JP2003291741A - Foamed laminated sheet for interior trim material for automobile, and interior trim material for automobile - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a foamed laminated sheet for an interior trim material for an automobile capable of precluding light from being leaked in even by irradiation of sunlight from a sun roof or the like and irregular reflection or the like from a room light, in a foamed laminated sheet layered with non- foamed layers comprising a thermoplastic resin on both faces of a foamed layer using a heat-resistant resin as a base resin, and to provide an automobile interior trim material using the laminated sheet. <P>SOLUTION: In this foamed laminated sheet for the interior trim material for the automobile, and the automobile interior trim material, 0.3 wt.% or more of coloring agent is contained in at least one of the non-foamed layers to be colored, in the foamed laminated sheet layered with the non-foamed layers 12, 14 comprising the thermoplastic resin on the both faces of the foamed layer 10 using the heat-resistant resin as the base resin. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a foam laminated sheet for an automobile interior material and an automobile interior material using the sheet. More specifically, the present invention relates to a foam laminated sheet for an automobile interior material, which does not cause light leakage even when exposed to sunlight or scattered light from an interior light, and an automobile interior material using the sheet.

[0002]

2. Description of the Related Art Conventionally, as an automobile ceiling material, a urethane foam laminated on a base material mainly composed of a thermoplastic resin foam, or styrene-maleic anhydride on both sides of a foamed layer of a styrene-maleic anhydride copolymer. A laminate sheet formed by laminating a non-foamed layer of an acid copolymer into a desired shape is widely used. These automobile ceilings are light in weight, have high heat insulating properties, and have excellent moldability.

However, when the above-described conventional automobile ceiling material is exposed to high temperature for a long time, it has insufficient heat resistance, and therefore the front portion hangs down due to its own weight (heat sag) or is deformed. Sometimes it caused problems.

Therefore, in order to solve these problems,
Automotive ceiling materials based on composite materials of inorganic glass fibers and plastics have come into use. However, in this composite material, although the quality of heat resistance can be maintained, weight reduction cannot be achieved, and since glass fiber is used, there is a problem that the recyclability is poor and the cost is high.

In order to solve such a problem, a modified PPE-based resin is formed on both surfaces of a foamed layer using a modified polyphenylene ether-based resin (hereinafter referred to as "modified PPE-based resin") that is lightweight and has heat resistance as a base resin. A foam laminated sheet for an automobile ceiling material using a foam laminated sheet in which a resin non-foamed layer is laminated has been proposed (Japanese Utility Model Publication No. 4-11162). The foamed laminated sheet for automobile ceiling material using the modified PPE resin has excellent heat resistance and is lightweight, so that it is possible to improve deformation at high temperatures and sag due to its own weight.

Further, in an automobile having a sunroof structure as shown in FIG. 1, sunlight is incident through the glass of the sunroof part, and depending on the incident angle, the sunlight may enter the space between the top plate of the automobile and the ceiling material of the automobile. There is a possibility of entering and directly irradiating the ceiling material of the car. As a result, there is a risk of causing light leakage in the room. In order to solve this point, a light shielding plate or the like is provided in the gap between the top plate of the automobile and the ceiling material in the sunroof part. However, as it causes an increase in material costs and manufacturing costs, the emergence of alternative methods to these. Is long-awaited.

Further, as shown in FIG. 2, there is a risk that light may be leaked from the ceiling material in the vicinity of the room light to the room due to the scattered light of the room light. In order to solve this problem, it is possible to use a room light with a structure that does not generate scattered light, blacken the inside of the automobile top plate, etc., but both cause an increase in material cost and manufacturing cost, The emergence of alternatives to these is also highly anticipated.

[0008]

DISCLOSURE OF THE INVENTION The present invention is intended for an automobile interior material which does not cause light leakage due to irradiation of sunlight or scattered light of an interior light without causing an extreme increase in material cost, manufacturing cost and the like. A foamed laminated sheet and an automobile interior material using the sheet are provided.

[0009]

Means for Solving the Problems The inventors of the present invention irradiate sunlight by adding a black pigment as a colorant typified by carbon black and an ultraviolet absorber, if necessary, in an outdoor non-foamed layer. Therefore, they have found that an automobile interior material can be obtained in which light leakage does not occur even by scattered light of an interior light, and completed the present invention.

That is, the present invention provides (1) at least one of a foamed laminated sheet in which a non-foamed layer containing a thermoplastic resin as a base resin is laminated on both sides of a foamed layer containing a heat-resistant resin as a base resin. 0.3 in non-foamed layer
A foam laminated sheet for an automobile interior material, which contains a coloring agent in an amount of at least wt%. (Claim 1) (2) At least one of the non-foamed layers contains carbon black as a coloring agent, and the foamed laminated sheet for automobile interior materials according to (1). (Claim 2) (3) The foamed laminated sheet for automobile interior materials according to (1) or (2), wherein the colored non-foamed layer contains an ultraviolet absorber. (Claim 3) (4) The ultraviolet absorber is selected from a hindered amine-based ultraviolet absorber, a benzotriazole-based ultraviolet absorber, and a benzophenone-based ultraviolet absorber, (3) a foam laminate for an automobile interior material. Sheet. (Claim 4) (5) The heat-resistant resin as a base resin of the foam layer is a modified polyphenylene ether resin (1)
A foamed laminated sheet for an automobile interior material according to any one of to (4). (Claim 5) (6) A foamed laminated sheet, wherein a non-foamed layer made of a thermoplastic resin is laminated on both sides of a foamed sheet having a heat-resistant resin as a base resin, and one non-foamed layer has a thickness of 0.3. An automobile interior material, which is colored so as to contain a coloring agent in an amount of at least wt% and is formed so that the colored non-foamed layer is located outside the automobile. (Claim 6)

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION A foam laminated sheet for an automobile interior material and an automobile interior material of the present invention will be described with reference to the drawings.

FIG. 3 shows the structure of a foam laminated sheet for an automobile interior material according to one embodiment of the present invention, in which a thermoplastic resin is formed on both surfaces of a foam layer 10 having a heat resistant resin as a base resin. The non-foamed layer (12, 14) is formed, and the non-woven fabric layer 18 for preventing abnormal noise is laminated on the surface of the non-foamed layer 14.

FIG. 4 shows the structure of an automobile interior material according to one embodiment of the present invention. A non-foamed layer made of a thermoplastic resin is formed on both sides of a foamed layer 10 made of a heat resistant resin as a base resin. (Indoor side non-foaming layer 12 and outdoor side non-foaming layer 14)
The non-foaming nonwoven fabric layer 18 is laminated on the surface of the outdoor non-foaming layer 14, and the skin material 20 is laminated on the surface of the indoor non-foaming layer 12 with the adhesive layer 22 interposed therebetween.

As the heat-resistant resin used as the base resin for the foam layer 10 of the present invention, any resin known to those skilled in the art as having heat resistance can be used. For example,
Heat-resistant polystyrene resins such as styrene-acrylic acid copolymer, styrene-maleic anhydride copolymer, styrene-itaconic acid copolymer; polystyrene or blends of heat-resistant polystyrene and polyphenylene ether (PPE), styrene to PPE A modified polyphenylene ether resin (modified PPE resin) such as a styrene / phenylene ether copolymer such as a graft polymer; a polycarbonate resin; and a polyester resin exemplified by polybutylene terephthalate or polyethylene terephthalate are used. These resins may be used alone or in combination of two or more. The foam sheet may be a single foam layer, or may be a sheet formed by laminating two or more foam layers.

Among these, it is preferable to use the modified PPE resin as the base resin for the foamed layer because it has excellent heat resistance and rigidity, and is easy to process and easy to manufacture.

Examples of PPE used in the modified PPE resin include poly (2,6-dimethylphenylene-1,
4-ether), poly (2-methyl-6-ethylphenylene-4-ether), poly (2,6-diethylphenylene-1,4-ether), poly (2,6-diethylphenylene-1,4-). Ether), poly (2-methyl-6)
-N-propylphenylene-1,4-ether), poly (2-methyl-6-n-butylphenylene-1,4-ether), poly (2-methyl-6-chlorophenylene-)
1,4-ether), poly (2-methyl-6-bromophenylene-1,4-ether), poly (2-ethyl-6)
-Chlorophenylene-1,4-ether) and the like, and these may be used alone or in combination of two or more kinds.

Among the modified PPE resins, the polystyrene resin (PS resin) forming a mixed resin with the PPE resin is styrene or its derivative such as α-methylstyrene,
It is a resin whose main component is 2,4-dimethylstyrene, monochlorostyrene, dichlorostyrene, p-methylstyrene, ethylstyrene and the like. Therefore, the PS resin is not limited to a homopolymer consisting of styrene or a styrene derivative, but may be a copolymer produced by copolymerizing with another monomer.

Specific examples of the styrene-based monomer to be polymerized, preferably graft-polymerized with the PPE-based resin include, for example, styrene, α-methylstyrene, 2,4-
Examples thereof include dimethyl styrene, monochloro styrene, dichloro styrene, p-methyl styrene and ethyl styrene. These may be used alone or in combination of two or more. Of these, styrene is versatile,
It is preferable in terms of cost.

When a modified PPE resin is used as the base resin used in the foam layer 10 of the present invention, the phenylene ether component is preferably 25 to 70 parts by weight, and the styrene component is preferably 75 to 30 parts by weight. More preferably, the phenylene ether component is 35 to 60 parts by weight, the styrene component is 65 to 40 parts by weight, and particularly preferably, the phenylene ether component is 38 to 58 parts by weight, and the styrene component is 62 to 42 parts by weight. When the phenylene ether component in the modified PPE resin is small,
The heat resistance tends to be inferior, and when the amount of the phenylene ether component is large, the viscosity at the time of heating and flowing increases, and foam molding tends to be difficult.

Primary foaming layer forming the foaming layer 10 (Because foaming (secondary foaming) occurs by heating when molding the foamed laminated sheet of the present invention as an automobile interior material, the foaming layer before molding is the primary foaming layer. The thickness of the layer is preferably 1 to 5 mm, more preferably 1.5 to 3.5 mm. The expansion ratio is preferably 3 to 20 times, more preferably 5 to 15 times. The cell diameter is preferably 0.05 to 0.9 mm, more preferably 0.1 to 0.7 mm. The closed cell ratio is preferably 70% or more, more preferably 80% or more. When the thickness of the primary foam layer is less than 1 mm, the strength and heat insulation properties are poor, and it may not be suitable as a foam laminated sheet for automobile interior materials. On the other hand, if it exceeds 5 mm, it is difficult for heat to be transferred to the central portion in the thickness direction of the foam layer 10 during molding heating, so that sufficient heating cannot be performed and moldability may deteriorate. In addition, if the heating time is extended to perform sufficient heating, the cells on the surface of the foam layer may be broken, and it may be difficult to obtain an acceptable product.

When the primary expansion ratio is less than 3, the flexibility is poor, breakage due to bending is likely to occur, and the effect of weight reduction is small. When the primary expansion ratio exceeds 20 times, the strength decreases and it is difficult to heat up to the central portion, so that the moldability tends to decrease. Furthermore, the cell diameter is 0.05
If it is less than mm, it is difficult to obtain sufficient strength, and it is 0.9 mm.
In the above cases, the heat insulation tends to be poor. In addition, when the closed cell ratio is 70% or less, the heat insulation and rigidity are poor, and
It becomes difficult to obtain the desired secondary expansion ratio by molding heating, and the moldability tends to be poor.

The amount of residual volatile components in the primary foam layer forming the foam layer 10 is preferably 1 to 5% by weight, more preferably 2 to 4% by weight, based on the total weight of the foam layer. 1% by weight of residual volatile components
If it is below the range, the secondary expansion ratio may be too low, which may affect the obtaining of good moldability. On the other hand, when the residual volatile component exceeds 5% by weight, there is a tendency that air pockets are generated between the non-foamed layer and the dimensional stability with time. The amount of the residual volatile component may be measured by gas chromatography, but usually, the volatile component is heated by heating the foamed layer test piece in a temperature range above the decomposition temperature and below the decomposition temperature. Can be sufficiently volatilized, and the weight difference before and after heating can be measured.

The base resin of the foamed layer 10 used in the present invention may include a cell regulator, an impact modifier, a lubricant, an antioxidant, an antistatic agent, a pigment, a stabilizer and an odor, if necessary. A reducing agent or the like may be added.

In the laminated foam sheet for automobile interior materials according to the present invention, non-foamed layers 12 and 14 having a thermoplastic resin as a base resin are laminated on both sides of a foam layer 10 having a heat resistant resin as a base resin. . This is because the movement of the foam layer needs to be controlled by the non-foam layer inside and outside the vehicle for the purpose of controlling deformation during heat resistance and stabilizing the shape of the molded body during molding.

The thermoplastic resin used in the non-foamed layers 12 and 14 is PS resin, heat-resistant PS resin, modified PP.
Examples include E-based resins, polyethylene terephthalate (PET) -based resins, polyamide (nylon) -based resins, and the like, which may be used alone or in combination of two or more kinds. When a modified PPE-based resin is used as the foam layer 10. From the viewpoint of adhesiveness to the resin layer, modified PPE-based resin and heat-resistant PS-based resin are preferably used.

When a modified PPE resin is used as the non-foamed layer 12, the PPE resin is polymerized or mixed with a monomer mainly composed of a styrene compound or a polymer thereof, as in the case of the foamed layer 10 described above. Modified by, for example, a mixed resin of PPE resin and PS resin,
PPE made by polymerizing a styrene monomer on a PPE resin-
Styrene copolymer, this copolymer and PS resin or P
Examples thereof include a mixture with a PE resin, a mixture of a copolymer thereof, a PPE resin, and a PS resin. Of these, a mixed resin of PPE-based resin and PS-based resin is preferable from the viewpoint of easy production.

Specific examples and preferable examples of these PPE resin, PS resin or styrene monomer, and PS
Specific examples of monomers that can be polymerized with a resin or a styrene monomer,
The reason for using it is the same as that described in the foam layer 10. However, as a preferred specific example of PS resin, high impact polystyrene (HIPS)
The styrene-butadiene copolymer represented by the formula (1) is preferable in that the effect of improving the impact resistance of the non-foamed layers 12, 14 is great.

When the modified PPE resin is used as the non-foamed layer 14, the PPE resin is polymerized or mixed with a monomer mainly containing a styrene compound or a polymer thereof, as in the case of the foamed layer 10 described above. Modified by, for example, a mixed resin of PPE resin and PS resin,
PPE made by polymerizing a styrene monomer on a PPE resin-
Styrene copolymer, this copolymer and PS resin or P
Examples thereof include a mixture with a PE resin, a mixture of a copolymer thereof, a PPE resin, and a PS resin. Of these, a mixed resin of PPE-based resin and PS-based resin is preferable from the viewpoint of easy production.

Specific examples and preferable examples of these PPE resin, PS resin or styrene monomer, and PS
Specific examples of monomers that can be polymerized with a resin or a styrene monomer,
The reason for using it is the same as that described in the foam layer 10. However, as a preferred specific example of PS resin, high impact polystyrene (HIPS)
The styrene-butadiene copolymer represented by the formula (1) is preferable in that the effect of improving the impact resistance of the non-foamed layers 12, 14 is great.

When a heat-resistant PS-based resin is used as the non-foamed layer 14, the heat-resistant PS-based resin used is a copolymer of styrene or its derivative and another monomer, and has the effect of improving heat resistance. As a monomer copolymerizable with styrene or a derivative thereof, for example, maleic acid, fumaric acid, acrylic acid, methacrylic acid, unsaturated carboxylic acid such as itaconic acid or a derivative thereof and an acid anhydride thereof,
Examples thereof include nitrile compounds such as acrylonitrile and methacrylonitrile, or derivatives thereof.

These may be used alone or in combination of two or more. Further, when styrene or a styrene derivative is polymerized, a synthetic rubber or a rubber latex is added and polymerized with an unsaturated carboxylic acid such as maleic acid, fumaric acid, acrylic acid, methacrylic acid or itaconic acid or a derivative thereof. And its acid anhydride,
It may be a copolymer with a nitrile compound such as acrylonitrile or methacrylonitrile. Of these,
Styrene-maleic anhydride-based copolymer, styrene-acrylic acid-based copolymer, styrene-methacrylic acid-based copolymer, acrylonitrile-butadiene-styrene copolymer has its heat resistance improving effect, versatility, and cost. Is preferred.

The heat-resistant PS resin may be used alone or in combination of two or more kinds. Also, heat resistant PS
The resin may be blended with another thermoplastic resin, and examples of the blended thermoplastic resin include polystyrene, HIPS, polycarbonate, polyester,
Examples thereof include polyamides and copolymers thereof. Among them, H is high in terms of versatility, capable of uniform dispersion, great effect of improving the impact resistance of the non-foamed layer, and cost.
IPS is preferred. Known HIPS can be used, and the content of the rubber component is usually 1 to 15% by weight.

In the present invention, the above non-foamed layer 14 contains a colorant for blocking light in the base resin forming it. This is because when automobile interior materials are directly irradiated with sunlight from the outside such as the sunroof as illustrated in FIG. 1,
Since the surface layer absorbs sunlight and blocks light from entering the interior, it is effective in preventing deterioration of the interior material of the automobile and preventing light leakage into the interior of the automobile. Further, as illustrated in FIG. 2, it is effective in preventing light leakage from the ceiling material in the vicinity of the indoor light to the vehicle interior due to scattered light of the indoor light.

Examples of the colorant contained in the base resin of the non-foamed layer 14 include inorganic fillers such as carbon black, titanium oxide, zinc oxide, iron oxide and aluminum oxide, cyanine blue, cyanine green, milori blue and slene. blue,
It contains organic or inorganic pigments such as cadmium red, cadmium yellow, cadmium orange, rouge, ultramarine and phthalocyanine blue. Among these, black pigments are effective, and among them, carbon black exhibits a remarkable light blocking effect even when added in a small amount, the light resistance of the base resin is improved in addition to the light blocking effect, and the antioxidant ability is high. It is a preferable colorant because it is advantageous in terms of cost and is used as an efficient black pigment.

The amount of carbon black contained in the base resin of the non-foamed layer 14 is preferably 0.3 to 5% by weight, more preferably 0.5 to 3% by weight. If it is 0.3% or less, the light blocking effect is not sufficient, and if it is 5% or more, the physical properties such as tensile strength, elongation, modulus and brittle point of the base resin tend to be deteriorated.

The non-foamed layer 14 contains bis- (2,2,6,6-tetramethyl-4-piperidyl) sepacate and bis- as a UV absorber in order to block photo-deterioration due to UV rays and UV rays in the base resin. (1,2,2,6,6-pentamethyl-4-piperidyl) sepacate, tetrakis (2,2,6,6-tetramethyl-4-piperidyl) sepacate, [dimethyl-1- (2-hydroxyethyl succinate) ) -4-Hydroxy-2,2,6,6-tetrapiperidine] condensate, 1,2,6,6-pentamethyl-4
-Hindered amine UV absorbers such as piperidyl-tridecyl-1,2,3,4-butanetetracarboxylate, 2- (2'-hydroxy-5'-methylphenyl) benzotriazole, 2- (2'-hydroxy-
3'-t-butyl-5'-methylphenyl-5-chloro) benzotriazole, 2- [2'-hydroxy-
3,5-bis (α, α-dimethylbenzyl) phenyl]
-2H-benzotriazole, 2,2'-methylenebis [4- (1,1,3,3-tetrabutyl)]-6-2H
-A benzotriazole-based UV absorber such as benzotriazole and a benzophenone-based UV absorber such as 2-hydroxy-4-methoxybenzophenone and 2-hydroxy-4-n-octoxybenzophenone.

The addition amount of the ultraviolet absorber contained in the base resin of the non-foamed layer 14 is preferably 1 to 10% by weight, more preferably 3 to 7% by weight. If it is 1% by weight or less, the effect of absorbing ultraviolet rays is not sufficient, and if it is 10% by weight or more, physical properties such as tensile strength, elongation, modulus and brittle point of the base resin tend to be deteriorated.

As a method of adding the colorant and the ultraviolet absorber contained in the base resin of the non-foamed layer 14, it is possible to directly blend the colorant and the ultraviolet absorber into the base resin. In order to improve the dispersibility of the colorant and the ultraviolet absorber in the base resin, a resin (masterbatch) containing a predetermined amount of the colorant and the ultraviolet absorber is prepared in advance, and the masterbatch is used as the base resin. The method of blending is preferred.

Next, the thickness of the non-foamed layers 12 and 14 is 50 to 50.
It is preferably 300 μm, more preferably 75 to 200 μm. When the thickness of the non-foamed layer is less than 50 μm, strength, rigidity,
The heat resistance tends to decrease, and if the thickness is more than 300 μm, the foamed laminated sheet tends to have poor moldability.

When forming a non-foamed layer, if necessary,
Impact modifiers, fillers, lubricants, antioxidants, antistatic agents, stabilizers, odor reducing agents and the like may be added alone or in combination of two or more.

The impact resistance improving agent is obtained by laminating the non-foamed layers 12 and 14 on the foamed layer 10 and punching the laminated sheet which has been secondarily foamed to form an automobile interior material. It is effective in preventing the non-foamed layers 12, 14 from cracking during transportation. The impact resistance improver may be used without particular limitation as long as it exhibits its effect when mixed with the base resin. The impact resistance improver may be a component introduced into a thermoplastic resin by modification by polymerization and capable of exerting an impact resistance improving effect. For example, a mixture containing an impact resistance improving component such as HIPS may be mixed. When used as a non-foaming layer, the non-foaming layers 12, 14
Can be given impact resistance.

In the automobile interior material according to the present invention, as shown in FIGS. 3 and 4, a non-woven fabric layer 18 for preventing abnormal noise is provided on the surface of the non-foamed layer 14 on the outdoor side. When the noise preventing material 18 is attached to an automobile, the inside of the automobile is rapidly cooled by a cooler or the like, or when traveling on an uneven road surface or when suddenly turning.
It is effective in preventing abnormal noise that may occur during running on a slab.

The non-woven fabric layer 18 for preventing abnormal noise is a cloth-like product in which the basic raw material fibers constituting the non-woven fabric are joined together using an adhesive (binder resin) or entangled by a mechanical method. Any type can be used if it exists.

In this case, the kind of the raw material fibers constituting the basis of the non-woven fabric is not particularly limited, and synthetic fibers, semi-synthetic fibers, or regenerated fibers which are fibers derived from natural fibers can be used. Specifically, polyester,
Examples thereof include synthetic fibers such as polypropylene, polyamide (nylon), and polyacrylonitrile. Among them, polyester fibers are more preferable, and polyethylene terephthalate fibers having particularly high heat resistance are particularly preferable.

As the fibers derived from natural fibers constituting the abnormal noise preventing non-woven fabric 18, not only original natural fibers such as cotton, wool and hemp but also fibrous materials made of natural materials, for example, cellulosic regenerated fibers are used. It is expressed as a concept including some rayon. Cotton or rayon, which is a recycled fiber, is preferable in terms of economy. Particularly, rayon is particularly preferable in consideration of processability such as dyeing. And it is also possible to use one kind or a mixture of two or more kinds of fibers derived from these natural fibers.
As the fibers used in combination with these fibers derived from natural fibers, synthetic fibers are preferable, and among the synthetic fibers, polyester fibers are more preferable as described above, and particularly polyethylene terephthalate fibers having high heat resistance are particularly preferable.

Polyester fiber 0 is particularly preferably used as the basic raw material fiber constituting this non-woven fabric.
-100% by weight, natural fiber-derived fibers 100-0% by weight
100 parts by weight of the constituent fibrous body consisting of 10 parts by weight of the adhesive fiber is used in practice.

Specific examples of the polyester fiber include polyethylene terephthalate and polybutylene terephthalate. The fibers derived from natural fibers include natural fibers such as wool, cotton, and cellulose, as described above, as well as rayon, which is a regenerated fiber of cellulose type, and rayon is most preferably used.

As the non-woven fabric layer 18 for preventing abnormal noise, adhesive fibers were added to the basic raw material fibers constituting the non-woven fabric and bonded by using an adhesive (binder resin) or entangled by a mechanical method. The use of the cloth-like material is more preferable because it improves the machinability when trimming the automobile interior material and the foam laminated sheet for automobile interior material of the present invention.

In the present invention, the core-sheath type and side-by-side type composite fibers as described below are used as the adhesive fibers to be mixed with the basic fiber raw material constituting the nonwoven fabric. A high melting point fiber is used as the core component of the core-sheath type fiber that is the adhesive fiber, and a low melting point fiber is used as the sheath component. Specifically, the sheath component has a melting point of 90 ° C to 14 ° C.
Those containing polyolefin resin such as polyethylene or polypropylene at 0 ° C, or polyethylene terephthalate copolymerized with polycarboxylic acid such as isophthalic acid, adipic acid, sebacic acid, etc., melting point 90 ° C ~
A core-sheath type composite fiber composed of a low melting point fiber containing a copolyester fiber having a temperature of 140 ° C. and a high melting point fiber containing a polyethylene terephthalate or the like as a core component can be used.

In the present invention, when a nonwoven fabric containing adhesive fibers is used as the nonwoven fabric layer 18 for preventing abnormal noise,
The non-woven fabric preferably contains 9 to 70 parts by weight of the adhesive fiber with 100 parts by weight of a fibrous body composed of polyester fibers and / or fibers derived from natural fibers.

When the content of the adhesive fiber is 9 parts by weight or more, the effect of retaining the entanglement of the fibers with the adhesive fiber is enhanced, and the trimming cut property is improved. Further, when the amount of the adhesive fiber is 70 parts by weight or less, the trimming-cutting property remains good, and the adhesive fiber is melted by heating at the time of heat molding during forming and the melted surface is formed. It is preferable because it is not excessively formed, it does not affect stretching strain during molding, and problems such as heat distortion do not occur.

Also, due to this fused surface, it is unlikely that the adhesiveness of tapes used for fixing the harness is inferior. Therefore, when the blending amount of the adhesive fiber is within the above range, it is most preferable for imparting good trimming cutability, moldability, and harness fixing adhesiveness, and is most suitable as a non-woven fabric capable of sufficiently exhibiting the noise prevention effect. Becomes

If the melting point of the low melting point fiber constituting the adhesive fiber is 90 ° C. or higher, the adhesive fiber will not be fused to the mold during the shaping process with the mold, resulting in abnormal noise. The appearance of the prevention layer does not become defective. Low melting point fiber has a melting point of 1
When the temperature is 40 ° C. or lower, the adhesive fiber is heated and melted well during processing such as thermoforming, the effect as the adhesive fiber can be sufficiently exhibited, and the trimming cut property is excellent.

Examples of the binder resin include water-soluble, solvent-soluble, viscose liquid, emulsion, synthetic resin powder, and the like. From the viewpoint of water resistance, flexibility, and workability, the emulsion resin is preferable. As the emulsion type, acrylonitrile butadiene latex, styrene butadiene latex, acrylate latex, vinyl acetate latex and the like are used, and these can be used alone or as a mixture of two or more kinds.

In order to form a non-woven fabric layer for preventing abnormal noise, basic raw material fibers (adhesive fibers and the like are mixed if necessary)
Can be chemically entangled with a binder resin. Alternatively, there is a method of mechanically entangling the basic raw material fibers and the adhesive fibers or the like. Examples of the entanglement method include a needle punching method and a hydroentangling method, and the nonwoven fabric layer 18 for preventing abnormal noise of the present invention is preferably one in which raw material fibers are entangled by the hydroentangling method.

The hydroentangling method is a method in which raw material fibers are entangled with each other by a high-pressure columnar flow, and the columnar flow is processed with a nozzle diameter of 100 to 200 μm and a nozzle pitch of 0.5 to 2 mm. The water pressure of the columnar flow is 2 MPa to 20 MPa, and a stretchable, high-strength nonwoven fabric can be obtained.

Next, considering the quality and cost, the nonwoven fabric layer 18 for preventing abnormal noise preferably has a basis weight of 10 to 50 g / m ² , and further 20 to 40 g / m ^2.
It is preferable to have a basis weight of m ² . 10 g / m ²
In the following basis weight, the non-foamed layer 14 may be partially exposed at the location where the nonwoven fabric layer 18 is provided, and an effective noise prevention effect may not be obtained. On the other hand, 50 g / m
^{If the} fabric weight is ² or more, the weight may be poor, the cost may be unnecessarily increased, and the interior material may be thermally deformed due to the molding strain of the nonwoven fabric 18.

As a method of providing the non-woven fabric layer 18 for preventing abnormal noise on the base material for automobile interior materials, the base resin of the outdoor non-foaming layer 14 is melted and the melted base resin of the outdoor non-foaming layer 14 is used. Pressure bonding with the foam layer 10 and the non-woven fabric layer 18 for preventing noise,
A method of laminating without substantially using an adhesive layer is preferable. The reason for this is that the base resin of the outdoor non-foamed layer 14 permeates the non-woven fabric layer 18 for preventing noise to a good degree, and good adhesiveness is obtained due to the anchor effect. , Stable adhesiveness that does not come off even when used in harsh environments, and that the core layer, non-foamed layer, and non-woven fabric layer are laminated simultaneously in one step, eliminating the complexity of work In addition, it is possible to suppress an increase in manufacturing cost because an adhesive layer is not substantially used.

Further, the outdoor non-foaming layer 14 of the foaming layer 10
The adhesive surface with is not easily damaged by the melted base resin of the outdoor non-foaming layer 14, and the outdoor non-foaming layer 1
4 and stronger non-woven fabric layer 18 for noise prevention can be obtained. Therefore, after the molten non-foamed base layer resin 14 is brought into contact with the non-woven fabric layer 18 for noise prevention, A method of bringing the foamed layer 10 into contact with the base resin of the melted outdoor non-foamed layer 14 from the opposite surface of the soundproof non-woven fabric layer 18 to perform pressure-bonding integration is more preferable.

As a method for providing the nonwoven fabric layer 18 for preventing abnormal noise on the base material for automobile interior materials, it is possible to laminate them through an adhesive layer, but in a harsh environment, especially when used under high temperature. In order to obtain stable adhesiveness, it is necessary to improve the adhesiveness and heat resistance of the adhesive layer, which increases the manufacturing cost and increases the number of steps for laminating adhesive layers that are difficult to handle, which complicates the work. There is a risk that it will become.

In the automobile interior material of the present invention, as shown in FIG. 4, a non-woven fabric layer 20 for a skin material is laminated on the surface of the non-foamed layer 12 on the indoor side with an adhesive layer 22 interposed therebetween.

As the non-woven fabric layer 20 for the skin material, any kind of cloth may be used as long as the raw material fibers are bonded by an adhesive, a molten fiber or a mechanical method. The type of raw material fiber is not particularly limited, and any of synthetic fiber, semi-synthetic fiber, and natural fiber can be used. Specifically, synthetic fibers such as polyester, polypropylene, polyamide (nylon), and polyacrylonitrile, and natural fibers such as wool, cotton, and cellulose can be used, and they can be used in combination. Polyester fiber is preferable, and particularly polyethylene terephthalate fiber having high heat resistance is preferable.

Further, examples of the skin material include woven fabric and non-woven fabric, but non-woven fabric is preferable from the viewpoint of moldability. Examples of the type of non-woven fabric include a bonding binder adhesive cloth, a needle punched cloth, a spun pond cloth, a spray fiber cloth, and a stitch bond cloth, depending on the manufacturing and processing method thereof, and any non-woven cloth can be used.

As a method for adhering the non-woven fabric layer 20 for the skin material to the automobile interior material, the skin material to which the adhesive layer 22 has been adhered in advance is adhered to the foamed laminated sheet by using a heat roll or the like, or the adhesive layer in advance. 22 is a method in which a skin material is temporarily attached to a foamed laminated sheet and molding and adhesion are simultaneously performed during heat molding, and the base resin of the non-foamed layer 12 is melted during the production of the foamed laminated sheet, and the melted non-foamed layer 12 A method in which a base resin is sandwiched between the foamed layer 10 and the skin material 20 and pressure-bonded is used. The method of melting the base resin of the non-foaming layer 12 at the time of manufacturing the foamed laminated sheet and sandwiching the melted base resin of the non-foaming layer 12 between the foam layer 10 and the skin material 20 and press-bonding is substantially an adhesive. Since no layer is used, it is more preferable in terms of cost.

Next, the non-woven fabric layer 20 for the skin material preferably has a basis weight of 100 to 300 g / m ² , and further 140 to 20 in consideration of quality and cost.
It preferably has a basis weight of 0 g / m ² . 10
When the basis weight is 0 g / m ² or less, it may not be possible to obtain a sufficient feel as an interior material. On the other hand, 300 g /
When the fabric weight is m ² or more, the molding strain of the skin material may affect the thermal deformation.

As the adhesive layer 22, the non-foaming layer 1 is formed by at least a chemical bond such as intermolecular force, hydrogen bond or covalent bond.
4 and the non-woven fabric layer 20 for the skin material are used to adhere to each other.

Specific examples of the adhesive layer 22 include vinyl acetate-based, cellulose-based, acrylic-based, polyamide-based, polyvinyl acetate-based thermoplastic adhesives, urethane-based adhesives, and the like.
Thermosetting adhesives such as melamine-based, phenol-based, epoxy-based, polyester-based and acrylic-based, chloroprene rubber-based, nitrile rubber-based, silicone rubber-based and other rubber-based adhesives, starch, protein, natural rubber and other natural materials Examples include physical adhesives and hot melt adhesives. Specific examples of hot melt adhesives include polyolefins, modified polyolefins, polyurethanes, ethylene-vinyl acetate copolymer resins, polyamides, polyesters, thermoplastic rubbers, styrene-butadiene copolymers, styrene. -Examples include those containing a resin such as isoprene copolymer system as a component.

Next, a method for manufacturing the automobile interior material of the present invention will be described. Foam layer 10 used in the present invention
The (primary foam layer) is obtained by melting and kneading a heat-resistant base resin containing various additives with an extruder at 150 ° C to 400 ° C.
Then, under high temperature and high pressure of 150 to 400 ° C. and 3 to 50 MPa, 1 to 15 parts of the foaming agent is press-fitted to 100 parts of the resin to adjust the foaming optimum temperature (150 to 300 ° C.), and a low pressure zone is used using a circular die or the like. After being extruded (usually in the atmosphere), it is brought into contact with a mandrel or the like, for example, 0.5 to 40.
Examples of the foaming agent used when manufacturing the foam layer 10 that can be manufactured by a method such as forming into a sheet while taking it off at a speed of m / min, cutting, and winding.
Hydrocarbon type foaming agents such as butane, propane and pentane can be used. These may be used alone or in combination of two or more.

As a method for laminating the non-foaming layer 14 and the noise preventing non-woven fabric layer 18 on the foamed layer 10, foam molding is carried out in advance, and the upper surface or the lower surface of the supplied foamed layer 10 is melted by an extruder. A method is preferred in which the base resin of the non-foamed layer 14 in the state is laminated in a layered manner by being sandwiched between the foamed layer 10 and the non-woven fabric layer 18 for preventing noise and pressure-bonded by a cooling roller or the like. Among them, the method of laminating by extruding the extruded foam sheet of the foamed layer 10 and extruding the non-foamed layer 14 in-line is preferable because the manufacturing process can be simplified.

As a method of molding a molded secondary expanded laminated body which is an automobile interior material from the obtained primary expanded laminated sheet, the expanded laminated sheet is clamped and guided in the center of a heating furnace having heaters at the top and bottom. After the secondary foaming by heating to a temperature suitable for molding, for example, 120 to 200 ° C,
With a temperature-controlled mold, the surface provided with the colored noise prevention film 18 is placed on the outside of the automobile, and the nonwoven fabric layer 20 for skin material is used.
The surface provided with is arranged so as to be mounted on the interior side of the automobile.

Examples of molding methods include plug molding, free drawing molding, plug and ridge molding, ridge molding, matched mold molding, straight molding, drape molding, reverse draw molding, air slip molding,
Examples of the method include plug assist molding and plug assist reverse draw molding.

When the above-mentioned (primary) foamed sheet is heated and secondary-foamed, the primary foamed sheet (foaming ratio: 3 to 20) is used.
Double, preferably 5 to 15 times, thickness: 1 to 5 mm, preferably 1.5 to 3.5 mm), usually 1.2 to 4
The secondary expansion is performed twice, but the secondary expansion is preferably 1.5 to 3 times (as a result, the sheet magnification after the secondary expansion is 3.6 to 80 times, preferably 7.5 to 5 times). 45 times,
More preferably, it is 10 to 40 times, and the thickness is 1.2 to 20.
0 mm, preferably 2.25 to 10.5 mm, more preferably 3.0 to 7.0 mm).

Although various embodiments of the laminated foam sheet for automobile interior materials according to the present invention have been described above, the present invention is not limited to the above-mentioned embodiments. For example, the foamed laminated sheet for automobile interior materials can be used for the foamed laminated sheet for interior materials of trains and the like, and should be broadly construed. Other than the above, the present invention is not limited to various improvements based on the knowledge of those skilled in the art without departing from the spirit of the present invention.
It can be implemented in a mode in which changes and modifications are made.

[0074]

The present invention will be described in more detail based on the following examples, but the invention is not intended to be limited thereby. Table 1 shows the resins used in Examples and Comparative Examples.

[0075]

[Table 1] The symbols used for the resins shown in Table 1 are as follows. Modified PPE: Modified polyphenylene ether resin PS: Polystyrene resin SMAA copolymer: Methacrylic acid modified polystyrene resin HIPS: High impact polystyrene resin The evaluation methods performed in Examples and Comparative Examples are shown below.

(Thickness of Foamed Layer and Molded Body) The thickness of the primary foamed sheet and the molded body was measured at 20 locations in the width direction, and the average of the measured values was calculated.

(Expansion Ratio) The density df of the primary foam sheet was measured according to JIS K 7222, and the density dp of the modified PPE resin was measured according to JIS K 7112, and calculated from the following formula.

Expansion ratio = dp / df (closed cell ratio) The expansion ratio was determined according to ASTM D-2859. (Using a multi-pycnometer (manufactured by Beckman)) (Cell diameter) The cross section of the foamed layer was observed with an optical microscope, 20 cell diameters were measured, and the average value of the measured values was calculated.

(Basis weight) A test piece having a size of 10 cm × 10 cm was cut out from 5 locations in the extrusion direction of the primary foamed sheet, and the weight thereof was measured, and then the average value was calculated.

(Light-shielding property) A 200 mm × 200 mm test piece was sampled from a foam laminated sheet or automobile interior material, and the test piece was placed at a distance of 1 m from the light source, and an infrared lamp (Iwasaki Electric Co., Ltd. ) 220 V-375 W) was irradiated, and light leakage from the indoor side and see-through of the skin material were observed.

Example 1 40% by weight of PPE resin component,
PPE resin (A) so that the PS resin component is 60% by weight
A foaming agent containing iso-butane as a main component (iso-butane / n-) based on 100 parts by weight of a mixed resin (Vicat softening temperature 145 ° C.) obtained by mixing 57.1 parts and 42.9 parts of PS resin (B). 3.4 parts by weight of butane = 85/15) and 0.32 parts by weight of talc were kneaded by an extruder.

This kneaded resin was extruded with a circular die, and wound into a roll on a take-up roll through a take-up roll to have a primary thickness of 2.4 mm and a primary expansion ratio of 13
Double, closed cell rate 90%, cell diameter 0.19mm, basis weight 1
A foamed sheet of 80 g / m ² was obtained.

Next, while feeding this foamed sheet from the roll, 49 parts of the SMAA copolymer resin (C) and HIP were used.
S resin (D) 49 parts, black masterbatch resin (E) 2
Part of the mixed resin was melted and kneaded by an extruder so that the resin temperature was 245 ° C., and extruded into a film using a T die. Observation of the obtained film. The colorant was uniformly dispersed, and neither foreign matter nor fisheye was observed. The carbon black content in the film was calculated to be 0.54% by weight.

After confirming that a film in which the black pigment was uniformly dispersed in appearance was obtained, a noise preventing material (Ceresu S0025 manufactured by Yuho Co., Ltd.) was supplied to extrude the film in a molten state. The above-mentioned non-foamed layer is laminated in such a manner that it is sandwiched between the noise preventing material and the foamed layer, and the thickness is 150 μm.
A non-foamed layer outside the colored chamber of m was formed.

Next, the sheet in which the colored non-foamed layer and the noise preventing material were formed on one side of the foamed layer was turned upside down from the roll and fed out, 20% by weight of PPE resin component and 8% of PS resin component 8.
28.6 PPE resin (A) so as to be 0% by weight
Part and 71.4 parts of PS resin (B) are mixed and kneaded by an extruder so that the resin temperature becomes 265 ° C., and extruded into a film using a T die to leave the foam layer. An indoor-side non-foaming layer having a thickness of 120 μm was formed on the other surface thus formed.

In this way, a foamed laminated sheet in which the outdoor non-foamed layer was colored was obtained. A 200 mm × 200 mm test piece was cut out from the obtained foamed laminated sheet, and a light-shielding test was performed. As a result, no light leakage was observed.

Example 2 A foamed laminated sheet in which the outdoor non-foaming layer was colored was prepared in the same manner as in Example 1 except that the black masterbatch resin (F) was used instead of the black masterbatch resin (E). Obtained.

The carbon black content in the non-foamed layer was calculated to be 0.5% by weight. A test piece of 200 mm × 200 mm was cut out from the obtained foam laminated sheet,
As a result of the light-shielding test, no light leakage was observed.

(Example 3) 46.5 parts of SMAA copolymer resin (C) and HIPS were used as constituent resins of the outdoor non-foaming layer.
Resin (D) 46.5 parts, black masterbatch resin (E)
2.0 parts, UV absorber (CLARIANT Akit
Sandellvor manufactured by engineersellschaft
VSU) 5.0 parts of the mixed resin was used, except that a foamed laminated sheet in which the outdoor non-foamed layer was colored was obtained in the same manner as in Example 1.

The carbon black content in the non-foamed layer was calculated to be 0.54% by weight. A 200 mm × 200 mm test piece was cut out from the obtained foamed laminated sheet, and a light-shielding test was performed. As a result, no light leakage was observed.

(Comparative Example 1) 50.0 parts of the SMAA copolymer resin (C) and HIPS were used as the constituent resin of the outdoor non-foaming layer.
Unexpectedly, 50.0 parts of resin (D) was used as a mixed resin.
In the same manner as in Example 1, a foamed laminated sheet in which the outdoor non-foamed layer was colored was obtained.

The content of carbon black in the non-foamed layer is 0% by weight in calculation. A 200 mm × 200 mm test piece was cut out from the obtained foamed laminated sheet and subjected to a light-shielding test. As a result, light leakage was observed.

(Comparative Example 2) 49.7 parts of the SMAA copolymer resin (C) and HIPS were used as the constituent resin of the outdoor non-foaming layer.
Resin (D) 49.7 parts, black masterbatch resin (E)
Except that 0.6 parts of the mixed resin was used, a foamed laminated sheet in which the outdoor non-foamed layer was colored was obtained in the same manner as in Example 1.

The content of carbon black in the non-foamed layer was calculated to be 0.16% by weight. A 200 mm × 200 mm test piece was cut out from the obtained foamed laminated sheet and subjected to a light-shielding test. As a result, light leakage was observed.

(Example 4) In the same manner as in Example 1,
A foamed laminated sheet in which the outdoor non-foamed layer was colored was obtained. On the non-foamed layer on the indoor side of the obtained foamed laminated sheet, a PET non-woven fabric skin material (RVC-100 manufactured by Japan Vilene Co., thickness about 1.0 mm) was hot-melt film (Cranbetter X2200 manufactured by Kurabo Industries Co., Ltd.). ) Temporarily stopped.

After the foamed laminated sheet having the skin material and the hot melt film temporarily fixed thereto was clamped and placed in a heating furnace and heated to a surface temperature of 150 ° C., and plug molding was carried out by a mold whose temperature was controlled to 60 ° C. Trimming and punching were performed to obtain an automobile interior material. 20 from the obtained automobile interior materials
As a result of cutting out a 0 mm × 200 mm test piece and conducting a light-shielding test, light leakage and see-through of the skin material were not observed.

Example 5 In the same manner as in Example 2,
A foamed laminated sheet in which the outdoor non-foamed layer was colored was obtained. On the non-foamed layer on the indoor side of the obtained foamed laminated sheet, a PET-based non-woven fabric skin material (RVC-100 manufactured by Japan Vilene Co., thickness about 1.0 mm) was hot-melt film (Cranbetter X2200 manufactured by Kurabo Industries Co., Ltd.). ) Temporarily stopped.

The foamed laminated sheet having the skin material and the hot melt film temporarily fastened was clamped on four sides, placed in a heating furnace and heated to a surface temperature of 150 ° C., and plug molding was carried out by a mold whose temperature was adjusted to 60 ° C. Trimming and punching were performed to obtain an automobile interior material. 2 from the obtained foam laminated sheet
As a result of cutting out a test piece of 00 mm × 200 mm and conducting a light-shielding test, light leakage and see-through of the skin material were not observed.

(Comparative Example 3) In the same manner as in Comparative Example 1,
A foamed laminated sheet was obtained. On the non-foamed layer on the indoor side of the obtained foamed laminated sheet, a PET-based non-woven fabric skin material (RVC-100 manufactured by Japan Vilene Co., thickness about 1.0 mm) was hot-melt film (Cranbetter X22 manufactured by Kurabo Industries Co., Ltd.).
It was temporarily fixed through 00).

[0100] The foamed laminated sheet having the skin material and the hot melt film temporarily fixed was clamped on four sides and placed in a heating furnace to be heated to a surface temperature of 150 ° C, and plug molding was performed with a mold whose temperature was controlled at 60 ° C. Trimming and punching were performed to obtain an automobile interior material. 2 from the obtained foam laminated sheet
As a result of cutting out a test piece of 00 mm × 200 mm and conducting a light-shielding test, light leakage and see-through of the skin material were observed.

[0101]

INDUSTRIAL APPLICABILITY The automobile interior material of the present invention can prevent light leakage to the inside of the automobile caused by sunlight irradiation and scattered light from interior lights.

[Brief description of drawings]

FIG. 1 is a schematic diagram showing how light leakage occurs inside a vehicle in a vehicle having a sunroof structure.

FIG. 2 is a schematic diagram showing how light is leaked into the interior of an automobile due to scattered light from an automobile interior light.

FIG. 3 is an enlarged cross-sectional explanatory view of a main part of the foam laminated sheet according to the present invention.

FIG. 4 is an enlarged cross-sectional explanatory view of a main part of an automobile interior material according to the present invention.

[Explanation of symbols]

a: Sunroof car top plate b: Automotive ceiling material c; Sunroof glass d: Metal plate e: Light leakage location f: Interior light 10; Foam layer 12, 14: Non-foamed layer 16; Adhesive layer 18: Nonwoven fabric layer for colored noise 20; Non-woven fabric layer for skin material 22: Adhesive layer

Claims (6)

[Claims] 1. A foamed laminated sheet in which a non-foamed layer containing a thermoplastic resin as a base resin is laminated on both sides of a foamed layer containing a heat-resistant resin as a base resin, and at least one non-foamed layer has a thickness of 0.3. A foam laminated sheet for an automobile interior material, which contains a coloring agent in an amount of at least wt%. 2. At least one of the non-foamed layers contains carbon black as a colorant.
A foamed laminated sheet for an automobile interior material as described above. 3. The foamed laminated sheet for automobile interior materials according to claim 1, wherein the colored non-foamed layer contains an ultraviolet absorber. 4. The foam laminated sheet for automobile interior materials according to claim 3, wherein the ultraviolet absorber is selected from hindered amine ultraviolet absorbers, benzotriazole ultraviolet absorbers, and benzophenone ultraviolet absorbers. 5. The foamed laminated sheet for automobile interior materials according to claim 1, wherein the heat-resistant resin as the base resin of the foamed layer is a modified polyphenylene ether resin. . 6. A foamed laminated sheet in which a non-foamed layer made of a thermoplastic resin is laminated on both sides of a foamed sheet having a heat-resistant resin as a base resin, one non-foamed layer being 0.3% by weight or more. An automobile interior material that is colored by containing the coloring agent of 1. and is molded so that the colored non-foamed layer is on the outside of the automobile.