric phenol may be a monohydric phenol, a polyhydric phenol, or a mixture of a monohydric phenol and a polyhydric phenol. Further, the thermosetting synthetic resin in the present invention comprises an initial condensate obtained by condensing a monohydric phenol with an aldehyde and / or an aldehyde donor, and a polyhydric phenol with an aldehyde and / or an aldehyde donor.
Alternatively, it may be an initial co-condensate obtained by co-condensing an initial condensate obtained by condensing with an aldehyde donor.

Examples of the monohydric phenol include phenol, o-cresol, m-cresol, p-cresol, ethylphenol, isopropylphenol, xylenol, 3,5-xylenol, butylphenol,
t-butylphenol, alkylphenols such as nonylphenol, o-fluorophenol, m-fluorophenol, p-fluorophenol, o-chlorophenol, m-chlorophenol, p-chlorophenol,
o-bromophenol, m-bromophenol, p-bromophenol, o-iodophenol, m-iodophenol, p-iodophenol, o-aminophenol, m-aminophenol, p-aminophenol, o
-Nitrophenol, m-nitrophenol, p-nitrophenol, 2,4-dinitrophenol, 2,4
Substituted monohydric phenols such as 6-trinitrophenol,
Polycyclic monohydric phenols such as naphthol;
These monohydric phenols can be used alone or in combination of two or more.

Examples of the above-mentioned polyhydric phenols include resorcinol, alkylresorcinol, pyrogallol, catechol, alkylcatechol, hydroquinone, alkylhydroquinone, phloroglucin, bisphenol, dihydroxynaphthalene and the like. These polyphenols may be used alone or in combination of two or more. It can be mixed and used. Preferred among the polyhydric phenols are resorcinol and alkylresorcin, and particularly preferred is alkylresorcinol, which has a higher reaction rate with aldehydes than resorcinol.

Examples of the above alkyl resorcinol include 5-methyl resorcin, 5-ethyl resorcin, 5-propyl resorcin, 5-n-butyl resorcin, 4,5
-Dimethylresorcin, 2,5-dimethylresorcin,
4,5-diethylresorcinol, 2,5-diethylresorcinol, 4,5-dipropylresorcinol, 2,5-dipropylresorcinol, 4-methyl-5-ethylresorcinol,
2-methyl-5-ethylresorcin, 2-methyl-5
There are propyl resorcin, 2,4,5-trimethyl resorcin, 2,4,5-triethyl resorcin and the like. Polyhydric phenol mixtures obtained by dry distillation of Estonian oil shale are inexpensive and contain a large amount of various highly reactive alkylresorcinols in addition to 5-methylresorcinol, and are therefore particularly preferred polyhydric phenolic raw materials in the present invention.

The aldehyde used for the condensation with the above monohydric phenol and / or polyhydric phenol means an aldehyde, and a compound capable of decomposing to produce an aldehyde or a mixture thereof. Examples of such a compound include formalin, Formaldehyde, paraformaldehyde, trioxane, acetaldehyde, propionaldehyde, polyoxymethylene, chloral, hexamethylenetetramine, furfural, glyoxal, n-butyraldehyde, caproaldehyde, allyl aldehyde, benzaldehyde, crotonaldehyde,
Acrolein, tetraoxymethylene, phenylacetaldehyde, o-tolualdehyde, salicylaldehyde and the like can be used alone or in combination of two or more.

The condensation of the above-mentioned monohydric phenol and / or polyhydric phenol with an aldehyde is usually carried out by using a hydroxide of an alkali metal or alkaline earth metal such as sodium hydroxide, potassium hydroxide, barium hydroxide or calcium hydroxide. Oxides of alkaline earth metals such as lime, lime, etc., weak acid salts of alkali metals such as sodium carbonate, sodium sulfite, sodium acetate and sodium phosphate, and amines such as ammonia, trimethylamine, triethylamine, hexamethylenetetramine and pyridine. Done below.

The phenolic precondensate is obtained by reacting sulfurous acid, bisulfite or metabisulfite with an alkali metal or a quaternary amine or quaternary ammonium such as trimethylamine or benzyltrimethylammonium. Sulfites, sulfomethylating agents such as hydroxyalkane sulfonates such as hydroxymethane sulfonate obtained by reacting these water-soluble sulfites with aldehydes, formaldehyde sodium sulfoxylate (Rongalit), benzaldehyde sodium xylate Alkali metal sulfoxylates of aliphatic and aromatic aldehydes, such as sodium hydrosulfite, magnesium hydrosulfite, etc., alkali metal, alkaline earth metal hydrosulfite (dithionite Salt), alkyl sulfo carboxylate such as sodium ethyl sulfoxylate, preferably sulfomethylated and / or sulfimethylation by Sulfimethylation agents such as hydroxy alkanoic sulfinic acid salts such as hydroxymethanesulfinic acid salt.

In order to improve the moldability, the above precondensates include polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, vinyl acetate polymer, acrylate ester polymer and styrene polymer. Styrene-butadiene copolymer, acrylonitrile-butadiene copolymer, acrylonitrile-butadiene-styrene copolymer, low melting point polyamide, one or more kinds of thermoplastic resin emulsion or aqueous solution or powder etc. Mixtures may be mixed. In addition, synthetic resins having active hydrogen, polyvinyl alcohol, polyacrylic acid, water-soluble polymers such as polyacrylic acid, ammonium polyacrylate, methylcellulose, carboxymethylcellulose, gelatin, casein, polysaccharides, colloids, calcium carbonate, talc, carbon black And third components such as pigments, dyes, flame retardants, flame retardants, water / oil repellents, insect repellents, preservatives, plasticizers, polyisocyanates, and block polyisocyanates.

In order to manufacture the reinforcing material (9), the glass fiber sheet (9A) and the fiber sheet (9B) are stacked and sprayed from the glass fiber sheet (9A) side and / or the fiber sheet (9B) side. A synthetic resin liquid is applied and impregnated with a coating machine such as a roll coater or a curtain flow coater, and then heated and dried. When the synthetic resin is an initial condensate of a thermosetting synthetic resin, it is preferable that the heating and drying step be in the B state.

When a thermoplastic resin is mixed with the precondensate, the precondensate liquid is mixed with the plastic resin liquid (solution or emulsion) and applied, or the precondensate liquid is applied. Then, a thermoplastic resin liquid is applied, or a thermoplastic resin is applied, and then an initial condensate liquid is applied. In this case, if the thermoplastic resin liquid is applied later, a layer containing a large amount of the thermoplastic resin will be formed on the surface of the reinforcing material (9), and this layer is used as an adhesive for bonding another sheet. You can do it. Further, by mixing the thermoplastic resin, the thermoplastic resin is plasticized and the moldability at the time of molding is improved.

In the case of continuous production, the glass fiber sheet (9A) and the fiber sheet (9B) were drawn from the glass fiber sheet (9A) roll and the fiber sheet (9B) roll, respectively, and superposed with a polymerization roll or the like. Thereafter, a method of applying a synthetic resin liquid and then introducing the liquid into a heating and drying chamber is employed.

In order to adhere to another sheet, a hot melt film (7) is attached to the surface of the reinforcing material (9) on the glass fiber sheet (9A) side and / or the fiber sheet (9B) side. Alternatively, an adhesive may be applied or sprayed. In the case of the above continuous process, usually a hot melt film (7)
Is pulled out of the roll and superimposed just before the heating and drying chamber.

As described above, the application of the synthetic resin liquid may be performed from either the glass fiber sheet (9A) side or the fiber sheet (9B) side. The amount of impregnation of the fiber sheet (9A) with the synthetic resin liquid can be increased.

A glass fiber sheet (4) is adhered to the back surface of the reinforcing material (9), and a hot melt film such as a polyethylene film, an ethylene-vinyl acetate copolymer film, a low melting polyamide film, a low melting polyester film, etc. (7) Via fiber sheet of non-woven fabric or knitted fabric
(8) is adhered. The glass fiber sheet (4) adheres to the substrate (2) side via an adhesive other than the above, and furthermore, a reinforcing material (9)
May be adhered.

In order to manufacture the interior material (11), a fiber sheet (15) is usually backed on a skin material (6) via a hot melt adhesive powder (16) scattered on an adhesive surface in advance. Alternatively, the fiber sheet (15) in which the hot melt adhesive powder (16) is scattered in advance on the bonding surface and the glass fiber sheet (3) are bonded by an adhesive. To back the fiber sheet (15) to the skin material (6), the fiber sheet is
(15) are stacked and hot-pressed at a temperature equal to or higher than the softening point of the hot-melt adhesive powder (16), or the fiber sheet (15) is heated at the above temperature to form the hot-melt adhesive powder (16). After softening, the fiber sheet (15) is overlaid on the skin material (6) and cold pressed. To bond the fiber sheet (15) and the glass fiber sheet (3), for example, a urethane resin adhesive, a melamine resin adhesive, an acrylic resin adhesive,
A vinyl acetate adhesive or the like is used.

The surface of the porous substrate (2) reinforced by the glass fiber sheet (3) is overlaid with a skin material (6) backed by a fiber sheet (15), or the porous substrate (2) The fiber sheet (15), the glass fiber sheet (3) and the skin material (6) are layered on top of each other, and the backside is lined with a hot melt film (7) via a reinforcing material (9) and a glass fiber sheet (4). Laminated fiber sheets (8) are stacked and hot pressed or cold pressed after heating. At this time, the adhesive used for the porous substrate (2) exudes to the outer surface of the glass fiber sheet (3) and
The fiber sheet (15) of (6) is bonded to the glass fiber sheet (3) and the reinforcing material (9) or the glass fiber sheet (4). Further, the reinforcing material (9) may be used entirely or partially as needed. However, the exudation of the adhesive was caused by a fiber sheet (1) in which hot melt adhesive powder (16) was scattered on the adhesive surface.
5) prevents it from reaching the skin material (6).

The molding is carried out simultaneously with the hot press or the cold press in the production process of the interior material (11), or after the porous substrate (2) is formed, the respective layers are laminated to form the hot press or the cold press. The method is performed by simultaneously molding the glass fiber sheet (3, 4) to the porous substrate (2) when the glass fiber sheet (3, 4) is bonded to the porous substrate (2), and then laminating other layers and hot pressing or cold pressing. In this way, for example, a ceiling material (11A) as shown in FIG. 2 is obtained.

[Embodiment 1] FIG. 3 shows the structure of the interior material of this embodiment. 15 parts by weight of a polyamide powder (16) having a softening point of 120 ° C. and a particle size of 200 mesh as a hot melt adhesive on one surface of a nonwoven fabric sheet (15) made of polyester fiber having a basis weight of 50 g / m ² and a thickening agent 50 as an agent
% By weight of ethyl acrylate, 5 parts by weight of methacrylic acid copolymer emulsion and 80 parts by weight of water, and after stirring, pH 7.6 with 27% by weight aqueous ammonia and 800 cps
/ 25 ° C., a dispersion of the polyamide powder (16) was spray-coated at a solid content of 10 g / m ² and then dried at 150 ° C. to apply the polyamide powder (16) to one surface of the fiber sheet (15). A fiber sheet (a) applied in a dot form was obtained.

Also, a glass mat having a basis weight of 100 g / m ²
(9A) was overlaid with a polyester nonwoven fabric (9B) having a basis weight of 15 g / m ² , and then a 50% by weight resol-type phenol alkyl resorcinol-formaldehyde initial cocondensate was added on the glass mat (9A) at a solid content of 100 g / m2. It was spray-coated at an application amount of m ² and dried at 150 ° C. for 10 minutes to prepare a reinforcing material (b).

Further, on one side of a polyester nonwoven fabric (8) having a basis weight of 30 g / m ² , a basis weight of 20 g / m ² and a softening point of 120 ° C.
A backing material (c) was prepared by laminating the polyamide film (7). In addition, a glass chopped strand mat having a basis weight of 100 g / m ² was placed on a glass fiber sheet (3, 4).
And

Using the above materials (a), (b) and (c),
As shown in FIG. 3, after applying a urethane resin adhesive C to both surfaces of a semi-rigid urethane resin sheet base material (2) having a basis weight of 500 g / m ² and a thickness of 10 mm at an application amount of 200 g / m ² , The reinforcing material (b), the glass fiber sheet (4), and the back material (c) were stacked on the back side. On the front side, a fiber sheet with hot melt adhesive (a) is laminated via a glass fiber sheet (3).
Further, a skin material (6) made of a polyester woven fabric having a basis weight of 300 g / m ² was overlaid.

When the above polymer was hot-pressed at 130 ° C. for 60 seconds, the moldability was good, and the urethane resin adhesive did not exude to the skin side by the fiber sheet with hot melt adhesive (a). A car ceiling material with excellent rigidity and excellent sound absorption properties was created.

[0050]

The interior material of the present invention uses a fiber sheet in which powder of a hot-melt adhesive is scattered on the bonding surface instead of the hot-melt film. Air permeability is ensured up to the position, and sound absorption is improved. In addition, since the reinforcing material lining the glass fiber sheet is laminated, the rigidity is excellent and the formability is good.

[Brief description of the drawings]

 1 to 3 show one embodiment of the present invention.

FIG. 1 is a side sectional view of an interior material.

FIG. 2 is a perspective view of an interior material for an automobile.

FIG. 3 is an exploded sectional view of an interior material.

FIG. 4 is a side sectional view of a conventional interior material.

[Explanation of symbols]

 2 Porous substrate 3,4 Glass fiber sheet 6 Skin material 11 Interior material 15 Fiber sheet 16 Hot melt adhesive powder 9A, 9B Laminated sheet (reinforcing agent)

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Kunori Ito 213-5, Minamishibata-cho, Tokai City, Aichi Prefecture 5 Nagoya Yuka Co., Ltd. F term (reference) 3D023 BA03 BB01 BB21 BC00 BE05 4F100 AG00D AG00E AK01D AK01E AK41 AK46 AT00C AT00E BA03 BA04 BA05 BA07 BA41B CB03B DD01B DG01A DG01D DG01E DJ00E EH46 GB08 JB13D JB13E JD02C JH01

Claims (7)

[Claims] 1. An interior material comprising a hot-melt adhesive powder interspersed on an adhesive surface of a fiber sheet, and a skin material is bonded via the hot-melt adhesive powder. 2. The interior material according to claim 1, wherein the skin material has air permeability. 3. An interior material wherein a glass fiber sheet is bonded to the back surface of a fiber sheet having hot melt adhesive powder scattered on the bonding surface. 4. A fiber sheet lined with a glass fiber sheet is adhered to the surface of a porous base material with an adhesive, and the skin material is further dispersed via hot melt adhesive powder scattered on the surface of the fiber sheet. Interior material characterized by adhesion 5. The interior material according to claim 4, wherein the skin material has air permeability. 6. The interior material according to claim 4, wherein a laminated sheet of a glass fiber sheet and a fiber sheet is adhered to the back surface of the porous substrate by an adhesive. 7. The interior material according to claim 6, wherein the laminated sheet is impregnated with a precondensate of a thermosetting synthetic resin.