JP2003039614A - Trim material for car - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a trim material for a car such as a luggage side or the like having rigidity and impact resistance, susceptible to low temperature molding and having a lining resin simultaneously bondable with the molding of a felt layer. SOLUTION: A lining layer of 700-3,000 g/m<2> containing a propylene resin and an EVA resin as main components is provided on the back surface of a fiber skin material, and the bending strength (maximum load) thereof is set to 6-40 N. Further, a recycle resin is used to conserve resources to obtain the trim material for the car having cost reducing effect.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to an automobile interior material suitable for a luggage side, a trunk side, a trunk front, a trunk rear, etc. of an automobile.

[0002]

2. Description of the Related Art Conventionally, polypropylene resin in which a filler is mixed on the back surface of a fiber skin material has been used. This product requires a high temperature at which polypropylene melts during molding, and it is difficult to attach a sound absorbing layer such as fiber felt to the resin layer at the same time to prevent friction noise. Adhesive layering is required by applying agents.

[0003]

The present invention has a backing resin that can be formed at a low temperature and can be attached at the same time when forming a felt layer, and has bending strength (maximum load), impact resistance, heat resistance, cold resistance, etc. The purpose was to provide automotive interior materials with the required quality. In addition, we aimed to use recycled resin in order to save resources and provide a low-cost backing material.

[0004]

Means for solving the above-mentioned problems are 700 including a polypropylene resin and an EVA resin as main components on the back surface of the fiber skin material according to the claims.
This can be solved by providing an automobile interior material characterized by comprising a backing layer of ˜3000 g / m ^{2 and having} a bending strength (maximum load) of 6 to 40 N. A resource-saving and inexpensive backing layer was achieved by using recycled resin as the raw material resin.

[0005]

[Embodiment] Interior materials such as automobile luggage side, trunk side, trunk front, and trunk rear are not only attractive, but also have high rigidity, shock resistance, and heat and cold resistance in addition to no friction noise. Is required. As the fiber skin material, a woven non-woven fabric, a woven fabric or a knitted fabric can be used, but a woven non-woven fabric made of polypropylene or polyester fiber is preferable in terms of price and moldability.

The polypropylene resin used for the backing material is preferably a highly rigid polypropylene resin having a flexural modulus of 1200 MPa or more. When the rigidity becomes low, the shape retention of the molded product becomes a problem. EVA resin has a VA% of 14
-30% is preferable. The EVA resin having a high VA% has a lower compounding ratio than the resin having a low VA%.
The polypropylene resin imparts rigidity, and the EVA resin imparts impact resistance, low temperature moldability, simultaneous adhesion of felt during molding, and cold resistance.

In order to set the bending strength (maximum load) of the automobile interior material to 6 to 40 N, 700 to 3000 g / m ² is required. If it is 700 g / m ² or less, a bending strength of 6 N cannot be obtained, and it becomes difficult to uniformly coat the back surface of the fiber skin material with extrusion. In particular, it becomes difficult to use a recycled resin containing a filler. If it exceeds 3000 g / m ² , heating time and cooling time after molding are required to be long, productivity is lowered, weight is increased, and it is not preferable in terms of resource saving and fuel consumption of vehicles.

[0008]

Example A resin used was blended on the back surface of the skin material and extruded from a T-die with a single-screw extruder to coat a predetermined amount to obtain a raw material to be used. For molding, a lower mold that meshes with an upper mold of automobile trim was used, and cooling water was circulated through the mold for cooling.

As the evaluation, the bending strength (maximum load) of the used raw material, the impact resistance, the simultaneous adhesion of felt on molding, the heat and cold resistance of the product, the difficulty, etc. were tested. Bending strength is ASTM
The method was performed according to D79DM. Take five test pieces of 50 × 150 mm from the length and width directions of the original fabric, and apply an overweight from the top surface at a speed of 50 mm / min using a test device.
The deflection curve under load was plotted, the maximum load required for breaking (N / 50 mm) was determined, and displayed as the average value of each length and width. With respect to impact resistance, the product was set on a steel plate at -40 [deg.] C., and a test was carried out by dropping a 500 g steel ball from a height of 50 cm to check for cracks in the product. Heat resistance,
The cold resistance test is 4 hours at 80 degrees Celsius, 0.5 hours at room temperature, 1.5 hours at -40 degrees Celsius, and 0.5 hours at room temperature with the vehicle actually mounted.
The appearance was observed by carrying out 4 cycles of r. The adhesiveness of felt is qualitative. I looked it up.

[0010]

Example 1 A 220 g / m ² polyester needle nonwoven fabric surface material made of recycled polypropylene (flexural modulus 177
0Mpa) 80%, recycled EVA resin for automobile floor carpet backing separation product 20% [VA2 of EVA% 28
Regenerated EVA resin consisting of 5 parts and 75 parts of calpet (calcium carbonate masterbatch manufactured by Nitto Koka)] was dry blended and supplied to the hopper of the extruder, and the cylinder temperature was 2
10 ° C, T die temperature 210 ° C, extrusion rate 1.0 m / m
An amount of 2.5 kg / m ² was applied. The bending strength (maximum load) of the obtained raw fabric was 28.5N.

In order to commercialize the raw material, it is heated to 140 ° C. below the melting point of polypropylene, and a fiber felt having a thickness of 10 mm is set between the upper and lower molds. Press molding and trimming were performed with a pierce mold and a water jet to obtain a luggage side product.

[0012] The quality of the product was such that the appearance was good, and felt was attached, which had impact resistance, heat resistance, cold resistance, and difficulty. That is, the product quality is high in rigidity, and it has a feature that it can be molded even if the time required for molding after heating is so long as 40 seconds, that is, it can be molded at low temperature.

[0013]

Example 2 Nylon fibers were tufted onto a 110 g / m ² polyester non-woven fabric to obtain a 400 g / m ² nylon tufted carpet skin material. Commercially available recycled polypropylene resin (bending elastic modulus 1770Mp
60% of a), 20% of recycled EVA resin which is an automobile floor carpet backing separated product, and 20% of calpet are dry-blended and supplied to the hopper of the extruder, and the cylinder temperature is 210 ° C, the T-die temperature is 210 ° C, and the extrusion speed. An amount of 2.4 kg / m ² was applied at 1.4 m / min. The bending rigidity of the original fabric was 32.5N.

In order to commercialize the product, the raw material is heated to a temperature of 150 ° C. which is lower than the melting point of polypropylene, inserted into a lower mold with a urethane foam sheet having a thickness of 10 mm at an open time of 50 sec, and hydraulically press-molded. Trimmed with a mold and water jet to make it a luggage side.

The resulting product had a good appearance and had felt, shock resistance, heat resistance, cold resistance, and difficulty felt attached. In other words, the product quality has high rigidity and can be molded even if the open time is long, and has a required quality that can be molded at low temperature.

[0016]

Example 3 220 g / m ² polyester needle non-woven fabric skin material, bumper recycled polypropylene resin 80
%, Recycling of car floor carpet backing separation E
Dry blend 20% of VA resin and supply it to the hopper of the extruder to obtain a cylinder temperature of 210 ° C. and a T-die temperature of 21.
1.0 kg / m ² was applied at 0 ° C. and an extrusion speed of 1.7 m / min to give a raw fabric. The bending rigidity of the raw fabric was 6.5N.

For commercialization, the raw fabric is heated to a temperature of 160 ° C., which is lower than the melting point of polypropylene, and the open time is 60 s.
It was inserted between molding dies in which a styrene foam sheet having a thickness of 10 mm was set in the lower mold by ec, hydraulically press-molded, and trimmed with a pierce mold and a water jet to form a luggage side.

The product quality obtained is a product with a good-looking foam sheet with heat resistance, cold resistance, and impact resistance that can be molded even with a long open time, can be molded at low temperature, and uses recycled resin. As a result, resource saving and cost advantages were obtained.

[0019]

The automobile interior material of the present invention has a required rigidity,
It has impact resistance, heat and cold resistance, difficulty, etc., and the heating temperature during molding can be made lower than before, and at that temperature simultaneously with molding, fiber felt etc. on the back side for sound and heat measures The sound absorbing and heat insulating layer of (3) could be simultaneously attached to the entire surface or a part of the same when necessary. Further, the polypropylene resin used can be a recycled bumper product, and the EVA resin can be a separated recycled product of a backing resin of an automobile carpet, and the effect of resource saving and cost reduction can be obtained.

   ─────────────────────────────────────────────────── ─── Continued front page    F term (reference) 4F100 AK07B AK68B AL05B AS00A                       BA02 BA06 BA10A BA10B                       DG01A DG11A DG15 EH17                       GB33 JA13B JJ03 JJ04                       JK01 JK10 JL16B YY00B

Claims (3)

[Claims] 1. 700 to 3000 g / containing polypropylene resin and EVA resin as main components on the back surface of the fiber skin material.
It consists of a backing layer of m ² and its bending strength (maximum load) is 6
Automotive interior material characterized by being ~ 40N. 2. The polypropylene resin has a flexural modulus of 1200 MPa or more (JIS-K6758), and the VA% of the EVA resin is 14 to 30%.
Car interior materials. 3. The automobile interior material according to claim 1 or 2, wherein the polypropylene resin and EVA resin are recycled resins.