JP2005028864A - Laminated surface material and laminate for interior triming material using same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a laminated surface material to which a proper sound absorption is given to keep calmness of the cabin of a vehicle or the like while being cheap and keeping sufficient decorativeness. <P>SOLUTION: In the laminated surface material made by laminating a multi-layered fiber body obtained by forming fibers into a layer shape by needle punching or with an air permeable adhesive agent on one surface of an air-permeable surface material, a property required for the surface material is made to be compatible with the sound absorption, by adjusting a rate ( a flat rate ) of fibers arranged in multi-layers parallel to the plane direction of the multi-layered fiber body and a rate (a cross rate) of fibers arranged so that they cross the fibers in the lengthwise direction of the air-permeable surface material. The obtained laminated surface material is laminated on an interior triming base material to be preferably used as the interior triming base material. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a laminated skin material, and more specifically, a laminated skin material for an interior material excellent in sound absorption characteristics, particularly in a high frequency range (for example, 4000 Hz or more), disposed at a site requiring sound absorption as an interior material. About.

  In the field of interior materials used for vehicles such as automobiles, it is desired to provide sound absorption characteristics in pursuit of comfort in the vehicle. On the other hand, inexpensive unskinned skin materials are frequently used for the design of interior materials, but it is technically difficult to impart sound absorption characteristics to these nonwoven fabric skin materials.

  Therefore, although it is expensive, a laminate of a porous material such as slab urethane and a breathable skin material is used (see Patent Document 1). However, since it is a dissimilar material as described above and is a thermosetting resin, the laminate is not only expensive but also difficult to recycle.

  Furthermore, in recent years, development of a sound absorbing material having an improved fiber structure has been promoted. For example, sound absorption is imparted by reducing the fiber diameter (see Patent Document 2).

  However, there is a problem that by making the fiber diameter thinner, the processability is lowered and coloring by coloring is difficult.

  In addition, in order to enhance the performance as a sound absorbing material for vehicles, a technique for laminating a bulky and flexible low density nonwoven material on the skin is disclosed, but a low density nonwoven fabric in which fibers are randomly oriented is simply tricot cloth. Therefore, further improvement is desired (see Patent Document 3). However, the term “random orientation” as used herein means that the plane rate and cross rate defined below are not adjusted.

Cut the flatness laminated skin material, take a SEM photo of the cross section of the multilayer fiber part, and draw vertical and horizontal lines in a cross on the plane with the thickness direction up and down at any place in the square with the thickness of the multilayer fiber part as one side. The number of fibers crossing the vertical line and the horizontal line was counted.
Number of fibers crossing the vertical line a
Number of fibers crossing the horizontal line b
Plane rate (%) = 100 × a / (a + b)
However, when calculating, measure at five or more locations and take the average value.

The crossing state of the fibers with a ratio of the fiber amount Q supplied in the flow (longitudinal) direction of the fiber laminate forming the cross rate multilayer fiber body and the fiber amount P supplied from the direction (width direction) perpendicular to the flow direction. Defined.
Cross rate (%) = 100 × P / Q
However, when all the fiber supplies differed from the flow direction, Q was the closest to the length direction of the multilayer fiber body, and P was the other.

Moreover, although patent document 3 is content to combine different materials, such as skin materials, such as a tricot cloth, and a low density nonwoven fabric, the combination of different materials inevitably becomes expensive. For this reason, it is desirable to combine the same kind of materials as much as possible to reduce the cost and to further improve the sound absorption characteristics. For these purposes, when combining a non-woven skin material and the same type of non-woven fabric, considering the dimensional stability, structural rigidity, cost, etc. Inevitably, needle punching without adjusting the flatness is often performed. However, if this needle punching process is performed, the fibers will stand in the thickness direction as a result, resulting in an increase in the vertical transmission of incident sound. Furthermore, even in the laminating process in which these two types of non-woven fabrics thus produced are laminated to produce a laminated skin material having excellent sound absorption characteristics, this laminating process is also considered in view of its adhesiveness, cost, and processability. Inevitably, needle punching is performed. If it does so, since a fiber will stand still in the thickness direction, it will result in increasing the perpendicular permeability | transmittance of incident sound still more. For these reasons, it was a limitation of the prior art that an effective improvement in sound absorption characteristics could not be expected even if a laminated skin material having excellent sound absorption characteristics was obtained using a non-woven fabric whose flatness was not adjusted.
JP 55-11947 A (pages 1 to 4) JP-A-6-122349 (pages 1 to 4) JP-A-14-215169 (pages 1-6)

    It is an object of the present invention to provide a laminated skin material and a laminate for interior materials that are excellent in light weight and recyclability, and in particular, have improved sound absorption characteristics on the high frequency side.

  The nonwoven fabric skin material is generally bundled by a method such as needle punching while fibers formed in multiple layers in the thickness direction are rearranged perpendicularly to the plane direction formed in the multiple layers. Although the required quality as the skin material can be satisfied by this binding, the expression of the sound absorption characteristics is not easily configured. Therefore, as a result of earnest study as a measure to satisfy the required characteristics as a skin material and also provide sound absorption characteristics, the multilayer fiber body is laminated on the back surface of the breathable skin material and the fiber structure of the multilayer fiber body is determined. By adjusting, it was found that both practical characteristics and sound absorption characteristics can be achieved, and the present invention has been completed.

That is, the present invention
[1] A laminated skin material, characterized in that a multilayer fiber body obtained by forming fibers in a state of being arranged in multiple layers is laminated on one surface of a breathable skin material (Claim 1). ,
[2] The laminated skin material according to [1], wherein the ratio (plane ratio) of fibers arranged in a multilayer in the plane direction of the multilayer fiber body is 50% or more of the fibers used ( Claim 2),
[3] The multilayer fiber body is characterized in that the ratio (cross ratio) of fibers arranged to intersect with the fibers in the length direction of the breathable skin material is 50 to 200%, [1] or [2] laminated skin material (claim 3),
[4] The laminated skin material according to any one of [1] to [3], wherein the breathable skin material and / or the multilayer fiber body is configured using a polyester fiber. (Claim 4),
[5] The laminated skin material according to any one of [1] to [4], wherein the breathable skin material and / or the multilayer fiber body is a nonwoven fabric (Claim 5).
[6] The laminated skin according to any one of [1] to [5], wherein the breathable skin material and / or the multilayer fiber body is constituted by using natural fibers or regenerated fibers. Material (Claim 6),
[7] The laminated skin material according to [6], wherein the amount of natural fiber or regenerated fiber is 20 to 80% of the total fiber amount (Claim 7).
[8] The laminated skin material according to [6], wherein the amount of fiber or recycled fiber is 40 to 70% of the total amount of fiber (claim 8),
[9] The laminated skin material according to any one of [1] to [8], wherein the air-permeable skin material and / or the multilayer fiber body is formed using a heat-sealing fiber. (Claim 9),
[10] The laminated skin material according to [9], wherein the amount of heat-sealing fibers is 5 to 30% of the total amount of fibers (claim 10),
[11] The laminated skin material according to [9], wherein the amount of heat-sealing fibers is 10% to 20% of the total amount of fibers (claim 11),
[12] The laminated skin material according to any one of [1] to [11], wherein the density of the multilayer fiber body is 0.1 g / cm ³ or less (claim 12),
[13] The laminated skin material according to any one of [1] to [12], wherein the density of the breathable skin material is one or more times the density of the multilayer fiber body (Claim 13),
[14] The laminated skin material according to [1] to [12], wherein the density of the breathable skin material is 1.5 times or more the density of the multilayer fiber body (claim 14),
[15] The laminated skin material according to any one of [1] to [14], wherein the breathable skin material and the multilayer fiber body are integrated by needling processing (Claim 15),
[16] The laminated skin material according to any one of [1] to [15], wherein the breathable skin material and the multilayer fiber body are integrated with a breathable adhesive layer. Item 16),
[17] A laminate for an interior material obtained by laminating the laminated skin material according to any one of [1] to [16] on a base material for an interior material (claim 17),
[18] The interior material laminate according to [17], wherein the interior material base material is made of a polyphenylene ether-based resin (claim 18).

  The laminated skin material of the present invention, as a skin material for interior materials, retains appropriate sound absorption characteristics (particularly on the high frequency side) for ensuring the quietness of the room, is inexpensive, and has sufficient decorative properties. Also holds. The laminated skin material of the present invention can be widely used as various laminates for interior materials by being laminated on the interior side of the interior material base material.

  The laminated skin material according to the present invention will be described.

  The multilayer fiber body referred to in the present invention is formed in a state in which fibers are arranged in multiple layers in a layered manner, and this is the number of layers formed by supplying fibers from one plane and unpacking them into a mat shape. In addition, it means a layer obtained by stacking in layers and spraying hot air and / or needle punching. Therefore, it can be obtained by the same method as the production of a web, which is a pre-process for producing a general nonwoven fabric. However, these production methods for obtaining this multilayer fiber body are an example, and are not particularly limited as long as the fibers are formed in a layered state in a multilayered manner.

  In addition, in the present invention, a multi-layer fiber body having a large degree of crossing of fibers (high cross rate) is different from supplying fibers from one general plane direction, and fibers from both the plane flow direction and the width direction. Is obtained by unifying and unpacking the material into a number of layers, layering them in layers, spraying hot air, and / or performing needle punching or the like. Also for the multilayer fiber body having a high cross rate, these production methods are merely examples, and are not particularly limited as long as the fibers are formed in a layered state in a multilayered manner.

The raw material of the multilayer fiber body obtained by forming the fibers of the present invention in layers is not particularly limited, and any of synthetic fibers, semi-synthetic fibers, natural fibers or regenerated fibers can be used. . Specifically, synthetic fibers such as polyester, polypropylene, polyamide (nylon), polyacrylonitrile, natural fibers such as wool and cotton, or regenerated fibers such as rayon can be used.
Further, it is also possible to use a mixture with a heat-fusible fiber having a function as a binder.

  In view of cost and processability as a raw material fiber, a polyester fiber is preferable, and a polyethylene terephthalate fiber is more preferable because of good shape maintenance at the time of heat molding.

  Furthermore, when exposed to a severe thermoforming press (for example, skin-integrated thermoforming), it is preferable to mix regenerated fibers such as rayon or natural fibers to improve shape maintainability during thermoforming. In particular, in view of cost and processability, it is preferable to mix 20% to 80% of regenerated fiber such as rayon or natural fiber, and more preferably 40% to 70%.

  It is preferable to use a heat-fusible fiber as a binder in the multilayer fiber body. Examples of the heat-fusible fiber used here include polyethylene, polypropylene, low melting point and low glass transition point (for example, about 60 ° C. to 180 ° C.) polyester (hereinafter, sometimes simply referred to as low melting point polyester), polyamide, and the like. Fiber, low-melting and low glass transition point polyolefin or polyester fiber as the sheath component, core-sheath type fiber with high melting point polyester fiber as the core component is preferable, when polyethylene terephthalate is used as the synthetic fiber, the same kind It is particularly preferable from the viewpoint of recyclability and the like to use polyester-based fibers (including core-sheath fibers) having a low melting point and a low glass transition point (for example, 60 ° C. to 180 ° C.) which are polymers. The mixing amount of the heat-fusible fiber in the entire fiber body is preferably 5 to 30%. When the content is more than 30%, the increase in the binding force between the fibers and the generation of the fiber mass may cause a decrease in sound absorption performance due to suppression of the vibration of the fiber part, or may cause a variation in the thickness of the fiber body. If it is 5% or less, the effect of mixing the heat-fusible fiber is not recognized.

  The thickness of the fiber is preferably 1 denier (1.1 dtex) to 10 denier (11.1 dtex). When it is less than 1 denier, the shape maintaining property of the fiber orientation is deteriorated, and the sag of the entire fiber body tends to be large. On the other hand, if it is larger than 10 denier, the fiber gap in the fiber body becomes large, the vertical transmission of the incident sound wave is increased, and the sound absorption performance may be lowered, or the fiber may be scattered or wrinkled. The fiber thickness is more preferably 2 denier to 7 denier.

Preferably 50 to 300 g / ^{m 2} as a fiber basis weight constituting the multilayer laminate, cost, practicality, particularly preferably 100 to 200 g / ^{m 2} from light weight.

  In order to manufacture a multilayer fiber body using the said raw material, the method similar to manufacture of the web which is a pre-process at the time of manufacturing a general nonwoven fabric can be employ | adopted.

  That is, for example, by supplying fibers from one plane as described above, unpacking and matting by a card method in layers, spraying hot air and / or applying needle punching, etc. It is obtained by integrating.

  Also, for the multilayer fiber body having a high cross rate in the present invention, for example, as described above, the fiber is supplied from both the plane flow direction and the width direction, unlike the case where the fiber is supplied from one general plane direction. However, it is obtained by unifying the layers by matting them in a card manner while layering them, layering them in layers, and blowing hot air and / or needle punching.

  In the production of a normal nonwoven fabric, the fibers constituting the multilayer fiber body are entangled with each other by needle punching or the like in the multilayer fiber body obtained as described above. By doing so, practical characteristics such as rigidity, workability, and dimensional stability are imparted.

  However, in a normal nonwoven fabric, most of the fibers that have been substantially planarly arranged by the needle punching process are rearranged in a direction parallel to the thickness. As a result, the vertical transmittance increases with respect to the incident sound, and the rate at which the incident sound is simply reflected is also increased, resulting in a significant decrease in sound absorption performance.

  Therefore, the multilayer fiber body formed by arranging the fibers obtained by matting by the card method in a layered manner in a multilayer manner reduces the number of needle punches in the needle punching process than usual. By adjusting the depth in the direction of decreasing the depth and leaving a large amount of fibers arranged in a plane, a multilayer fiber body having a large amount of fibers arranged in a plane, that is, a high plane rate can be obtained.

  Depending on the method of laminating the multilayer fiber body and the breathable skin material, the arrangement of the fibers may change, but after laminating the multilayer fiber body and the breathable skin material, the final The amount of fibers arranged in the plane direction of the fibers (plane rate) is preferably 50% or more, more preferably 60% or more, and most preferably 66% or more. In this way, random directions The structure in which the number of fibers arranged in the plane direction is larger than the number of fibers arranged in the plane is such that the fiber laminate structure works efficiently with respect to incident sound and exhibits good sound absorption.

  Furthermore, in the fiber supply when manufacturing the multilayer fiber body, the multilayer fiber body (cross ratio: 50 to 200%) in which the degree of crossing in the supply in the flow direction and the supply in the perpendicular direction is increased is the fiber Since the confounding property between them is improved, it is effective for the development of sound absorbing performance and exhibits a great effect. The cross rate is more preferably 75 to 150%.

  The multilayer fiber body of the present invention is intended to increase the sound absorption performance solely by adjusting the flatness ratio to a high level or by adjusting the cross rate to a large extent. Although it is high, the surface property and the design property are rather insufficient, and it may not have a function as a skin material. For this reason, the multilayer fiber body is provided with a function as a skin material by laminating and integrating with a breathable skin material having a normal surface property and excellent design as in the present invention. It is possible to provide the sound absorption performance as well.

  In addition, it has been described above that the arrangement of the fibers may change depending on the method of laminating the multilayer fiber body and the breathable skin material, which may affect the plane rate. This means the following. That is, when the multilayer fiber body and the breathable skin material are laminated with an adhesive as will be described later, the arrangement of the fibers of the multilayer fiber body, that is, the plane rate does not change, but the multilayer fiber body and the breathable skin material are not changed. When the material is laminated by needle punching, the arrangement of the fibers of the multilayer fiber body changes. However, it is stated that the flatness of the multilayer fiber body in the present invention refers to the flatness of the final multilayer fiber body after the multilayer fiber body and the breathable skin material are laminated.

  Next, the breathable skin material may be the same as or similar to the multilayer fiber body described above, but the breathable skin material should be used as a skin material exposed to the indoor side or the surface side. Therefore, it is necessary to consider general practical characteristics as an interior material such as wear resistance as well as the use of a material superior in decorativeness and design than the multilayer fiber body. That is, what is used as a conventional skin material for automobile interior materials can be used. For example, cloth, knit and non-woven fabric can be mentioned. A combination of them is used as appropriate. Among these, a nonwoven fabric made of polyethylene terephthalate fiber is particularly preferable from the viewpoint of cost and weather resistance.

  When a nonwoven fabric is used as the breathable skin material, it can be manufactured in the same manufacturing process as the multilayer fiber body. By adjusting the number of punchings and the needle stroke in the needle punching process, it is possible to increase the interlacing of the fibers and increase the rigidity of the fiber body, thereby imparting designability and wear resistance. Furthermore, a design property and abrasion resistance can be provided by resin coating on the design surface.

  Moreover, the heat-fusible fiber similar to what is used with a multilayer fiber body, a recycled fiber, or a natural fiber can be used.

Basis weight of the permeable surface material is preferably 50 to 300 g / ^{m 2,} cost, practicality, particularly preferably 50 to 150 g / ^{m 2} from light weight.

  As a method for laminating the breathable skin material and the multilayer fiber body, a method of laminating using an adhesive, a method of lightly needling, a method of laminating heat-fusible fibers and laminating by heat fusion, etc. are generally used. be able to. Furthermore, two or more of these laminating methods can be used in combination for lamination.

  The adhesive used when laminating the breathable skin material and the multilayer fiber body preferably has breathability in order to develop sound absorption. As a method of bonding through an air-permeable adhesive layer, a multilayer fiber is formed through a non-woven hot-melt adhesive having a network structure such as low-melting polyethylene, low-melting polyester, and polyamide. Temporarily fix the body and the skin material, and by blowing hot air to heat and integrate the above breathable hot melt adhesive, a method of interposing a urethane-based, epoxy-based, silicone-based adhesive layer, After applying latex such as acrylonitrile-butadiene-based latex, styrene-butadiene-based latex, vinyl acetate-based latex, acrylate-based latex, etc. And a method of integrating by drying.

  Note that the adhesive layer obtained by applying latex to the surface of the skin material and / or the multilayer fiber body and drying it has good air permeability.

  In some cases, the breathable skin material and the multilayer fiber body are bonded together by adjusting the amount of the above-mentioned binder fiber that may be included in the material of the multilayer fiber body.

  The method for adhering the breathable skin material and the multilayer fiber body may be either single or composite.

  In the laminated skin material, the density of the breathable skin material and the multilayer fiber body also greatly affects the sound absorption. That is, by providing a difference in density between the breathable skin material and the multilayer fiber body, the sound absorption improvement effect is further increased. The density of the breathable skin material is 1 or more times that of the multilayer fiber body, and more preferably 1.5 times or more. By providing the density ratio as described above, the breathable skin material is given a function as a skin material and exhibits high sound absorption performance as a whole laminated skin material.

Furthermore, the multilayer fiber body preferably has a low density, and is preferably 0.1 g / cm ³ or less.

  As described above, a laminated skin material in which a multilayer fiber body obtained by forming fibers in layers on the back of a breathable skin material is laminated on an interior material base material, thereby providing a good laminate for interior materials. Get the body.

  For the lamination of the laminated skin material to the base material for interior material, a method suitable for each application such as a house and a car is adopted from the adhesive strength and the presence or absence of molding after lamination. For example, when used as an interior material for a vehicle or the like, a general laminating method can be employed for an interior material for a vehicle. Examples include a method of heat-sealing with a vehicle substrate via a hot melt film, a method of bonding via an epoxy adhesive, a silicone adhesive, a urethane adhesive, acrylonitrile It is carried out by a method of adhering via butadiene latex, styrene-butadiene latex, vinyl acetate latex, acrylate latex or the like.

  Here, foamed laminated sheets, glass fiber sheets, and the like are suitably used as the interior material base material. For example, a foamed laminated sheet with glass fiber mats laminated on both sides of the urethane foam core layer, and glass fiber integrated with a heat-sealing resin (for example, polyethylene, polypropylene, low melting point polyester, polyamide resin, etc.) Sheet. Also, on either side of the foamed layer made of polystyrene, polypropylene, polyphenylene ether resin, etc., either a) polystyrene (PS) resin, b) polypropylene resin, or c) polyphenylene ether (PPE) resin. Examples are those obtained by laminating one or more non-foamed layers.

  Among the above, from the viewpoints of processability, heat resistance, moldability, etc., non-foamed material comprising at least one of the above a) PS-based resin and c) PPE-based resin on both sides of the foamed layer of the polyphenylene ether-based resin. What laminated | stacked the layer is preferable.

  When the obtained laminate for interior material is used as a ceiling material interior material for a vehicle such as an automobile, it is used by being molded by thermoforming or the like with the laminated skin material as the inner surface.

  Hereinafter, the present invention will be described in more detail based on examples, but the present invention is not limited thereby.

In addition, about the numerical value used by this invention, it measures with the following measuring method.
Normal incident sound absorption coefficient: Measured using a normal incident sound absorption coefficient measuring device defined in ASTM-E-1050.

  Table 1 shows a list of examples and comparative examples shown below.

(Example 1)
Polyethylene terephthalate (Toyobo Co., Ltd., type 707) 93 parts by weight of fineness 2 denier (2.2 decitex), cut length 51 mm, fineness 4 denier (4.4 decitex), cut length 51 mm low Melting point polyethylene terephthalate (manufactured by Toyobo Co., Ltd., type EE7) A fiber mixed with 7 parts by weight of fiber is supplied in an equal amount from two directions perpendicular to the flow direction by a card method, and then dispersed in a mat shape. Multi-layer fiber body by applying needle punching with the number of punches and stroke adjusted, adjusting the basis weight to 100 g / m ² and density 0.083 g / cm ³ , blowing hot air at a temperature of 200 ° C. for 5 minutes, and returning to normal temperature (A) was obtained.
90 parts by weight of polyethylene terephthalate (Toyobo Co., Ltd., type 707) having a fineness of 2 denier (2.2 decitex) and a cut length of 51 mm and a fineness of 7 denier (7.8 decitex) ), A non-woven skin material (a) having a basis weight of 100 g / m ² and a density of 0.083 g / cm ³ consisting of 10 parts by weight of rayon fiber having a cut length of 51 mm (Daiwabo Rayon Co., Ltd., type CD7.8 decitex × 51 mm). By adjusting the number of punches and the stroke of needling and laminating and integrating, a laminated skin material in which the fiber arrangement of the multilayer fiber body (A) was adjusted to a plane rate of 70% and a cross rate of 100% was obtained. Table 2 and FIG. 1 show the results of measurement of the normal incidence sound absorption coefficient in the air layer of 0 mm behind the obtained laminated skin material.

(Example 2)
A multi-layer fiber body (A) similar to that obtained in Example 1 and a non-woven fabric skin material (a) similar to that used in Example 1 were formed into a fibrous polyethylene hot melt film (40 g / m ² ) (Oishi Industry) Temporarily fastened at 200 ° C. for 5 minutes and laminated with a pressure roll, and the fiber arrangement of the multilayer fiber body (A) was adjusted to a plane rate of 90% and a cross rate of 100%. A laminated skin material was obtained. Table 2 and FIG. 1 show the results of measurement of the normal incidence sound absorption coefficient in the air layer of 0 mm behind the obtained laminated skin material.

(Example 3)
Polyethylene terephthalate (Toyobo Co., Ltd., type 707) 93 parts by weight of fineness 2 denier (2.2 decitex), cut length 51 mm, fineness 4 denier (4.4 decitex), cut length 51 mm low Melting point polyethylene terephthalate (manufactured by Toyobo Co., Ltd., type EE7) A fiber mixed with 7 parts by weight of fiber is supplied by card method from one direction of the flow direction and sprayed in a mat shape. Adjusted needle punching is performed to adjust the basis weight to 100 g / m ² and the density to 0.083 g / cm ³ , spray hot air at a temperature of 200 ° C. for 5 minutes, and return to room temperature to obtain a multilayer fiber body (A ′). It was.
A multilayer fibrous body (A ′) and a nonwoven fabric skin material (a) similar to that of Example 1 are temporarily fixed with a fibrous hot melt film (40 g / m ² ) similar to that used in Example 2, and the temperature is 200 ° C. Hot air was blown for 5 minutes and laminated with a pressure roll to obtain a laminated skin material in which the fiber arrangement of the multilayer fiber body (A ′) was adjusted to a plane rate of 90% and a cross rate of 10%. Table 2 and FIG. 1 show the results of measurement of the normal incidence sound absorption coefficient in the air layer of 0 mm behind the obtained laminated skin material.

(Example 4)
The multilayer fiber body (A) obtained in Example 1 and a polyethylene terephthalate fiber having a basis weight of 130 g / m ^{2, a} density of 2 denier with a density of 0.129 g / cm ³ and a cut length of 51 mm (manufactured by Toyobo Co., Ltd., type 707) 90 Non-woven skin material (b) of weight part, fineness 7 denier, cut length 51 mm (Daiwabo Rayon Co., Ltd. type CD7.8 decitex x 51 mm) is laminated and integrated by adjusting the number of punches and stroke of needling. As a result, a laminated skin material in which the fiber arrangement of the fiber laminate (A) was adjusted to a plane rate of 70% and a cross rate of 100% was obtained. Table 2 and FIG. 1 show the results of measurement of the normal incidence sound absorption coefficient in the air layer of 0 mm behind the obtained laminated skin material.

(Example 5)
Polyethylene terephthalate with fineness of 2 denier (2.2 decitex), cut length 51 mm (Toyobo Co., Ltd., type 707) 93 parts by weight fiber, fineness of 4 denier (4.4 decitex), cut length of 51 mm, low melting point Polyethylene terephthalate (manufactured by Toyobo Co., Ltd., type EE7) Fiber mixed with 7 parts by weight of fiber is supplied in an equal amount from two directions perpendicular to the flow direction and dispersed in a mat form, A multi-layer fiber body is obtained by applying needle punching with an adjusted punch count and stroke, adjusting the basis weight to 130 g / m ² and density of 0.129 g / cm ³ , blowing hot air at a temperature of 200 ° C. for 5 minutes, and returning to normal temperature. B) was obtained.
The multilayer fiber body (B) and the nonwoven fabric surface material (b) similar to that used in Example 4 are laminated and integrated by adjusting the number of punches and strokes of needling, so that the multilayer fiber body (B) portion A laminated skin material in which the fiber arrangement was adjusted to a plane rate of 70% and a cross rate of 100% was obtained. Table 2 and FIG. 1 show the results of measurement of the normal incidence sound absorption coefficient in the air layer of 0 mm behind the obtained laminated skin material.

(Example 6)
The laminate for interior material obtained by laminating the laminated skin material obtained in Example 1 on the following base material for interior material (Y) was obtained. Table 2 and FIG. 1 show the results of measuring the normal incident sound absorption coefficient in the air layer of 0 mm behind the obtained laminate for interior material.
Composition of base material for interior material (Y):
57.1 parts by weight of a modified PPE resin (manufactured by GE Plastics Co., Ltd., Noryl EFN4230: PPE component / PS component = 70/30) and PS so as to be 40% by weight of PPE resin component and 60% by weight of PS resin component Foaming agent (iso-butane / isobutane as a main component) with respect to 100 parts by weight of a mixed resin obtained by mixing 42.9 parts by weight of a resin (A & M Styrene Co., Ltd., polystyrene G8102: PS component 100%). n-butane = 85/15) 3.6 parts by weight and 0.32 parts by weight of talc are kneaded with an extruder, extruded with a circular die, wound into a take-up roll in the form of a roll through a take-up roll, and the primary thickness A foamed sheet having 2.4 mm, a primary foaming ratio of 14 times, a closed cell ratio of 88%, a cell diameter of 0.15 mm, and a basis weight of 150 g / m ² was obtained.
Next, while feeding the foam sheet from the roll, 50 parts by weight of methacrylic acid-modified polystyrene (A & M Styrene Co., Ltd., polystyrene G9001: PS component / methacrylic acid = 92/8), high impact polystyrene (HIPS) (A & M styrene) Co., Ltd., polystyrene H8117: PS component / rubber component = 87.5 / 12.5) A mixed resin mixed with 50 parts by weight was melted and kneaded with an extruder so that the resin temperature would be 245 ° C. Extruded into a film using a die, and on the other hand, supplied with a water needle punched nonwoven fabric (Cereth S8020, manufactured by Yuhou Co., Ltd.) having a surface weight of 25 g / m ² as a nonwoven fabric for preventing abnormal noise, and in a molten state A non-foamed layer is laminated in a form sandwiched between a foamed sheet and a water-punched non-woven fabric, and the basis weight is 150 g / m ² A thermal PS-based outdoor non-foamed layer was formed.
Next, PPE resin (Noryl EFN4230: PPE component / PS component, manufactured by GE Plastics Co., Ltd.) is used so that the laminated surface has a PPE resin component of 20% by weight and a PS resin component of 80% by weight on the back side. = 70/30) 28.6 parts by weight of PS resin (A & M Styrene Co., Ltd., polystyrene G8102: PS component 100%) mixed resin was mixed so that the resin temperature would be 265 ° C. Melted and kneaded with an extruder and extruded into a film using a T-die. On the other hand, as a skin layer adhesive layer, a polyolefin hot melt film (manufactured by Oishi Sangyo Co., Ltd., OS film: polyolefin resin / tack agent) = 98/3, with face: 30 g / m ²⁾ supplies, stacked in a manner that sandwiches the film-like non-foamed layer in the foamed sheet and the skin adhesive layer in a molten state To form a modified PPE system having a basis weight of 120 g / ^{m 2} indoor non-foamed layer. In this way, a base material for interior material (Y) is obtained in which the non-foamed layer is laminated on both sides of the foamed layer, the noise prevention layer is laminated on the outdoor skin layer, and the adhesive layer is laminated on the indoor skin layer. It was.
The interior material base (Y) is heated so that the front and back surface temperature is about 140 ° C., and then the laminated skin material (1) is placed thereon and press molding (upper and lower mold clearance: 6 mm) is performed simultaneously. Trimming and punching were performed to obtain an automobile interior ceiling material (laminated body for interior material).

(Example 7)
35 parts by weight of polyethylene terephthalate fiber having a fineness of 2 denier and a cut length of 51 mm (manufactured by Toyobo Co., Ltd., type 707), low melting point polyethylene terephthalate fiber having a fineness of 4 denier and a cut length of 51 mm (manufactured by Toyobo Co., Ltd., Type EE7) 15 parts by weight, and fiber mixed with 50 parts by weight of rayon fiber having a fineness of 3 denier (3.3 decitex) and a cut length of 51 mm (manufactured by Daiwabo Rayon Co., Ltd., type CD3.3 decitex × 51 mm) Equal amounts from two directions perpendicular to the surface are supplied by a card method and dispersed in a mat shape, and then needle punching is performed with the number of punches and stroke adjusted, and the basis weight is 100 g / m ² and the density is 0.083 g / cm ^3. Multi-layer fiber by adjusting it to 200 ° C and blowing hot air at a temperature of 200 ° C for 5 minutes and returning to normal temperature A body (C) was obtained. The multilayer fiber body (C) and the nonwoven fabric skin material (a) similar to that used in Example 1 are adjusted by adjusting the number of punches and the depth of needling, and then subjected to hot air treatment to integrate and laminate the multilayer fiber. A laminated skin material was obtained in which the fiber arrangement of the body (C) portion was adjusted to a plane rate of 70% and a cross rate of 100%.
The base material for interior material (Y) similar to that used in Example 6 was passed through a hot roll to melt and soften the skin layer adhesive layer, and the above-mentioned laminated skin material was pressure-bonded and temporarily fixed thereon. .
Next, the laminated skin material is heated to about 165 ° C., and the back surface of the base material (the surface opposite to the laminated skin) is heated to 140 ° C., and is integrally molded by press molding (upper and lower mold clearance: 7.5 mm). Trimming and punching were performed to obtain an automobile interior ceiling material (laminated body for interior material (W)). Table 2 and FIG. 1 show the measurement results of the normal incident sound absorption coefficient in the air layer 0 mm behind the obtained laminate for interior material (W).

(Example 8)
93 parts by weight of polyethylene terephthalate fiber having a fineness of 2 denier and a cut length of 51 mm (manufactured by Toyobo Co., Ltd., type 707), and low melting point polyethylene terephthalate fiber having a fineness of 4 denier and a cut length of 51 mm (Toyobo Co., Ltd.) Co., Ltd., type EE7) Fibers mixed with 7 parts by weight are fed in equal amounts from two directions perpendicular to the flow direction by a card method, sprayed in a mat shape, and then randomly subjected to needle punching, with a basis weight The multilayer fiber body (D) was obtained by adjusting to 130 g / m ² and a density of 0.129 g / cm ³ , blowing hot air at a temperature of 200 ° C. for 5 minutes, and returning to normal temperature. The multilayer fiber body (D) and the nonwoven fabric skin material (b) used in Example 4 are subjected to needle punching at random to be laminated and integrated so that the fiber arrangement of the multilayer fiber body (D) portion is 15% flatness A laminated skin material having a cross rate of 43% was obtained. Table 2 and FIG. 1 show the results of measurement of the normal incidence sound absorption coefficient in the air layer of 0 mm behind the obtained laminated skin material.

(Comparative Example 1)
Table 2 and FIG. 1 show the results of measuring the normal incident sound absorption coefficient in the back air layer of 0 mm of the nonwoven fabric skin material (a) used alone in Example 1.

(Comparative Example 2)
90% by weight polyethylene terephthalate fiber having a fineness of 2 denier and a cut length of 51 mm (manufactured by Toyobo Co., Ltd., type 707), and rayon fiber having a fineness of 7 denier and a cut length of 51 mm (manufactured by Daiwabo Rayon Co., Ltd., type CD7) .8 decitex × 51 mm) Non-woven skin material having a basis weight of 200 g / m ² and a density of 0.166 g / cm ³ consisting of 10% by weight. It is shown in 1.

(Comparative Example 3)
Behind the laminate for interior material obtained by laminating (by simultaneous molding) the nonwoven fabric skin material (a) used in Example 1 on the same base material for interior material (Y) as used in Example 6 Table 2 and FIG. 1 show the results of measuring the normal incident sound absorption coefficient when the air layer is 0 mm.

It is a chart showing the sound absorption characteristic in each Example about a laminated skin material of this invention, and a comparative example.

Claims (18)

  A laminated skin material, wherein a multilayer fiber body obtained by forming fibers in a state of being arranged in multiple layers in a layered manner is laminated on one surface of a breathable skin material.   The laminated skin material according to claim 1, wherein the ratio (plane rate) of fibers arranged in a multilayer in the plane direction of the multilayer fiber body is 50% or more of the fibers used.   3. The multilayer fiber body according to claim 1, wherein a ratio (cross rate) of fibers arranged so as to intersect with fibers in the length direction of the breathable skin material is 50 to 200%. Laminated skin material.   The laminated skin material according to any one of claims 1 to 3, wherein the breathable skin material and / or the multilayer fiber body is configured using a polyester fiber.   The laminated skin material according to any one of claims 1 to 4, wherein the breathable skin material and / or the multilayer fiber body is a nonwoven fabric.   The laminated skin material according to any one of claims 1 to 5, wherein the breathable skin material and / or the multilayer fiber body is formed using natural fibers or regenerated fibers.   The laminated skin material according to claim 6, wherein the amount of natural fibers or regenerated fibers is 20 to 80% of the total amount of fibers.   The laminated skin material according to claim 6, wherein the amount of fibers or recycled fibers is 40 to 70% of the total amount of fibers.   The laminated skin material according to any one of claims 1 to 8, wherein the breathable skin material and / or the multilayer fiber body is configured by using heat-sealing fibers.   The laminated skin material according to claim 9, wherein the amount of heat-sealing fibers is 5 to 30% of the total amount of fibers.   The laminated skin material according to claim 9, wherein the amount of heat-sealing fibers is 10% to 20% of the total amount of fibers. The laminated skin material according to any one of claims 1 to 11, wherein the density of the multilayer fiber body is 0.1 g / cm ³ or less.   The laminated skin material according to any one of claims 1 to 12, wherein the density of the breathable skin material is one or more times the density of the multilayer fiber body.   The laminated skin material according to claim 1, wherein the density of the breathable skin material is 1.5 times or more the density of the multilayer fiber body.   The laminated skin material according to any one of claims 1 to 14, wherein the breathable skin material and the multilayer fiber body are integrated by needling.   The laminated skin material according to any one of claims 1 to 15, wherein the breathable skin material and the multilayer fiber body are integrated with an air-permeable adhesive layer.   The laminated body for interior materials formed by laminating | stacking the laminated skin material of any one of Claims 1-16 on the base material for interior materials.   The laminate for interior material according to claim 17, wherein the interior material base material comprises a polyphenylene ether resin.

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