JP2004090413A

JP2004090413A - Molded interior material and method for manufacturing it

Info

Publication number: JP2004090413A
Application number: JP2002254652A
Authority: JP
Inventors: Masahiko Mikami; 三上　正彦
Original assignee: Sanwa Kogyo Co Ltd
Current assignee: Sanwa Kogyo Co Ltd
Priority date: 2002-08-30
Filing date: 2002-08-30
Publication date: 2004-03-25

Abstract

<P>PROBLEM TO BE SOLVED: To facilitate remolding in recycling and to satisfy weight reduction and such functions as sound absorbing performance without using a urethane as a base material as a product using a urethane base material as the base material is inferior in recyclability. <P>SOLUTION: A molded interior material is composed of laminating reinforcing fiber materials 3 and 4 on both sides of the base material 2 comprising a cotton-like porous cushioning body, laminating an adhesive 6 comprising a thermoplastic resin and a skin 7 in this order on the outside of one of the reinforcing fiber materials 3, and laminating a back surface paper 8 on the outside of the other reinforcing fiber material 4. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、形状安定性に優れた軽量の車両用成形天井材、成形ドアトリム、リヤパッケージトレイ、トノボード、車両用フロア材等の成形内装材及びその製造方法に関する。
【０００２】
【従来の技術】
従来より、発泡ウレタンを基材とする内装材は軽量・吸音性能等に優れ、一般的な自動車用内装材として多く使用されている。この構造は、ウレタン基材を成形し、また内装表皮を貼り付けるために、イソシアネートに代表される熱硬化性樹脂の接着剤を塗布した網目状マットの補強材（ガラスマット）を媒体として、ホットプレスで成形及び表皮貼付けされるのが一般的である。
【０００３】
【発明が解決しようとする課題】
しかし、この内装製品をリサイクルしようとする時、粉砕しそれを固めるのに熱硬化性樹脂を使用しているために、新たなバインダー（接着剤）が必要となって非常にコスト高になる。そのために、リサイクルせずに焼却処分されているのが通例である。しかし、将来の環境規準が厳しくなってきた時に対応できないことが予測され、脱ウレタン基材の内装材が必要となってきている。
【０００４】
従来の脱ウレタン基材としては、段ボール、レジンフェルト、ウッドチップシート等が知られているが、これらは、ウレタン基材が有していた軽量化や吸音性能等が悪化しており、十分な機能を満足するものが得られていない。
【０００５】
【課題を解決するための手段】
本発明は、基材としてウレタンを使用することの不具合を考慮して、非ウレタンの基材を使用していながら、ウレタン発泡材と同様に軽量化や吸音性能を有する基材を新たに使用することとし、さらに、熱可塑性樹脂製の接着剤を基材に含有することでリサイクルを容易とし、非ウレタン基材の強度不足をその両側に配設したカーボン繊維層で補うようにしたものである。
【０００６】
具体的には、請求項１の発明は、綿状多孔質クッション体からなるベース材と、該ベース材の両側に積層された補強繊維材と、一方の補強繊維材の外側に熱可塑性樹脂からなる接着剤及び表皮を順に積層し、他方の補強繊維材の外側に裏面紙を積層してなる成形内装材である。
【０００７】
この構成では、非ウレタンのベース材が十分に軽量化され、吸音性能を有するとともに、ベース材の両側に補強繊維材を積層したので、ベース材の強度不足を十分に補強できる。それとともに、熱可塑性接着剤を使用しているので、リサイクル使用が容易である、
請求項２の発明は、請求項１に記載の成形内装材において、綿状多孔質クッション体がアクリル、ポリエステル等の化学繊維の不織布綿からなるので、成形性が良く、量産性に優れる。
【０００８】
請求項３の発明は、請求項１に記載の成形内装材において、綿状多孔質クッション体がケナフ、サイザル、麻、サボテン、竹、木等の天然植物繊維の少なくとも１種からなるので、低コストで多量に入手できる。また、天然素材であり、リサイクル時や処分時に公害問題を発生することがない。
【０００９】
請求項４の発明は、請求項３に記載の成形内装材において、天然植物繊維の繊維長が１０〜１００ｍｍで、繊維径が１．０ｍｍ以下である。繊維径とは、断面円形以外の場合には直径の短いほうの長さであり、直径１．０ｍｍを超えると、成形品表面に繊維の凹凸が現れ外観を著しく損なうので好ましくない。さらには、直径０．５ｍｍ以下のものが好ましい。繊維長は１０ｍｍ以下では要求される補強効果が得られず、逆に繊維長が１００ｍｍよりも長すぎると、互いに絡まって均一に分散できない。さらには、３０ｍｍ〜５０ｍｍのものが好ましい。なお繊維長は全て均一な長さのものに揃える必要はなく、上記範囲の長さのものであれば異なった長さのものでも良い。
【００１０】
請求項５の発明は、請求項１ないし４のいずれかに記載の成形内装材において、綿状多孔質クッション体の目付けが２００〜１０００ｇ／ｍ^２であり、その厚さが成形前で２０〜５０ｍｍであるので、軽量で吸音性能を備え、かつ成形性の良いものが得られる。
【００１１】
請求項６の発明は、請求項５に記載の成形内装材において、綿状多孔質クッション体の目付けが４００〜６００ｇ／ｍ^２であるので、さらに高性能なものが得られる。
【００１２】
請求項７の発明は、請求項１ないし６のいずれかに記載の成形内装材において、ベース材に熱可塑性樹脂からなる接着剤が混入されているので、接合性能が良好で、かつ成形性を有するものを得られる。
【００１３】
請求項８の発明は、請求項７に記載の成形内装材において、熱可塑性樹脂からなる接着剤の混入割合がベース材の５〜５０重量％であるので、接着剤が染み出ることなく、かつベース材を効果的に接合できる。
【００１４】
請求項９の発明は、請求項７又は８に記載の成形内装材において、熱可塑性樹脂がオレフィン、ポリエステル、ポリアミド、ナイロンのいずれかからなるので、安定して接合できる。
【００１５】
請求項１０の発明は、請求項１ないし９のいずれかに記載の成形内装材において、補強繊維材は、カーボン繊維にアクリル、ポリエステル等の化学繊維が混紡された繊維束からなるので、高価なカーボン繊維を少なくでき低コスト化できるとともに、接合性を改善できる。
【００１６】
請求項１１の発明は、請求項１ないし９のいずれかに記載の成形内装材において、補強繊維材は、カーボン繊維にケナフ、サイザル、麻、サボテン、竹、木等の天然植物繊維の少なくとも１種が混合されてなるので、低コストで多量に入手できる。また、天然素材であり、リサイクル時や処分時に公害問題を発生することがない。
【００１７】
請求項１２の発明は、請求項１１に記載の成形内装材において、天然植物繊維の繊維長が１０〜１００ｍｍで、繊維径が１．０ｍｍ以下である。繊維径とは、断面円形以外の場合には径の短いほうの長さであり、直径１．０ｍｍを超えると、成形品表面に繊維の凹凸が現れ外観を著しく損なうので好ましくなく、さらには、直径０．５ｍｍ以下のものが好ましい。繊維長は１０ｍｍ以下では要求される補強効果が得られず、逆に繊維長が１００ｍｍよりも長すぎると、互いに絡まって均一に分散できない。さらには、３０ｍｍ〜５０ｍｍのものが好ましい。なお繊維長は全て均一な長さのものに揃える必要はなく、上記範囲の長さのものであれば異なった長さのものでも良い。
【００１８】
請求項１３の発明は、請求項１０ないし１２のいずれかに記載の成形内装材において、カーボン繊維と他の混入繊維との重量割合は、カーボン繊維：３０〜７０％に対して他の混入繊維：７０〜３０％であるので、高価なカーボン繊維を少なくでき、低コスト化できる。
【００１９】
他の混入繊維が３０％以下、即ちカーボン繊維が７０％以上になると、コストアップとなる。また、基材及び表皮との接合強度が低下し、接合力を高める手段を別途講じる必要がある。
【００２０】
他の混入繊維が７０％以上、即ちカーボン繊維が３０％以下になると、基材の強度が不足し、成形内装材としての使用に耐えられるものが得られない。したがって、カーボン繊維と混入繊維との重量割合は、上記範囲にすることが好ましい。特に、カーボン繊維：６０〜４０で混入繊維：４０〜６０とすることが、さらに好ましい。
【００２１】
請求項１４の発明は、請求項１０ないし１３のいずれかに記載の成形内装材において、補強繊維材は、カーボン繊維と他の混入繊維とが積層方向に混在して成形された格子状のシート材からなるので、ある部分の断面を見るとカーボン繊維を挟んでその両側に混入繊維が存在したり、別の断面を見ると混入繊維を挟んでその両側にカーボン繊維が存在したりする状態であり、カーボン繊維と混入繊維との接合強度が高く、ベース材との接合強度にも優れる。
【００２２】
請求項１５の発明は、請求項１０ないし１４のいずれかに記載の成形内装材において、カーボン繊維に混入する混入繊維が、ベース材の綿状多孔質クッション体繊維と同種の繊維からなるので、ベース材との接合性に優れ、ベース材の強度補強に効果的である。
【００２３】
請求項１６の発明は、請求項１ないし１５のいずれかに記載の成形内装材において、補強繊維材に熱可塑性樹脂からなる接着剤が混入されているので、接合性に優れ、かつリサイクル時任意の形状に成形でき、リサイクルが容易である。
【００２４】
請求項１７の発明は、請求項１６に記載の成形内装材において、熱可塑性樹脂からなる接着剤の混入割合が補強繊維材の５〜５０重量％であるので、接着剤がこの補強繊維材から染み出ることなく、かつ接合性を確保できる。
【００２５】
請求項１８の発明は、請求項１７に記載の成形内装材において、熱可塑性樹脂からなる接着剤の混入割合が補強繊維材の１０〜３０重量％であるので、接着剤が補強繊維材から染み出ることを防止しつつ、かつ接合性をさらに良好に確保できる。
【００２６】
請求項１９の発明は、請求項１６ないし１８のいずれかに記載の成形内装材において、熱可塑性樹脂がオレフィン、ポリエステル、ポリアミド、ナイロンのいずれかからなるので、適切な接合性を確保できる。
【００２７】
請求項２０の発明は、請求項１ないし１９のいずれかに記載の成形内装材において、成形内装材が車両の成形天井であるので、成形天井として実用的なものが得られる。特に、大きな成形天井の細分化によるリサイクルが容易であり、この成形天井を焼却処分しても、有害成分を発生しないので、公害問題上からも、優れている。
【００２８】
請求項２１の発明は、成形内装材の製造方法であって、綿状多孔質クッション体からなるベース材の両側に補強繊維材が積層され、熱可塑性樹脂からなる接着剤を含有する基材を用意し、該基材を１８０〜２３０℃に加熱した後、一方の補強繊維材の外側に熱可塑性樹脂からなる接着剤及び表皮を順に積層するとともに、他方の補強繊維材の外側に裏面紙を積層して、コールド金型内で加圧成形することを特徴とする。
【００２９】
この製造方法では、基材の取り扱いが容易であり、生産性に優れる。特に、熱可塑性接着剤を使用しているので、リサイクル使用時に、他の形状に成形することが容易であり、リサイクル利便性に優れる。
【００３０】
請求項２２の発明は、成形内装材の製造方法であって、綿状多孔質クッション体からなるベース材と、熱可塑性樹脂からなる接着剤を含有する補強繊維材とを用意し、上記ベース材を１８０〜２３０℃に加熱した後、該ベース材の両側に補強繊維材層を積層し、一方の補強繊維材層の外側に熱可塑性樹脂からなる接着剤層及び表皮を順に積層するとともに、他方の補強繊維材の外側に裏面紙を積層して、コールド金型内で加圧成形することを特徴とする。
【００３１】
この製造方法では、コールド成形型内に各種素材をセットして一度に成形するので、基材の予備成形が不要でありコストダウンできる。また請求項２１と同様に、熱可塑性接着剤を使用しているので、リサイクル使用時に、他の形状に成形することが容易であり、リサイクル利便性に優れる。
【００３２】
本発明では、天然繊維やポリエチレン綿等の化学繊維の綿状多孔質クッション体からなるベース材と、該ベース材の伸縮性と強度を確保・向上させるために、ベース材の両側に補強繊維材を積層した基材となし、該基材に熱可塑性樹脂をバインダーとして混入させておき、ホットプレートで加熱した後、他の材料とともにコールド金型で成形して製品を得るものである。
【００３３】
このベース材の多孔質クッション体の材質として使用する植物繊維は、セルロースを主体とした植物を分岐切断または粉砕したものであって、麻、ケナフ、サイザル繊維、竹繊維、木質繊維の単体・或は混合体である。木質繊維は木から得られる。木としては、杉、松、けやき、ひのき、ひば、桜、ポプラ、樅などが挙げられる。特にサイザル繊維が生産性、コスト等から好ましい。化学繊維としては、アクリルやポリエステル等の不織布綿が使用できるが、アクリルはコストが高く、ポリエチレンが綿として得られやすいので、ポリエステルのほうがより適している。なお、化学繊維と天然繊維を混在させてベース材を形成しても良い。
【００３４】
ベース材の目付けは２００〜１０００ｇ／ｍ^２の範囲が好適であって、特に４００〜６００ｇ／ｍ^２の範囲が好ましい。ベース材層の厚みは自然のままで２０〜５０ｍｍに積層した綿マットとし、成形後に４〜１０ｍｍ程度に圧縮ざれるものが好適である。
【００３５】
また、植物繊維は、繊維長が１０〜１００ｍｍで、繊維長は１．０ｍｍ以下（例えば０．２〜０．８ｍｍ）のものとすることが好ましい。繊維径とは、断面円形以外の場合には径の短いほうの長さであり、直径１．０ｍｍを超えると、成形品表面に繊維の凹凸が現れ外観を著しく損なうので好ましくなく、さらには、直径０．５ｍｍ以下のものが好ましい。繊維長は１０ｍｍ以下では要求される補強効果が得られず、逆に繊維長が１００ｍｍよりも長すぎると、互いに絡まって均一に分散できない。自動車天井のような大きな面積の成形品にも比較的簡単にかつ均一に散布でき、かつ充分な補強効果を得るためには１０〜１００ｍｍの寸法が好ましい。さらには、３０ｍｍ〜５０ｍｍのものが好ましい。なお繊維長は全て均一な長さのものに揃える必要はなく、上記範囲の長さのものであれば異なった長さのものでも良い。
【００３６】
ベース材に混入する熱可塑性樹脂からなる接着剤は、オレフィン、ポリエステル、ポリアミド、ナイロン等が使用できる。ポリアミドやナイロンはコストが高く、オレフィンは耐熱温度がそれほで高くないので、自動車用成形内装材としてはポリエステルが好適である。
【００３７】
この接着剤の量は、少なすぎると接合力に欠け、多すぎると染み出るので、ベース材の５〜５０重量％の範囲で混入することが好ましい。
【００３８】
補強繊維材は、上記ベース材の温熱伸縮性を拘束規制し、成形後の耐変形性を向上するために、ベース材の両側からサンドイッチ状に挟み込むように積層されている。
【００３９】
補強繊維材としては、天然繊維や化学繊維が用いられ、カーボン繊維を用いる場合には、その目付けは２０〜２００ｇ／ｍ^２とすることが好ましく、特に３０〜１００ｇ／ｍ^２とすることが好ましい。カーボン繊維も植物繊維と同様に、直径は１．０ｍｍ以下であり、長さは１０ｍｍ〜１００ｍｍのものを使用することが好ましい。カーボン繊維は、特に、それ自身が吸湿及び／又は乾燥で伸縮せず、軽量であり、少量でベース材の強度を補強でき、焼却時に無公害でありメリットを有する。
【００４０】
カーボン繊維は、単体のカーボン繊維のクロスを使用しても良いが、接着しにくいので、網目状などに絡ませて積層して、隙間を形成する必要がある。また、カーボン繊維のコストが高い。
【００４１】
このように、カーボン繊維は高コストであり、繊維同士の接着性が弱いので、他の繊維を混入して使用することが好ましい。その際の混入繊維としては、ベース材に使用した天然繊維や化学繊維が使用可能であり、カーボン繊維と天然植物繊維との混合体、あるいはカーボン繊維とアクリル繊維、ポリエチレン繊維との混合体として使用する。
【００４２】
カーボン繊維と他の混入繊維との重量割合は、カーボン繊維：３０〜７０％に対して他の混入繊維：７０〜３０％であるので、高価なカーボン繊維を少なくでき、低コスト化できる。
【００４３】
他の混入繊維が３０％以下、即ちカーボン繊維が７０％以上になると、コストアップとなる。また、基材及び表皮との接合強度が低下し、接合力を高める手段を別途講じる必要がある。
【００４４】
他の混入繊維が７０％以上、即ちカーボン繊維が３０％以下になると、基材の強度が不足し、成形内装材としての使用に耐えられるものが得られない。したがって、カーボン繊維と混入繊維との重量割合は、上記範囲にすることが好ましい。特に、カーボン繊維：６０〜４０で混入繊維：４０〜６０とすることが、さらに好ましい。
【００４５】
また、カーボン繊維と他の混入繊維とが積層方向に混在して成形された格子状のシート材とすると、ある部分の断面を見るとカーボン繊維を挟んでその両側に混入繊維が存在したり、別の断面を見ると混入繊維を挟んでその両側にカーボン繊維が存在したりする状態であり、カーボン繊維と混入繊維との接合強度が高く、ベース材との接合強度にも優れるので好ましい。また、このように絡ませた場合には、接着剤の量も少なくすることができる。
【００４６】
カーボン繊維層の接着剤としては、オレフィン、ポリエステル、ポリアミド、ナイロン、ＥＶＡ等の熱可塑性樹脂が使用できる。特に、コストや耐熱温度等を考慮すると、ポリエステルが好適である。その使用量は、少なすぎると接着性に欠け、多すぎると染み出るので、繊維重量の５〜５０重量％、特に１０〜３０重量％とし、絶対量としては１００ｇ／ｍ^２以下とすることが好ましい。
【００４７】
表皮としては、公知の不織布、トリコット単体、或はウレタンフォームとのラミネート材、ポリオレフィン、ポリエステル、ポリアミド系の織布または不織布、ビニールレザーが挙げられる。表皮と基材との接合のために、両者間にウエブ（くもの巣）状のホットメルト接着剤からなるシートを使用する。なお、このシートは上記した熱可塑性接着剤が使用可能であるが、ポリエステルが好適である。特に、このシートは、多孔質シートとし、吸音性を確保することが必要である。
【００４８】
裏面紙は、基材側から、熱可塑性樹脂のホットメルト膜、不透過フィルム、熱可塑性樹脂のホットメルト接着剤、不織布の積層体を積層したものを使用する。不透過フィルムは通気止めが狙いで、ＰＰ、ナイロン、ＰＥＴ等を使用する。不透過フィルムが不要な場合には、熱可塑性樹脂のホットメルト膜、不織布の積層体からなる裏面紙でも良い。
【００４９】
また、表皮側に不透過フィルムを必要とする際には、多孔質シートと表皮との間に不透過フイルムを配設しても良い。
【００５０】
次に、本発明の成形内装材の製造方法を説明する。
（１）　ベース材とその両側の補強繊維材とは、金型で成形する前に予め積層しサンドイッチ構造の基材としておく。この場合の積層方法としては、ニードルパンチ法による接合、あるいは補強繊維材に熱可塑性接着剤を塗布して、ベース材に貼り付ける方法が適用される。この際の接着剤量は５〜１００ｇ／ｍ^２で、特に５〜５０ｇ／ｍ^２が好ましい。
【００５１】
成形時には、上記のように用意した基材を、ホットプレートで１８０℃〜２３０℃、３０秒〜５分程度加熱し、成形可能な柔らかさにする。
【００５２】
そして、基材の上側（製品の室内側）に熱可塑性樹脂製ウエブ状ホットメルト接着剤及び表皮を、下側に裏面紙を重ね、コールドプレス金型で望む形状・製品厚さに加圧成形する。
【００５３】
その際、表皮と基材間の熱可塑性樹脂製ウエブ状ホットメルト接着剤及び、裏面紙に貼り付けた熱可塑性樹脂製ウエブ状ホットメルト接着剤は基材の熱で軟化し、基材と表皮、基材と裏面紙を成形金型内で溶着する。成形後、製品を取り出して冷却する。
（２）　別の方法として、予めベース材と補強繊維材を接合しないで、製品成形時に金型の中で他の材料と同時に接合する。この場合、ベース材に染み込ませた熱可塑性樹脂のバインダーによって自然に接合されることもありうるが、確実に接合するためには、上記熱可塑性樹脂の接着剤を補強繊維材に塗布しておいたほうが好ましい。この際の接着剤量は５〜１００ｇ／ｍ^２で、特に５〜５０ｇ／ｍ^２が好ましい。
【００５４】
この製造方法では、ベース材層をホットプレートで１８０℃〜２３０℃、３０秒〜５分程度加熱し、成形可能な柔らかさにする。そして、この両側に補強繊維材を積層し、後は前の製造方法と同様に、ホットメルト接着剤、表皮、裏面紙を積層して、コールドプレス金型で望む形状・製品厚さに加圧成形する。
本発明の成形内装材は、自動車用成形内装材、例えば自動車用成形天井、成形ドアトリム、リヤパッケージトレイ、フロア材等に使用できる。自動車に限らず、他の乗物にも適用可能である。
【００５５】
【発明の実施の形態】
図に基づき本発明の実施例を説明する。図１は本発明の成形内装材を自動車の成形天井に適用した際の成形天井の斜視図を示し、図２は図１の部分断面図を示す。図３は図２の断面を分解した状態を示す。
【００５６】
図１に示すように、成形天井１は、中央が凹んだ立体形状に形成される。成形天井１の断面は、図２及び図３に示すように、ベース材２の両側に補強繊維材３，４が配設された基材５を備え、その車室内側に熱可塑性樹脂製ウエブ状ホットメルト接着剤６、表皮７を備え、車室外側に裏面紙８が接着されている。
【００５７】
次に、上記実施例に関わる成形内装材の製造方法を説明する。
【００５８】
（実施例１）
直径０．５ｍｍ以下、長さ３０〜５０ｍｍで、目付け５００ｇ／ｍ^２のサイザル繊維の多孔質クッション体（１２００ｍｍ×１６００ｍｍ）に、ポリエステル系接着剤をベース材に対して２０重量％混入したものを作成する。このベース材の両側に、サイザル繊維とカーボン繊維とを約１００ｇ／ｍ^２の目付けで均一に散布し、ポリエステル系接着剤で互いに接着して形成した補強繊維材を接合して、サイザル繊維のクッション体の両側にカーボン繊維とサイザル繊維との混合体からなる補強繊維材でサンドイッチした基材を作成する。
【００５９】
こうして用意した基材をホットプレートで１８０℃〜２３０℃、３０秒〜５分程度加熱し、成形可能な柔らかさにする。そして、基材の上側（製品の室内側）に熱可塑性樹脂製ウエブ状ホットメルト接着剤及び表皮を、下側に裏面紙を重ね、コールドプレス金型で加圧成形するとともに、互いを接着させる。成形接着後、成形品を金型から取り出し、幅：１２００ｍｍ×１６００ｍｍ、そして天井を形成する全ての材料を含めた総厚が７．５ｍｍとなった成形天井を製造した。
【００６０】
（実施例２）
直径０．５ｍｍ以下、長さ３０〜５０ｍｍのポリエチレン繊維の綿状クッション体（１２００ｍｍ×１６００ｍｍ×２０ｍｍ）に、ポリエステル系接着剤をベース材に対して１５重量％混入したものを作成する。このベース材の両側に、ポリエステル繊維とカーボン繊維とを約１００ｇ／ｍ^２の目付けで均一に散布し、ポリエステル系接着剤で互いに接着して形成した補強繊維材を接合して、ポリエステル繊維のクッション体の両側にカーボン繊維とポリエステル繊維との混合体からなる補強繊維材でサンドイッチした基材を作成する。
【００６１】
こうして用意した基材をホットプレートで１８０℃〜２３０℃、３０秒〜５分程度加熱し、成形可能な柔らかさにする。そして、基材の上側（製品の室内側）に熱可塑性樹脂製ウエブ状ホットメルト接着剤及び表皮を、下側に裏面紙を重ね、コールドプレス金型で加圧成形するとともに、互いを接着させる。成形接着後、成形品を金型から取り出し、幅：１２００ｍｍ×１６００ｍｍ、そして天井を形成する全ての材料を含めた総厚が７．５ｍｍとなった成形天井を製造した。
【００６２】
（実施例３）
実施例２のベース材と補強繊維材とを接合しないで別々に作成して用意した。そして、ホットプレートで１８０℃〜２３０℃、３０秒〜５分程度加熱し、成形可能な柔らかさにした。そして、表皮、熱可塑性樹脂製ウエブ状ホットメルト接着剤、補強繊維材、ベース材、補強繊維材、裏面紙を重ね、コールドプレス金型で加圧成形するとともに、互いを接着させた。成形接着後、成形品を金型から取り出し、幅：１２００ｍｍ×１６００ｍｍ、そして天井を形成する全ての材料を含めた総厚が７．５ｍｍとなった成形天井を製造した。
【００６３】
実施例１，２及び３で得られた成形天井の周囲を固定して、高湿度雰囲気、低温雰囲気、高温雰囲気に置いた場合の中央部分の垂れ下がり度合を検査した。その結果、ウレタンマットの両側にガラス繊維を配設した成形天井と遜色ない性能が得られた。
【００６４】
【発明の効果】
本発明では、綿状多孔質クッション体からなるベース材と、該ベース材の両側に積層された補強繊維材と、一方の補強繊維材の外側に熱可塑性樹脂からなる接着剤及び表皮を順に積層し、他方の補強繊維材の外側に裏面紙を積層してなる成形内装材であるので、ウレタン及び熱硬化性接着剤を使用せずに軽量かつ吸音性に優れた成形内装材を得ることができる。それとともに、熱可塑性接着剤を使用しているので、リサイクル使用が容易である、
【図面の簡単な説明】
【図１】本発明の成形天井の斜視図を示す。
【図２】図１の成形天井の部分断面図を示す。
【図３】図２の分解説明図を示す。
【符号の説明】
１　　　成形天井
２　　　ベース材
３　　　補強繊維材
４　　　補強繊維材
５　　　基材
６　　　ホットメルト接着剤（熱可塑性樹脂からなる接着剤）
７　　　表皮
８　　　裏面紙[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a lightweight molded ceiling material, a molded door trim, a rear package tray, a tonneau board, a vehicle floor material and the like having excellent shape stability and a method of manufacturing the same.
[0002]
[Prior art]
Conventionally, interior materials based on urethane foam are excellent in light weight and sound absorbing performance, and are often used as general automotive interior materials. This structure uses a mesh mat reinforcing material (glass mat) coated with an adhesive of a thermosetting resin represented by isocyanate as a medium to mold a urethane base material and attach an interior skin. It is common to form and apply the skin with a press.
[0003]
[Problems to be solved by the invention]
However, when the interior product is to be recycled, a new binder (adhesive) is required because the thermosetting resin is used to pulverize and harden the interior product, which is very costly. Therefore, they are usually incinerated without being recycled. However, it is predicted that it will not be able to cope with future strict environmental standards, and interior materials made of a urethane-free base material are required.
[0004]
As conventional urethane-removable base materials, corrugated cardboard, resin felt, wood chip sheets, and the like are known.However, these have deteriorated the weight reduction and sound absorbing performance of the urethane base material, and have a sufficient The one that satisfies the function has not been obtained.
[0005]
[Means for Solving the Problems]
The present invention, in consideration of the problem of using urethane as a base material, while using a non-urethane base material, newly uses a base material having a light weight and a sound absorbing performance like a urethane foam material Further, by containing a thermoplastic resin adhesive in the base material, recycling is facilitated, and the lack of strength of the non-urethane base material is compensated for by the carbon fiber layers disposed on both sides thereof. .
[0006]
Specifically, the invention of claim 1 provides a base material comprising a cotton-like porous cushion body, a reinforcing fiber material laminated on both sides of the base material, and a thermoplastic resin on the outside of one of the reinforcing fiber materials. Is a molded interior material obtained by sequentially laminating an adhesive and a skin, and laminating a back paper outside the other reinforcing fiber material.
[0007]
In this configuration, the non-urethane base material is sufficiently reduced in weight and has sound absorbing performance, and the reinforcing fiber material is laminated on both sides of the base material, so that insufficient strength of the base material can be sufficiently reinforced. At the same time, because it uses a thermoplastic adhesive, it can be easily recycled.
According to the second aspect of the present invention, in the molded interior material according to the first aspect, since the cotton-like porous cushion body is made of non-woven fabric cotton made of a chemical fiber such as acrylic or polyester, the moldability is good and the mass productivity is excellent.
[0008]
According to a third aspect of the present invention, in the molded interior material according to the first aspect, the cotton-like porous cushion body is made of at least one of natural plant fibers such as kenaf, sisal, hemp, cactus, bamboo, and wood. Available in large quantities at cost. In addition, it is a natural material, and does not cause pollution problems at the time of recycling or disposal.
[0009]
According to a fourth aspect of the present invention, in the molded interior material according to the third aspect, the natural vegetable fiber has a fiber length of 10 to 100 mm and a fiber diameter of 1.0 mm or less. The fiber diameter is the length of the smaller diameter when the cross section is other than circular, and when the diameter exceeds 1.0 mm, fiber irregularities appear on the surface of the molded article, which is not preferable because the appearance is significantly impaired. Further, those having a diameter of 0.5 mm or less are preferable. If the fiber length is less than 10 mm, the required reinforcing effect cannot be obtained. Conversely, if the fiber length is longer than 100 mm, the fibers are entangled with each other and cannot be uniformly dispersed. Furthermore, the thing of 30 mm-50 mm is preferred. It is not necessary that the fiber lengths are all uniform, and different lengths may be used as long as the lengths are within the above range.
[0010]
According to a fifth aspect of the present invention, in the molded interior material according to any one of the first to fourth aspects, the basis weight of the cotton-like porous cushion body is 200 to 1000 g / m ² , and the thickness thereof is 20 to 1000 g / m ² before molding. Since it is 50 mm, it is lightweight, has sound absorbing performance, and has good moldability.
[0011]
According to the sixth aspect of the present invention, in the molded interior material according to the fifth aspect, the basis weight of the cotton-like porous cushion body is 400 to 600 g / m ² , so that a higher performance material can be obtained.
[0012]
According to a seventh aspect of the present invention, in the molded interior material according to any one of the first to sixth aspects, an adhesive made of a thermoplastic resin is mixed into the base material, so that the joining performance is good and the moldability is improved. What you have is obtained.
[0013]
According to the invention of claim 8, in the molded interior material according to claim 7, since the mixing ratio of the adhesive made of a thermoplastic resin is 5 to 50% by weight of the base material, the adhesive does not exude, and The base material can be effectively joined.
[0014]
According to a ninth aspect of the present invention, in the molded interior material according to the seventh or eighth aspect, the thermoplastic resin is made of any one of olefin, polyester, polyamide, and nylon, so that stable joining can be achieved.
[0015]
According to a tenth aspect of the present invention, in the molded interior material according to any one of the first to ninth aspects, the reinforcing fiber material is made of a fiber bundle in which a chemical fiber such as acrylic or polyester is blended with carbon fiber, so that it is expensive. The carbon fiber can be reduced, the cost can be reduced, and the joining property can be improved.
[0016]
According to an eleventh aspect of the present invention, in the molded interior material according to any one of the first to ninth aspects, the reinforcing fiber material includes at least one of natural fiber such as kenaf, sisal, hemp, cactus, bamboo, and wood. Since the seeds are mixed, a large amount can be obtained at low cost. In addition, it is a natural material, and does not cause pollution problems at the time of recycling or disposal.
[0017]
According to a twelfth aspect of the present invention, in the molded interior material according to the eleventh aspect, the natural vegetable fiber has a fiber length of 10 to 100 mm and a fiber diameter of 1.0 mm or less. The fiber diameter is the length of the shorter diameter when the cross section is other than circular, and when the diameter exceeds 1.0 mm, the unevenness of the fiber appears on the surface of the molded article and the appearance is significantly impaired, which is not preferable. Those having a diameter of 0.5 mm or less are preferred. If the fiber length is less than 10 mm, the required reinforcing effect cannot be obtained. Conversely, if the fiber length is longer than 100 mm, the fibers are entangled with each other and cannot be uniformly dispersed. Furthermore, the thing of 30 mm-50 mm is preferred. It is not necessary that the fiber lengths are all uniform, and different lengths may be used as long as the lengths are within the above range.
[0018]
According to a thirteenth aspect, in the molded interior material according to any one of the tenth to twelfth aspects, the weight ratio of the carbon fiber to the other mixed fiber is 30 to 70% of the carbon fiber and the other mixed fiber. : 70% to 30%, so that expensive carbon fibers can be reduced and the cost can be reduced.
[0019]
If the content of other mixed fibers is 30% or less, that is, 70% or more of carbon fibers, the cost increases. In addition, the bonding strength between the base material and the skin is reduced, and it is necessary to take additional measures to increase the bonding strength.
[0020]
If the content of other mixed fibers is 70% or more, that is, 30% or less of carbon fibers, the strength of the base material is insufficient, and a material which can be used as a molded interior material cannot be obtained. Therefore, it is preferable that the weight ratio between the carbon fiber and the mixed fiber be in the above range. In particular, it is more preferable to set the carbon fiber to 60 to 40 and the mixed fiber to 40 to 60.
[0021]
According to a fourteenth aspect of the present invention, in the molded interior material according to any one of the tenth to thirteenth aspects, the reinforcing fiber material is a grid-like sheet formed by mixing carbon fibers and other mixed fibers in the laminating direction. Since it is made of material, if you look at the cross section of a certain part, there are mixed fibers on both sides of the carbon fiber, and if you look at another cross section, there are carbon fibers on both sides of the mixed fiber. Yes, the bonding strength between the carbon fiber and the mixed fiber is high, and the bonding strength with the base material is also excellent.
[0022]
According to a fifteenth aspect of the present invention, in the molded interior material according to any one of the tenth to fourteenth aspects, the mixed fiber mixed with the carbon fiber is made of the same type of fiber as the cotton-like porous cushion body fiber of the base material. It has excellent bondability with the base material and is effective for reinforcing the strength of the base material.
[0023]
According to a sixteenth aspect of the present invention, in the molded interior material according to any one of the first to fifteenth aspects, an adhesive made of a thermoplastic resin is mixed in the reinforcing fiber material, so that the bonding property is excellent, and an optional material can be recycled. And easy to recycle.
[0024]
According to a seventeenth aspect of the present invention, in the molded interior material according to the sixteenth aspect, the mixing ratio of the adhesive made of a thermoplastic resin is 5 to 50% by weight of the reinforcing fiber material. It does not ooze out and can ensure the bonding property.
[0025]
In the invention according to claim 18, in the molded interior material according to claim 17, the mixing ratio of the adhesive made of a thermoplastic resin is 10 to 30% by weight of the reinforcing fiber material. It is possible to prevent the adhesive from coming out and to further ensure the bonding property.
[0026]
According to a nineteenth aspect of the present invention, in the molded interior material according to any one of the sixteenth to eighteenth aspects, the thermoplastic resin is made of any one of olefin, polyester, polyamide, and nylon, so that appropriate bonding properties can be secured.
[0027]
In the invention of claim 20, in the molded interior material according to any one of claims 1 to 19, the molded interior material is a molded ceiling of a vehicle, so that a practical molded ceiling can be obtained. In particular, recycling is facilitated by subdividing a large molded ceiling, and even if this molded ceiling is incinerated, no harmful components are generated, which is excellent in terms of pollution.
[0028]
The invention according to claim 21 is a method for producing a molded interior material, wherein a reinforcing fiber material is laminated on both sides of a base material made of a cotton-like porous cushion body, and a base material containing an adhesive made of a thermoplastic resin is provided. After preparing and heating the substrate to 180 to 230 ° C., an adhesive and a skin made of a thermoplastic resin are sequentially laminated on the outside of one reinforcing fiber material, and the back paper is laminated on the outside of the other reinforcing fiber material. It is characterized by laminating and pressing in a cold mold.
[0029]
In this manufacturing method, the handling of the base material is easy and the productivity is excellent. In particular, since a thermoplastic adhesive is used, it can be easily formed into another shape when recycled, and is excellent in recycling convenience.
[0030]
The invention according to claim 22 is a method for producing a molded interior material, comprising preparing a base material made of a cotton-like porous cushion body and a reinforcing fiber material containing an adhesive made of a thermoplastic resin. After heating to 180 to 230 ° C., a reinforcing fiber material layer is laminated on both sides of the base material, and an adhesive layer and a skin made of a thermoplastic resin are sequentially laminated on the outside of one reinforcing fiber material layer, and the other. The back paper is laminated on the outside of the reinforcing fibrous material described above, and pressure-molded in a cold mold.
[0031]
In this manufacturing method, since various materials are set in the cold mold and molded at once, it is not necessary to preform the base material and the cost can be reduced. Further, as in the case of the twenty-first aspect, since a thermoplastic adhesive is used, it can be easily formed into another shape at the time of recycling, and is excellent in recycling convenience.
[0032]
In the present invention, a base material comprising a cotton-like porous cushion body made of a natural fiber or a synthetic fiber such as polyethylene cotton, and reinforcing fiber materials are provided on both sides of the base material in order to secure and improve the elasticity and strength of the base material. Are laminated as a base material, a thermoplastic resin is mixed in the base material as a binder, heated on a hot plate, and then molded with a cold mold together with other materials to obtain a product.
[0033]
The plant fiber used as the material of the porous cushion body of the base material is obtained by branch-cutting or pulverizing a plant mainly composed of cellulose, and is a simple substance of hemp, kenaf, sisal fiber, bamboo fiber, and wood fiber. Is a mixture. Wood fibers are obtained from wood. Trees include cedar, pine, keyaki, cypress, cypress, cherry, cherry blossom, poplar, and fir. In particular, sisal fibers are preferred from the viewpoint of productivity, cost, and the like. As the chemical fiber, non-woven cotton such as acrylic and polyester can be used. However, acrylic is more suitable because polyester is expensive and polyethylene can be easily obtained as cotton. The base material may be formed by mixing chemical fibers and natural fibers.
[0034]
Basis weight of the base material is a preferred range of 200 to 1000 g / ^{m 2,} in particular in the range of 400-600 g / ^{m 2} is preferred. It is preferable that the thickness of the base material layer be a cotton mat laminated to 20 to 50 mm as it is, and that the material be compressed to about 4 to 10 mm after molding.
[0035]
Further, the plant fiber preferably has a fiber length of 10 to 100 mm and a fiber length of 1.0 mm or less (for example, 0.2 to 0.8 mm). The fiber diameter is the length of the shorter diameter when the cross section is other than circular, and when the diameter exceeds 1.0 mm, the unevenness of the fiber appears on the surface of the molded article and the appearance is significantly impaired, which is not preferable. Those having a diameter of 0.5 mm or less are preferred. If the fiber length is less than 10 mm, the required reinforcing effect cannot be obtained. Conversely, if the fiber length is longer than 100 mm, the fibers are entangled with each other and cannot be uniformly dispersed. A size of 10 to 100 mm is preferable in order to be able to relatively easily and uniformly spray a molded product having a large area such as an automobile ceiling and to obtain a sufficient reinforcing effect. Furthermore, the thing of 30 mm-50 mm is preferred. It is not necessary that the fiber lengths are all uniform, and different lengths may be used as long as the lengths are within the above range.
[0036]
As the adhesive made of a thermoplastic resin mixed into the base material, olefin, polyester, polyamide, nylon, or the like can be used. Polyamides and nylons are expensive, and olefins are not so high in heat resistance. Therefore, polyester is suitable as a molded interior material for automobiles.
[0037]
If the amount of the adhesive is too small, the bonding strength will be lacking, and if it is too large, the adhesive will ooze out.
[0038]
The reinforcing fiber material is laminated so as to sandwich it from both sides of the base material in order to restrict the thermal expansion and contraction of the base material and improve the deformation resistance after molding.
[0039]
As the reinforcing fiber material, natural fiber or chemical fiber are used, in the case of using the carbon fibers, it is preferred that the basis weight is preferably in the 20 to 200 g / ^{m 2,} in particular to 30 to 100 g / ^{m 2} . Like the plant fiber, the carbon fiber preferably has a diameter of 1.0 mm or less and a length of 10 mm to 100 mm. In particular, the carbon fiber itself does not expand and contract due to moisture absorption and / or drying, is lightweight, can reinforce the strength of the base material in a small amount, has no pollution during incineration, and has advantages.
[0040]
As the carbon fiber, a single carbon fiber cloth may be used, but since it is hard to adhere, it is necessary to form a gap by entangled in a network or the like and laminated. Also, the cost of carbon fiber is high.
[0041]
As described above, the carbon fiber is expensive and the adhesion between the fibers is weak. Therefore, it is preferable to use a mixture of other fibers. Natural fibers or chemical fibers used for the base material can be used as the mixed fiber at that time, and used as a mixture of carbon fiber and natural plant fiber, or a mixture of carbon fiber and acrylic fiber, polyethylene fiber I do.
[0042]
Since the weight ratio of carbon fiber to other mixed fiber is 30 to 70% of carbon fiber and 70 to 30% of other mixed fiber, expensive carbon fiber can be reduced and cost can be reduced.
[0043]
If the content of other mixed fibers is 30% or less, that is, 70% or more of carbon fibers, the cost increases. In addition, the bonding strength between the base material and the skin is reduced, and it is necessary to take additional measures to increase the bonding strength.
[0044]
If the content of other mixed fibers is 70% or more, that is, 30% or less of carbon fibers, the strength of the base material is insufficient, and a material which can be used as a molded interior material cannot be obtained. Therefore, it is preferable that the weight ratio between the carbon fiber and the mixed fiber be in the above range. In particular, it is more preferable to set the carbon fiber to 60 to 40 and the mixed fiber to 40 to 60.
[0045]
Also, if a lattice-like sheet material formed by mixing carbon fibers and other mixed fibers in the laminating direction, when looking at a cross section of a certain portion, mixed fibers exist on both sides of the carbon fiber, Looking at another cross-section, carbon fibers are present on both sides of the mixed fiber, which is preferable because the bonding strength between the carbon fiber and the mixed fiber is high and the bonding strength with the base material is excellent. In addition, when entangled in this way, the amount of adhesive can be reduced.
[0046]
As the adhesive for the carbon fiber layer, a thermoplastic resin such as olefin, polyester, polyamide, nylon, and EVA can be used. Particularly, in consideration of cost, heat resistance temperature, and the like, polyester is preferable. When the amount is too small, the adhesiveness is poor, and when the amount is too large, it exudes. Therefore, the amount is 5 to 50% by weight, especially 10 to 30% by weight of the fiber weight, and the absolute amount is 100 g / m ² or less. preferable.
[0047]
Examples of the skin include a known nonwoven fabric, a tricot simple substance, a laminate material with urethane foam, a polyolefin, polyester, polyamide-based woven or nonwoven fabric, and vinyl leather. In order to join the skin and the base material, a web (spider web) -like sheet made of a hot melt adhesive is used between the two. In addition, although the thermoplastic adhesive mentioned above can be used for this sheet, polyester is preferable. In particular, it is necessary that this sheet be a porous sheet to ensure sound absorption.
[0048]
As the back paper, a laminate of a hot melt film of a thermoplastic resin, an impermeable film, a hot melt adhesive of a thermoplastic resin, and a nonwoven fabric laminated from the substrate side is used. The impermeable film uses PP, nylon, PET, or the like for the purpose of preventing ventilation. When an impermeable film is not required, a hot melt film of a thermoplastic resin or a back paper made of a laminate of a nonwoven fabric may be used.
[0049]
When an impermeable film is required on the skin side, an impermeable film may be provided between the porous sheet and the skin.
[0050]
Next, a method for producing the molded interior material of the present invention will be described.
(1) The base material and the reinforcing fiber materials on both sides of the base material are laminated beforehand as a base material having a sandwich structure before being molded by a mold. In this case, as a lamination method, bonding by a needle punch method, or a method in which a thermoplastic adhesive is applied to a reinforcing fibrous material and affixed to a base material is applied. The amount of the adhesive at this time is 5 to 100 g / m ² , and particularly preferably 5 to 50 g / m ² .
[0051]
At the time of molding, the base material prepared as described above is heated on a hot plate at 180 ° C. to 230 ° C. for about 30 seconds to 5 minutes to make it moldable soft.
[0052]
Then, a web-like hot-melt adhesive made of thermoplastic resin and skin are layered on the upper side of the base material (inside of the product), and the backside paper is layered on the lower side, and pressed with a cold press mold to the desired shape and product thickness. I do.
[0053]
At that time, the thermoplastic resin web-like hot melt adhesive between the skin and the base material and the thermoplastic resin web-like hot melt adhesive attached to the back paper are softened by the heat of the base material, and the base material and the skin Then, the base material and the back paper are welded in a molding die. After molding, the product is taken out and cooled.
(2) As another method, the base material and the reinforcing fiber material are not joined in advance, but are joined together with other materials in a mold at the time of product molding. In this case, the bonding may be spontaneous with the binder of the thermoplastic resin impregnated in the base material.However, in order to ensure the bonding, the adhesive of the thermoplastic resin is applied to the reinforcing fiber material. Is preferred. The amount of the adhesive at this time is 5 to 100 g / m ² , and particularly preferably 5 to 50 g / m ² .
[0054]
In this manufacturing method, the base material layer is heated on a hot plate at 180 ° C. to 230 ° C. for about 30 seconds to 5 minutes to make it moldable. Then, the reinforcing fiber material is laminated on both sides, and then the hot melt adhesive, the skin, and the back paper are laminated in the same manner as in the previous manufacturing method, and pressed to the desired shape and product thickness with the cold press mold. Mold.
The molded interior material of the present invention can be used for molded interior materials for automobiles, for example, molded ceilings for automobiles, molded door trims, rear package trays, floor materials, and the like. The present invention is applicable not only to automobiles but also to other vehicles.
[0055]
BEST MODE FOR CARRYING OUT THE INVENTION
An embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view of a molded ceiling when the molded interior material of the present invention is applied to a molded ceiling of an automobile, and FIG. 2 is a partial sectional view of FIG. FIG. 3 shows a state where the cross section of FIG. 2 is exploded.
[0056]
As shown in FIG. 1, the molded ceiling 1 is formed in a three-dimensional shape with a concave center. As shown in FIGS. 2 and 3, the cross section of the molded ceiling 1 includes a base material 5 on both sides of a base material 2 on which reinforcing fiber materials 3 and 4 are disposed. A hot-melt adhesive 6 and a skin 7 are provided, and a back paper 8 is adhered to the outside of the cabin.
[0057]
Next, a method for manufacturing a molded interior material according to the above-described embodiment will be described.
[0058]
(Example 1)
A porous cushion body (1200 mm × 1600 mm) of sisal fiber having a diameter of 0.5 mm or less, a length of 30 to 50 mm, and a basis weight of 500 g / m ² , in which a polyester-based adhesive is mixed at 20% by weight based on the base material. create. On both sides of the base material, a sisal fiber and a carbon fiber are uniformly spread with a basis weight of about 100 g / m ² , and a reinforcing fiber material formed by bonding each other with a polyester-based adhesive is joined to form a cushion of the sisal fiber. A base material is sandwiched on both sides of the body with a reinforcing fiber material comprising a mixture of carbon fibers and sisal fibers.
[0059]
The base material thus prepared is heated on a hot plate at 180 ° C. to 230 ° C. for about 30 seconds to 5 minutes to make it moldable. Then, a web-like hot-melt adhesive made of a thermoplastic resin and a skin are laminated on the upper side of the base material (the indoor side of the product), and the back paper is laminated on the lower side, and pressed together with a cold press mold, and are bonded to each other. . After the molding and bonding, the molded product was taken out of the mold, and a molded ceiling having a width of 1200 mm × 1600 mm and a total thickness of 7.5 mm including all the materials forming the ceiling was manufactured.
[0060]
(Example 2)
A cotton-like cushion body (1200 mm × 1600 mm × 20 mm) of polyethylene fiber having a diameter of 0.5 mm or less and a length of 30 to 50 mm is prepared by mixing a polyester-based adhesive at 15% by weight with respect to the base material. A polyester fiber and a carbon fiber are uniformly spread on both sides of the base material with a basis weight of about 100 g / m ² , and a reinforcing fiber material formed by bonding the polyester fiber and the carbon fiber to each other with a polyester-based adhesive is joined to form a cushion of the polyester fiber. A base material sandwiched between reinforcing fibers made of a mixture of carbon fibers and polyester fibers on both sides of the body is prepared.
[0061]
The base material thus prepared is heated on a hot plate at 180 ° C. to 230 ° C. for about 30 seconds to 5 minutes to make it moldable. Then, a web-like hot-melt adhesive made of a thermoplastic resin and a skin are laminated on the upper side of the base material (the indoor side of the product), and the backside paper is laminated on the lower side. . After the molding and bonding, the molded product was taken out of the mold, and a molded ceiling having a width of 1200 mm × 1600 mm and a total thickness of 7.5 mm including all the materials forming the ceiling was manufactured.
[0062]
(Example 3)
The base material and the reinforcing fiber material of Example 2 were separately prepared without being joined. Then, the mixture was heated on a hot plate at 180 ° C. to 230 ° C. for about 30 seconds to 5 minutes to make it moldable. Then, the skin, the web-like hot-melt adhesive made of thermoplastic resin, the reinforcing fiber material, the base material, the reinforcing fiber material, and the back paper were stacked, pressed together with a cold press mold, and adhered to each other. After the molding and bonding, the molded product was taken out of the mold, and a molded ceiling having a width of 1200 mm × 1600 mm and a total thickness of 7.5 mm including all the materials forming the ceiling was manufactured.
[0063]
The periphery of the molded ceiling obtained in Examples 1, 2, and 3 was fixed, and the degree of sagging of the central portion when the ceiling was placed in a high-humidity atmosphere, a low-temperature atmosphere, or a high-temperature atmosphere was inspected. As a result, performance comparable to that of a molded ceiling having glass fibers disposed on both sides of the urethane mat was obtained.
[0064]
【The invention's effect】
According to the present invention, a base material made of a cotton-like porous cushion body, a reinforcing fiber material laminated on both sides of the base material, and an adhesive and a skin made of a thermoplastic resin are sequentially laminated outside one of the reinforcing fiber materials. And since it is a molded interior material obtained by laminating a back paper on the outside of the other reinforcing fiber material, it is possible to obtain a molded interior material which is lightweight and excellent in sound absorption without using urethane and a thermosetting adhesive. it can. At the same time, because it uses a thermoplastic adhesive, it can be easily recycled.
[Brief description of the drawings]
FIG. 1 shows a perspective view of a molded ceiling of the present invention.
FIG. 2 shows a partial cross-sectional view of the molded ceiling of FIG.
FIG. 3 is an exploded explanatory view of FIG. 2;
[Explanation of symbols]
Reference Signs List 1 molded ceiling 2 base material 3 reinforcing fiber material 4 reinforcing fiber material 5 base material 6 hot melt adhesive (adhesive made of thermoplastic resin)
7 Skin 8 Back paper

Claims

A base material made of a cotton-like porous cushion body,
Reinforcing fiber material laminated on both sides of the base material,
An adhesive and a skin made of a thermoplastic resin are sequentially laminated on the outside of one reinforcing fiber material,
A molded interior material comprising a back paper laminated on the outside of the other reinforcing fiber material.

The molded interior material according to claim 1,
A molded interior material characterized in that the cotton-like porous cushion body is made of non-woven cotton made of chemical fiber such as acrylic or polyester.

The molded interior material according to claim 1,
A molded interior material characterized in that the cotton-like porous cushion body is made of at least one kind of natural plant fiber such as kenaf, sisal, hemp, cactus, bamboo, and wood.

The molded interior material according to claim 3,
A molded interior material, wherein the natural vegetable fiber has a fiber length of 10 to 100 mm and a fiber diameter of 1.0 mm or less.

The molded interior material according to any one of claims 1 to 4,
A molded interior material characterized in that the cotton-like porous cushion body has a basis weight of 200 to 1000 g / m ² and a thickness of 20 to 50 mm before molding.

The molded interior material according to claim 5,
Molded interior material basis weight of flocculent porous cushion body is characterized by a 400-600 g / ^{m 2.}

The molded interior material according to any one of claims 1 to 6,
A molded interior material comprising a base material mixed with an adhesive made of a thermoplastic resin.

The molded interior material according to claim 7,
A molded interior material characterized in that the mixing ratio of an adhesive made of a thermoplastic resin is 5 to 50% by weight of the base material.

The molded interior material according to claim 7 or 8,
A molded interior material characterized in that the thermoplastic resin is made of any one of olefin, polyester, polyamide and nylon.

The molded interior material according to any one of claims 1 to 9,
The molded interior material is characterized in that the reinforcing fiber material is a fiber bundle in which carbon fibers are mixed with chemical fibers such as acrylic and polyester.

The molded interior material according to any one of claims 1 to 9,
A molded interior material characterized in that the reinforcing fiber material is at least one of natural plant fibers such as kenaf, sisal, hemp, cactus, bamboo, and wood mixed with carbon fibers.

The molded interior material according to claim 11,
A molded interior material, wherein the natural vegetable fiber has a fiber length of 10 to 100 mm and a fiber diameter of 1.0 mm or less.

The molded interior material according to any one of claims 10 to 12,
A molded interior material characterized in that the weight ratio of carbon fiber to other mixed fiber is 30 to 70% of carbon fiber and 70 to 30% of other mixed fiber.

The molded interior material according to any one of claims 10 to 13,
A molded interior material, wherein the reinforcing fiber material is a lattice-shaped sheet material formed by mixing carbon fibers and other mixed fibers in the laminating direction.

The molded interior material according to any one of claims 10 to 14,
A molded interior material characterized in that the mixed fiber mixed with the carbon fiber is made of the same kind of fiber as the cotton-like porous cushion body fiber of the base material.

The molded interior material according to any one of claims 1 to 15,
A molded interior material characterized in that an adhesive made of a thermoplastic resin is mixed in a reinforcing fiber material.

The molded interior material according to claim 16,
A molded interior material characterized in that a mixing ratio of an adhesive made of a thermoplastic resin is 5 to 50% by weight of the reinforcing fiber material.

The molded interior material according to claim 17,
A molded interior material characterized in that a mixing ratio of an adhesive made of a thermoplastic resin is 10 to 30% by weight of the reinforcing fiber material.

The molded interior material according to any one of claims 16 to 18,
A molded interior material characterized in that the thermoplastic resin is made of any one of olefin, polyester, polyamide and nylon.

The molded interior material according to any one of claims 1 to 19,
A molded interior material, wherein the molded interior material is a molded ceiling of a vehicle.

A reinforcing fiber material is laminated on both sides of a base material made of a cotton-like porous cushion body, and a base material containing an adhesive made of a thermoplastic resin is prepared,
After heating the substrate to 180-230 ° C,
An adhesive and a skin made of a thermoplastic resin are sequentially laminated on the outer side of one reinforcing fiber material, and a back paper is laminated on the outer side of the other reinforcing fiber material, and pressure-molded in a cold mold. Method for producing molded interior material.

Prepare a base material made of a cotton-like porous cushion body and a reinforcing fiber material containing an adhesive made of a thermoplastic resin,
After heating the base material to 180 to 230 ° C,
Laminate reinforcing fiber material on both sides of the base material,
An adhesive and a skin made of a thermoplastic resin are sequentially laminated on the outer side of one reinforcing fiber material, and a back paper is laminated on the outer side of the other reinforcing fiber material, and pressure-molded in a cold mold. Method for producing molded interior material.