JP2003334875A - Trim material of car and base material therefor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a base material for a trim material of a car capable of reducing the noise in the car in order to enhance the comfortability of a passenger while holding characteristics as the base material for the trim material of the car such as lightweight properties, heat insulating properties, molding processability, heat resistance or the like, and to provide the trim material of the car obtained therefrom. <P>SOLUTION: The base material for the trim material of the car is obtained by laminating an impermeable film on either one of both surfaces of a foamed laminated sheet, wherein the base material has through-holes and having an air impermeable film for sealing the through-holes laminated thereto and has a foamed layer as a core layer, and non-foamed layers are laminated on both surfaces of the foamed layer. This base material has a high sound absorbing capacity by utilizing the interference effect of the vibration of the film on the through-holes and the sonic waves in the air layer behind the base material. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a base material for automobile interior materials and an automobile interior material. More specifically, the present invention relates to an automobile interior material base material and an automobile interior material used for forming an automobile interior material capable of reducing vehicle interior noise in order to improve passenger comfort.

[0002]

2. Description of the Related Art Conventionally, styrene has been used as an automobile interior material.
On the upper and lower surfaces of the foamed layer of the maleic anhydride copolymer, styrene-
A laminated sheet formed by laminating a non-foamed layer of a maleic anhydride copolymer into a desired shape has been widely used.
These automobile interior materials are light in weight, have high heat insulating properties, and have excellent moldability.

However, the conventional automobile interior materials as described above have insufficient heat resistance when exposed to high temperatures for a long time, so that the front portion hangs down due to its own weight (heat sag) or is deformed. Could occur.

Therefore, in order to solve these problems,
Automotive interior 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 polyphenylene ether resin (hereinafter referred to as "modified PPE resin") which is lightweight and has heat resistance is provided with modified P on both sides of the foam layer.
A foamed laminated sheet for automobile interior materials using a foamed laminated sheet in which a PE-based resin non-foamed layer is laminated has been proposed (Japanese Utility Model Publication No. 4-11162). In addition, JP-A-6-3444
No. 83 discloses a foaming ratio of 5 to 20 times, a thickness of 2 to 6 mm,
Modified PP with various physical properties such as open cell ratio 5-25%
A foam laminated sheet for automobile interior materials, in which a modified PPE resin non-foamed layer is laminated on both sides of an E resin foamed layer, has been proposed. The foamed laminated sheet for automobile interior materials using these modified PPE-based resins 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.

Furthermore, in recent years, automobiles have become more sophisticated and have higher performance, and quietness inside the vehicle is required. However, in the interior material for automobiles using the above modified PPE resin foam laminated sheet, the quietness inside the vehicle is improved. Sound absorption performance that is deeply related is not added, and in order to add sound absorption performance, it is necessary to use an expensive skin material with sound absorption performance, paste a sound absorbing material such as a urethane foam layer, etc. , Causing an increase in material costs and manufacturing costs.

On the other hand, conventionally, urethane foam (Japanese Patent Laid-Open No. 63-1) has been used as an automobile interior material having sound absorbing performance.
No. 99182), urethane foam and fiber (Japanese Patent Laid-Open No. 2-182)
63703) and short fibers (JP-A-2-95838) are known. In automobile interior materials with these sound absorbing properties, when sound is applied to the base material, the air vibrations are transmitted to the air in the pores inside the base material, and viscous friction of the air occurs in the pores, causing noise. Part of the energy of is converted into heat energy, and sound absorption performance occurs. In other words, the vibration is damped by the resistance to the movement of air,
The effect of reducing the sound is used. However, since this effect is exhibited only when the substrate has air permeability, it is necessary to use a foamed laminated sheet having open cells.

However, when a base material having air permeability is used, when air flows from the inside of the vehicle to the outside of the vehicle,
The skin layer plays a role of a filter, and the upper part of the skin layer becomes a problem because it becomes dirty like holes.

On the other hand, in the method for enhancing the sound absorbing performance of the non-air-permeable closed-cell foam laminated sheet itself, by making the foam layer highly foamed, the degree of freedom of vibration of the non-foamed layer laminated on the foam layer is increased. It is known to utilize the sound interference effect due to the vibration of the non-foamed layer. However, the sound absorbing performance of the non-breathable base material has been desired to be improved in response to the recent demand for higher performance.

[0010]

Means for Solving the Problems In the base material for automobile interior materials, the inventors of the present invention provided a through-hole in a foamed laminated sheet, and laminated a ventilation film on at least one surface of the foamed laminated sheet. By doing so, it is found that high sound absorption can be imparted by exhibiting the effect of interference between sound waves in the vibration of the film on the through-hole portion and the air layer behind the base material without causing a problem with indoor ventilation stains, and the present invention It came to completion.

That is, according to the present invention, 1) a ventilation film (3) having a plurality of through holes (2) and sealing them.
A base material for automobile interior materials, which is composed of a base material (1) in which the above are laminated. 2) The base material for automobile interior materials according to 1), wherein the base material (1) is a foam laminated sheet having a foam layer (4) as a core layer and a breathable film (3) laminated on the foam laminated sheet. Material.

3) The foamed laminated sheet is characterized in that a non-foamed layer (5, 6) made of a thermoplastic resin is laminated on both sides of a foamed layer (4) containing a heat-resistant resin as a base resin. The base material for automobile interior materials as described. 4) The diameter of the through hole provided in the foam laminated sheet is 0.1 mm.
Approximately 20 mm, Claim 1, 2, or 3
The base material for automobile interior materials as described.

5) The thickness of the ventilation film (3) is 5μ
The base material for automobile interior materials according to 1), 2), 3), or 4), characterized in that it has a size of m to 200 μm. 6) The base material resin of the foam layer (4) is composed of a modified polyphenylene ether resin, 1), 2),
The substrate for an automobile interior material according to 3), 4) or 5). 7) The base resin of at least one non-foaming layer (5, 6) laminated on the foaming layer (4) is composed of a modified polyphenylene ether resin, 1), 2), 3),
4), 5) or 6) the base material for automobile interior materials.

8) The content of the phenylene ether component in the modified polyphenylene ether resin as the base resin of the foam layer (4) is 25% by weight to 70% by weight, and the content of the styrene component is 75% by weight. % To 30% by weight, 1), 2), 3), 4), 5), 6) or 7) the substrate for automobile interior materials.

9) Base material (1) having a plurality of through holes (2) and laminated with a ventilation film (3) for sealing the through holes (2)
However, on one side of a foamed laminated sheet in which a non-foamed layer (5, 6) made of a thermoplastic resin is laminated on both sides of a foamed layer (4) having a heat-resistant resin as a base resin 3) is laminated, and a base material for automobile interior materials, in which a skin material is laminated on one surface of the base material (1). 10) The base material for automobile interior materials according to 9), wherein the skin material is a non-woven fabric. 11) An automobile interior material obtained by molding the substrate for an automobile interior material according to any one of 1) to 10).

[0016]

BEST MODE FOR CARRYING OUT THE INVENTION Next, examples of an automobile interior material and a foam laminated sheet for an automobile interior material according to the present invention will be described in detail with reference to the drawings.

FIG. 1 schematically shows the structure of an automobile interior material according to one embodiment of the present invention, in which a through hole (2) is provided.
The base material (1) in which the air-permeable film (3) and the breathable film (3) are laminated is a foamed laminated sheet in which the non-foamed layers (5, 6) are laminated on both sides of the foamed core layer (4), with an adhesive layer interposed therebetween. The breathable film is laminated, the skin material (7) is laminated on the surface of the breathable film, and the noise prevention layer (8) is laminated on the back surface. However, the present invention is not limited by the presence or absence of the abnormal noise prevention layer (8).

FIG. 2 schematically shows the structure of an automobile interior material according to another embodiment of the present invention, in which a base material (1) having a through hole (2) and a ventilation film (3) laminated thereon.
Is a foamed laminated sheet in which non-foamed layers (5, 6) are laminated on both sides of a foamed layer (4), and a ventilation-stop film laminated via an adhesive layer (10) is used as an abnormal noise prevention layer. Used on the back surface side of the adhesive layer (9) with the skin material (7)
Are stacked.

FIG. 3 schematically shows the structure of an automobile interior material according to still another embodiment of the present invention. Further, the structure is shown in FIG. The noise prevention layer (8) is laminated.

The above-mentioned base material may use any foamed core layer or non-foamed layer as long as it holds the through holes and the air-permeable film. Further, the foamed laminated sheet as illustrated, and further, the specific structure having the noise preventing layer and the skin material is not necessarily limited.

As a material constituting the base material, in consideration of molding processability, light weight, heat resistance, heat insulating property, recyclability and cost performance, thermoplastic resin is used for the foamed core layer containing heat resistant resin as the base material resin. It is preferable to use a base material in which a non-foamed layer made of a resin is laminated.

As the heat resistant resin used in the foamed layer (4) of the present invention, any resin generally known in the art as having heat resistance and generally commercially available can be used. For example, heat-resistant polystyrene resins such as styrene-acrylic acid copolymer, styrene-maleic anhydride copolymer, styrene-itaconic acid copolymer; polystyrene (PS) or heat-resistant polystyrene and polyphenylene ether (PPE) Modified polyphenylene ether resins (modified PPE resins) such as blends, styrene / phenylene ether copolymers such as styrene graft polymers on PPE; polycarbonate resins; and polyester resins exemplified by polybutylene terephthalate and polyethylene terephthalate A polyolefin resin such as polypropylene or polyethylene. Two or more kinds of these resins may be used.

Among these, the modified PPE resin is preferable because it is excellent in quality such as heat resistance and rigidity, and is easy to process and manufacture. Examples of the PPE resin used 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-)
Dipropylphenylene-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 are used alone or in combination of two or more kinds.

The modified PPE resin and the PS resin mixed with the PPE resin include styrene and its derivatives such as α-methylstyrene, 2,4-dimethylstyrene, monochlorostyrene, dichlorostyrene, p-methylstyrene, and the like. It is a resin whose main component is ethylstyrene. 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 (4) of the present invention, the phenylene ether component is usually 25 to 70 parts by weight, and the styrene component is 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. Is good. P
If the mixing ratio of the PE-based resin is low, the heat resistance tends to be poor, and if the mixing ratio of the PPE-based resin is high, the viscosity at the time of heating and flowing increases, and thus foam molding tends to be difficult.

As the foaming agent in foaming, a general-purpose gas can be used as long as it has good compatibility with the heat-resistant resin used in the foaming layer (4). A hydrocarbon-based gas is preferable, and examples thereof include butane and pentane. Among these, as a foaming agent for forming the foamed layer (4) using the modified PPE resin as the heat resistant resin, butane gas is excellent in compatibility with the heat resistant resin and foamability, and even in butane gas, particularly with isobutane. A mixed gas having a mixing ratio of 85:15 with normal butane shows a very excellent foaming property. The foaming agent in the foam layer (4) is preferably 1 to 7 parts by weight, and most preferably 3 to 5 parts by weight.

The foamed layer (4) using the modified PPE resin as the heat resistant resin has a thickness of 3 to 20 mm, more preferably 4 to 1
It is preferably 0 mm. The thickness of the foam layer (4) is 3 m
If it is less than m, the strength and heat insulating properties may be poor and it may not be suitable as an automobile interior material. On the other hand, if it exceeds 20 mm, it may be unsuitable for practical use due to reasons such as securing a space in the interior of the automobile and restrictions on interior design.

The foaming layer (4) using the modified PPE resin as a heat resistant resin preferably has a foaming ratio of 20 to 100 times, more preferably 30 to 60 times. This is because the automobile interior material in the present invention reduces the elastic modulus of the foam layer (4) and utilizes the sound interference effect due to the vibration of the non-foam layer laminated on the foam layer (4). When the magnification is less than 20 times, the effect of reducing the elastic modulus is not sufficient and the sound absorbing performance tends not to be improved. When the expansion ratio is 100 times or more, the cell film density tends to be too low and the heat resistance tends to deteriorate.

The foamed layer (4) using the modified PPE resin as the heat resistant resin has a closed cell ratio of 70% or more, and further 8
0% or more is preferable. When the closed cell ratio is 70% or less,
Insulation and rigidity tend to be poor.

In the heat-resistant resin of the foam layer (4) used in the present invention, if necessary, a cell regulator, a lubricant, an antioxidant, an antistatic agent, a pigment, a stabilizer, an odor reducing agent and the like. You may add.

Next, as the thermoplastic resin used in the non-foamed layer (5, 6), heat resistant PS resin, modified PPE resin, polypropylene resin, polyethylene resin, polyethylene terephthalate (PET) resin, polyamide (Nylon) type resin, etc.
Alternatively, two or more kinds of them are used in combination, but when a modified PPE-based resin is used as the foaming layer (4), the modified PPE-based resin and the heat-resistant P are used from the viewpoint of adhesiveness with the resin layer.
S-based resins are preferably used.

When the modified PPE resin is used as the non-foamed layer (5, 6), as in the case of the foamed layer (4) described above,
A PPE-based resin and a styrene-based compound-based monomer or a polymer thereof is used for modification by polymerization or mixing. For example, a mixed resin of a PPE-based resin and a PS-based resin, a PPE-based resin with styrene is used. P produced by polymerizing a system monomer
Examples thereof include a PE-styrene copolymer, a mixture of this copolymer and a PS resin or a PPE resin, and a mixture of the copolymer, 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 (4).

When the modified PPE resin is used as the base resin used in the non-foamed layers (5, 6), the phenylene ether component is preferably 15 to 75 parts by weight, and the styrene component is preferably 75 to 25 parts by weight. , And more preferably,
The phenylene ether component is preferably 20 to 60 parts by weight, and the styrene component is preferably 80 to 40 parts by weight. If the proportion of the PPE-based resin used is too small, the heat resistance tends to be poor, and if the proportion of the PPE-based resin used is too large, the viscosity at the time of heating and flowing increases, which may make molding difficult.

A heat-resistant PS resin which is preferable as a base resin for the non-foamed layer (5, 6) is a copolymer of styrene or its derivative and another monomer (hereinafter referred to as "St copolymer"). The monomer copolymerizable with styrene or a derivative thereof having an effect of improving heat resistance is, for example, an unsaturated carboxylic acid such as maleic acid, fumaric acid, acrylic acid, methacrylic acid or itaconic acid or a derivative thereof. And acid anhydrides, nitrile compounds such as acrylonitrile and methacrylonitrile, or derivatives thereof. These may be used alone or in combination of two or more. The amount of the monomer copolymerizable with styrene or its derivative having the effect of improving heat resistance is usually 40 parts by weight or less, preferably 30 parts by weight or less.

When styrene or a styrene derivative is polymerized, a synthetic rubber or rubber latex is added and polymerized with an unsaturated carboxylic acid such as maleic acid, fumaric acid, acrylic acid, methacrylic acid or itaconic acid. Alternatively, it may be a copolymer with a derivative thereof and an acid anhydride thereof, a nitrile compound such as acrylonitrile and methacrylonitrile. Among these, styrene-maleic anhydride-based copolymer, styrene-acrylic acid-based copolymer, styrene-methacrylic acid-based copolymer, acrylonitrile-butadiene-styrene copolymer is its heat resistance improving effect, versatility It is preferable in terms of cost.

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,
Polyolefins such as polyethylene and polypropylene,
Examples thereof include vinyl chloride resins such as polyvinyl chloride, polyether ether sulfones, polysulfones, polyamides and copolymers thereof. Among them, HIPS is preferable in terms of versatility, uniform dispersion, great effect of improving impact resistance of the non-foamed layer, cost, and the like.
Known HIPS can be used, and the content of the rubber component is usually 1 to 15% by weight.

The thickness of the non-foamed layer (5, 6) is 50 to 300.
μm, more preferably 75 to 200 μm. If the thickness of the non-foamed layer (5, 6) is less than 50 μm, the strength,
The rigidity and heat resistance are poor, and when it is thicker than 300 μm, the moldability of the laminated sheet tends to be poor.

When forming the non-foamed layer (5, 6), if necessary, impact resistance improver, filler, lubricant, antioxidant, antistatic agent, pigment, stabilizer, odor reducing agent, etc. May be added alone or in combination of two or more.

The impact resistance improver is punched when a non-foamed layer (5, 6) is laminated on the foamed layer (4) to form a secondary foamed laminated sheet as an automobile interior material, or a laminated sheet. It is effective to prevent cracking of the non-foamed layer (5, 6) when the or molded product is transported. 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 layer (5,
Impact resistance can be imparted to 6).

A base material (1) comprising a foamed layer (4) and non-foamed layers (5, 6) laminated on both sides of the foamed layer (4), or a base material further laminated with an adhesive layer, a noise suppressing layer, etc. The through hole to be held is a cylindrical hole provided by punching or the like, and the diameter of the circle is preferably 0.1 mm to 20 mm. If the diameter is 0.1 mm or less, the vibration of the ventilation film laminated on the base material (1) is hindered so that it is not sufficiently expressed, and if it is 20 mm or more, the handling property and rigidity after molding are increased. Deteriorates, and the shape of the molded body and deformation during heat treatment become large, so that a stable product cannot be obtained. The pitch of the through holes is preferably larger than the diameter of the holes and 100 mm or less. If the pitch is as small as the diameter of the holes, the shape of the molded product cannot be maintained, the handling properties and rigidity after molding will deteriorate, and the molded product shape and deformation during heat resistance will increase, making it a stable product. You will not be able to get it. If it is over 100 mm, the sound absorbing performance cannot be exhibited.

As the film used as the air-venting film, any film known to those skilled in the art as long as it does not allow air to pass therethrough, and any film which is commercially available can be used. Among them, the polyolefin film is preferable because of good adhesion to the non-foamed layer, the skin material and the noise preventing layer. For example, homopolymers such as low-density polyethylene, high-density polyethylene and linear polyethylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene and methacrylate, acrylate, butene and other olefins can be copolymerized. Copolymers with monomers, polyethylene-based resins consisting of mixtures thereof, propylene homopolymers, propylene vinyl acetate copolymers, propylene and methacrylate, acrylates, butenes and other olefins A polypropylene resin composed of a copolymer with the body, a mixture thereof or the like is preferable. Of these, polyethylene is preferable in view of heat sealability, and linear low-density polyethylene (L-LDPE) is more preferable. As shown in FIGS. 1 and 2, this film (3) functions as a skin material and an abnormal noise prevention layer adhesive layer.

The thickness is preferably 5 μm to 200 μm. 5 μm
In the following cases, the adhesiveness of the skin material or the noise preventing layer laminated thereon is deteriorated and a good molded product cannot be obtained. Further, when the thickness is 200 μm or more, sufficient vibration is not expressed on the through holes, and it becomes impossible to impart desired sound absorbing performance.

As a specific example of the skin material (7), a material used as a conventional automobile interior material can be used. For example, woven cloth and non-woven cloth are arranged, and these include polyethylene terephthalate, polypropylene, polyamide (nylon), polyacrylonitrile, modacrylic (for example,
Synthetic resins such as "Kanekaron (registered trademark)" manufactured by Kanegafuchi Chemical Industry Co., Ltd., natural materials such as wool and cotton, and combinations thereof are used. If necessary, a foam layer made of polyurethane foam may be laminated in a single layer or a plurality of layers on the surface material (7).

The base material for automobile interior materials described above can be satisfactorily molded by a commonly used molding method. At that time, regarding the base material for automobile interior materials laminated with the skin material,
This skin material is molded so as to be on the inside of the vehicle.

[0047]

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

[0048]

[Table 1]

The symbols relating to the resins shown in Table 1 are as follows. Modified PPE: Modified polyphenylene ether resin PS: Polystyrene resin HIPS: High impact polystyrene resin

The evaluation methods used in Examples and Comparative Examples are shown below. Evaluation of foamed laminated sheet for automobile interior materials, base material for automobile interior materials (thickness of foam layer and molded body) Primary foamed sheet, measured thickness at 20 places in the width direction of the molded body, and The average value 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. Foaming ratio = dp / df

(Closed cell ratio) Measured according to ASTM D-2859. (Using a multi-pycnometer (manufactured by Beckman)) (Basis weight) From 5 points in the extrusion direction of the primary foam sheet,
Cut out a 100 mm x 100 mm test piece,
After measuring their weight, an average value was calculated.

(Measurement of normal incidence sound absorption coefficient) JIS-A-14
It was evaluated by measuring the normal incidence sound absorption coefficient according to No. 05. Note that the sound was incident from the skin material side in order to approach the mounting state in an automobile. The measurement was performed with a measuring machine having a diameter of 29 mm (measurement frequency range: 500 to 6300 Hz) and a back air layer of 15 mm. As the criteria for judgment, the following criteria were used in consideration of the average normal incidence sound absorption coefficient of 1000 Hz to 5000 Hz required in the market for automobile interior materials. Average normal incidence sound absorption coefficient from 1000Hz to 5000Hz ○ ・ ・ 0.25 or more × ・ ・ Less than 0.25

(Example 1) As the foam layer (4), PP was used.
To 100 parts by weight of a mixed resin obtained by mixing 57.1 parts by weight of modified PPE resin (A) and 42.9 parts by weight of PS resin (B) so that the E resin component is 40% by weight and the PS resin component is 60% by weight. Then, 3.4 parts by weight of a blowing agent containing iso-butane as a main component (iso-butane / n-butane = 85/15% by weight) was kneaded by an extruder. A thickness of 5.5 mm formed by extrusion and foaming with a circular die, a foaming ratio of 35 times,
A foam layer having a closed cell rate of 85% and a basis weight of 160 g / m ² was used.

As the non-foaming layer (5) on the indoor side, 28.6 parts by weight of modified PPE resin (A) and PS resin (B) are added so that the PPE resin component is 20% by weight and the PS resin component is 80% by weight. A 120 μm thick film made of a mixed resin in which 71.4 parts by weight was mixed was used.

As the outdoor-side non-foaming layer (6), a film having a thickness of 150 μm was used, which was a mixture of 50 parts of the SMAA copolymer resin (C) and 50 parts of the HIPS resin (D).

The abnormal noise preventing layer (8) is made of polyethylene terephthalate having a fiber diameter of 1.6 dtex and a fiber length of 4
A 0 mm web was used, and a water needle punched non-woven fabric sheet having a surface weight of 25 g / m ² obtained by subjecting the top surface of the web to water needle punching was used.

The air-proof film (3) has a thickness of 1
A 0 μm L-LDPE (linear low-density polyethylene) unstretched film was used.

As the air-permeable film adhesive layer (10), 100 parts by weight of an epoxy resin (Epiretz 880SAW65 manufactured by Japan Epoxy Resin Co., Ltd.) and 20 parts of a curing agent (Epicure U manufactured by Japan Epoxy Resin Co., Ltd.) were used.
By mixing 30 parts by weight, a mixed solution obtained by diluting the mixture 10 times with ethanol was applied at 30 g / m ² using a roll coater and used. As the skin material layer (7), PE with a thickness of about 1 mm
A T-type nonwoven fabric skin material was used.

The through hole (2) is a foamed laminate comprising a foamed layer (4), indoor / outdoor non-foamed layers (5, 6), a noise suppressing layer (8), and a ventilation film adhesive layer (10). A circular through hole (2) with a diameter of 8.0 mm that penetrates in the thickness direction of
One piece was provided in the vertical and horizontal 29 mm square.

A part of a base material for automobile interior materials formed by using the above-mentioned material in the same structure as in FIG. 1 was cut out so that the through hole was 29 mmφ so that the through hole was at the center. The rate was measured. As a result, 1000H
The average sound absorption coefficient from z to 5000 Hz is 0.31,
It was enough to meet the market demand.

(Example 2) Except for the abnormal noise prevention layer (8), skin material adhesive layer (9): polyolefin hot melt film (Oishi Sangyo Co., Ltd .: Hirodyne 7586, surface weight: 30 g / m) ² ) The same constituent material as in Example 1 except that the foam layer (4), the indoor / outdoor non-foam layer (5,
6), a circular through hole (2) having a diameter of 8.0 mm, which penetrates in the thickness direction of the foam laminate comprising the skin material adhesive layer (9) and the air-permeable film adhesive layer (10), One piece is provided on each side of 29 mm square, and with the skin material, a part of the automobile interior material base material similar to that shown in Fig. 2 in which a ventilation film is laminated on the back side is cut out at 29 mmφ so that the through hole is in the center and is vertical. The vertical incident sound absorption coefficient was measured as a sample for measuring the incident sound absorption coefficient. As a result, the average sound absorption coefficient in the range of 1000 Hz to 5000 Hz was 0.33, which sufficiently satisfied the market demand.

(Embodiment 3) The noise prevention layer (8) is the same as that in Embodiment 1.
The same as that used in Example 2, except that the skin adhesive layer (9) is the same as in Example 2 except that the noise prevention layer (8) is laminated on the outermost side of Example 2 (FIG. 2). A part of the same automobile interior material base material as in FIG. 3 which is the same as that in FIG. as a result,
The average sound absorption coefficient at 1000 Hz to 5000 Hz is 0.30.
And sufficiently satisfied the demands of the market.

(Comparative Example 1) A part of an automobile interior material base material having the same structure as in Example 1 except that the through hole was not provided was cut out in the same manner as in Example 1 and the normal incidence sound absorption coefficient was measured. As a result, the average sound absorption coefficient at 1000 Hz to 5000 Hz is 0.
It was 11, which was not enough to meet the market demand.

[0065]

EFFECTS OF THE INVENTION By using a base material having through holes and laminated with a ventilation film, the effect of film vibration on the through hole portion and the interference effect of sound waves in the air layer behind the base material can be exhibited. . As a result, a high sound absorbing performance can be imparted to any base material without the problem of dirt due to ventilation, and a low-cost and excellent sound absorbing base material for an automobile interior material and an automobile interior material can be provided.

[Brief description of drawings]

FIG. 1 is a schematic enlarged cross-sectional view of a main part of a base material for an automobile interior material according to the present invention.

FIG. 2 is an enlarged cross-sectional schematic view of another main part of the base material for automobile interior materials according to the present invention.

FIG. 3 is an enlarged cross-sectional schematic view of an essential part showing another embodiment of a base material for an automobile interior material according to the present invention.

[Explanation of symbols] 1: Base material 2: Through hole 3: Ventilation film 4: Foam core layer 5: Indoor side non-foaming layer 6: Outdoor non-foaming layer 7: Skin material 8: Noise prevention layer 9: Skin material adhesive layer 10: Ventilation film adhesive layer

   ─────────────────────────────────────────────────── ─── Continued front page    F term (reference) 3D023 BA03 BA05 BB01 BB21 BE07                 4F100 AK01B AK01C AK01E AK12                       AK42 AK54C AL06C AT00C                       AT00E BA03 BA04 BA05                       BA07 BA10A BA10B BA10C                       BA10D BA10E DC11A DG06                       DG15E DJ01B DJ01C DJ01E                       EC09 EC092 EH17 EH172                       EJ02 EJ022 GB33 JB16B                       JB16E JD02B JD02D JH01                       JJ03C YY00B YY00C YY00D

Claims (11)

[Claims] 1. A base material for an automobile interior material, which comprises a base material (1) having a through hole (2) and laminated with a ventilation film (3) for sealing the through hole (2). 2. The automobile according to claim 1, wherein the base material (1) is a foam laminated sheet having a foam layer (4) as a core layer and a ventilation film (3) laminated on the foam laminated sheet. Base material for interior materials. 3. A foamed laminated sheet, wherein a non-foamed layer (5, 6) made of a thermoplastic resin is laminated on both sides of a foamed layer (4) having a heat-resistant resin as a base resin. Two
The base material for automobile interior materials as described. 4. The foamed laminated sheet according to claim 1, wherein the through holes provided in the foamed laminated sheet have a diameter of 0.1 mm to 20 mm.
Or the base material for automobile interior materials according to 3. 5. The ventilation film (3) has a thickness of 5 μm.
The base material for automobile interior materials according to claim 1, 2, 3, or 4, wherein the base material has a thickness of ˜200 μm. 6. The base material for automobile interior materials according to claim 1, 2, 3, 4, or 5, wherein the base resin of the foam layer (4) is a modified polyphenylene ether resin. 7. The base resin of at least one non-foaming layer (5, 6) laminated on the foaming layer (4) is composed of a modified polyphenylene ether resin. The base material for automobile interior materials according to 4, 5, or 6. 8. The modified polyphenylene ether resin, which is the base resin of the foaming layer (4), has a phenylene ether component content of 25% by weight to 70% by weight and a styrene component content of 75% by weight. % To 30% by weight, the base material for automobile interior materials according to claim 1, 2, 3, 4, 5, 6 or 7. 9. A base material (1) having a plurality of through holes (2) and laminated with a ventilation film (3) for sealing the through holes (2),
Ventilation film (3) on either side of a foamed laminated sheet in which a non-foamed layer (5, 6) made of a thermoplastic resin is laminated on both sides of a foamed layer (4) using a heat-resistant resin as a base resin. Is laminated, and a skin material is laminated on one surface of the substrate (1). 10. The base material for automobile interior materials according to claim 9, wherein the skin material is a non-woven fabric. 11. An automobile interior material obtained by molding the base material for automobile interior material according to any one of claims 1 to 10.