JP2005059434A - Skin material of inner surface of seat or door of vehicle and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide the skin material of the inner surface of the seat or door of a vehicle excellent in dimensional stability without using a backing material comprising a synthetic resin layer. <P>SOLUTION: The skin material of the inner surface of the seat or door of the vehicle is constituted by laminating a fiber fleece 2 on the rear of a knitted fabric 1 such as moquette or tricot. The constituent fibers 3 and 3 or the like of the fiber fleece 2 and the constituent threads 4 and 4 or the like of the knitted fabric 1 are entangled with each other. Dimensional stability is imparted to the knitted fabric 1, in its turn, the whole of the skin material by this entanglement. The constituent fibers 3 of the fiber fleece 2 are not substantially exposed to the surface of the knitted fabric 1. The air permeability of the knitted fabric 1 is preferably 6-30 cc/cm<SP>2</SP>when measured by a Frazier method prescribed in JIS L1096. Further, the weight basis of the fiber fleece 2 is preferably 10-60 g/m<SP>2</SP>. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a skin material used for a seat of a vehicle such as an automobile or a train or an inner surface of a door.

  Conventionally, a knitted fabric such as a moquette or tricot has been stretched on the surface of a vehicle seat or the inner surface of a door. And in order to give cushioning properties, the polyurethane foam is laminated and bonded to the back surface of the knitted fabric. As a method of laminating and laminating polyurethane foam on the back of the knitted fabric, a method of laminating and laminating using an adhesive, or applying an unfoamed polyurethane resin to the back of the knitted fabric, For example, a method of foaming polyurethane resin is employed. In particular, the latter mold foaming method is rational and preferable because an adhesive is unnecessary.

  However, when the latter method is adopted, when the unfoamed polyurethane resin foams and expands, the knitted fabric may be distorted. For this reason, in order to give dimensional stability to a knitted fabric, providing the backing material which consists of various synthetic resin layers is performed. That is, a synthetic resin liquid is applied to the back surface of a knitted fabric, dried and solidified to provide a synthetic resin layer. As this synthetic resin layer, those made of polyurethane resin (Patent Document 1) and those made of acrylic resin are used (Patent Document 2).

Japanese Patent Laid-Open No. 5-117354 (claims and paragraph number 0002 on page 2) JP-A-5-279963 (claims and paragraph number 0002 on the second page)

  However, when a backing material made of a synthetic resin layer is provided on the back surface of the knitted fabric, there are the following drawbacks. That is, in order to give sufficient dimensional stability to the knitted fabric, a large amount of synthetic resin must be applied, which increases the weight of the synthetic resin layer and the weight of the entire skin material. . In addition, in order to give cushioning properties, when polyurethane foam is laminated on the back surface of the skin material by the mold foaming method, the adhesive strength between the skin material and polyurethane foam does not increase, and it is easy to peel off. there were.

  Then, this inventor considered whether the fiber fleece currently used as the backing of a pile carpet can be used as a backing of a knitted fabric. That is, in a pile carpet in which a pile is planted on a primary base fabric such as non-woven fabric, a fiber fleece is laminated on the back surface of the primary base fabric (the side opposite to the surface on which the pile is planted) as a backing. (Japanese Patent Laid-Open No. 2001-115372). In this fiber fleece, the constituent fibers of the fiber fleece are entangled with the constituent fibers of the pile existing on the back surface of the primary base fabric, and the pile is prevented from coming off. The inventor considered that the dimensional stability of the knitted fabric could be realized by using this technique.

  As a result, as predicted by the present inventors, the constituent fibers of the fiber fleece laminated on the back surface of the knitted fabric were entangled with the constituent yarns of the knitted fabric, and the dimensional stability of the knitted fabric could be improved. Also, as a result, unexpectedly, when polyurethane foam is laminated on the back surface of the skin material by a mold foaming method, part of the polyurethane foam enters the fiber fleece on the laminated surface, and the skin material It was found that the peel strength of the polyurethane foam was increased. The present invention is based on such knowledge.

  That is, the present invention comprises a fiber fleece laminated on the back surface of a knitted fabric such as a moquette or tricot, the constituent fibers of the fiber fleece and the constituent yarns of the knitted fabric are entangled with each other, and the fibers The constituent fiber of the fleece relates to the skin material of the inner surface of the vehicle seat or door, which is not substantially exposed on the surface of the knitted fabric.

As the knitted fabric 1 used in the skin material according to the present invention, any material can be used as long as it is conventionally stretched on the surface of a vehicle seat or the inner surface of a door. Specifically, a woven fabric such as a moquette or a knitted fabric such as a tricot is used. In particular, among the conventionally known knitted fabrics 1, it is preferable to employ one having an air permeability of 6 to 30 cc / cm ² / sec. This is because, in the present invention, the constituent fibers 3, 3,... Of the fiber fleece 2 and the constituent yarns 4, 4,. It is. That is, since a high-pressure water flow is applied from the fiber fleece 2 side, when the air permeability of the knitted fabric 1 exceeds 30 cc / cm ² / sec, the water flow easily penetrates, and the constituent fibers 3, 3,. This is because there is a risk of appearing on the surface of the knitted fabric 1. Further, when the air permeability of the knitted fabric 1 is less than 6 cc / cm ² / second, the water flow is difficult to pass through the knitted fabric 1 and stays like a puddle on the knitted fabric 1, and the constituent fibers of the fiber fleece 2 There is a possibility that 3, 3,. The air permeability of the knitted fabric 1 is measured by the Frazier method specified in JIS L 1096.

  A fiber fleece 2 is laminated on the back surface of the knitted fabric 1. The fiber fleece 2 is one in which a large number of constituent fibers 3, 3,... Are deposited and the constituent fibers 3, 3,. This entanglement is a strong entanglement and cannot be unraveled even if it is pulled with fingers. And the constituent fibers 3, 3,... Of the fiber fleece 2 are also entangled with the constituent yarns 4, 4,.

As the constituent fiber 3 of the fiber fleece 2, conventionally known natural fibers or synthetic fibers are used. In particular, polyester fibers are generally used. The fineness and fiber length of the constituent fibers 3 are arbitrary, but generally the fineness is about 1 to 10 dtex and the fiber length is about 10 to 80 mm. The basis weight of the fiber fleece 2 is also arbitrary, but generally about 10 to 60 g / m ² is preferable. When the basis weight is less than 10 g / m ² , the amount of the constituent fiber is small, the entanglement with the constituent yarns 4, 4,... Is insufficient, and the dimensional stability of the knitted fabric 1 tends to be insufficient. . If the basis weight exceeds 60 g / m ² , the resulting skin material tends to be heavy.

  The most preferable method for producing the skin material according to the present invention is as follows. That is, by laminating the fiber web 22 on the back surface of the knitted fabric 1 such as a moquette or tricot and performing hydroentanglement treatment from the fiber web 22 side, the constituent fibers 3, 3,. Are entangled to form the fiber fleece 2, and the constituent fibers 3, 3,... And the constituent yarns 4, 4,. 3,... Are not substantially exposed on the surface of the knitted fabric 1.

  The fiber web 22 used in the method according to the present invention is formed by depositing the constituent fibers 3, 3,..., And the constituent fibers 3, 3,. Is. Such a fiber web 22 is laminated on the back surface of the knitted fabric 1. When the water flows 5, 5,... Ejected from the water entangling device 6 at high pressure are applied from the fiber web 22 side, the high-pressure water flow 5 is applied to the constituent fibers 3, 3,. .., 5..., And twisting and other movements occur, and the constituent fibers 3, 3,. At the same time, the constituent fibers 3, 3,... Are entangled with the constituent yarns 4, 4,... Of the knitted fabric 1 to improve the dimensional stability of the knitted fabric 1.

  In the water entanglement process, the knitted fabric 1 is maintained while maintaining high energy in the water flow 5, 5,... By appropriately adjusting the ejection pressure of the water flows 5, 5,. Do not penetrate the surface of By this adjustment, the constituent fibers 3, 3,... Of the fiber web 22 are prevented from appearing on the surface of the knitted fabric 1. For example, when the air permeability of the knitted fabric 1 is high, there is a risk that the water flow 5, 5,... Remains at high energy and penetrates the surface of the knitted fabric 1, and accordingly, the constituent fibers 3, 3,.・ Also, there is a risk that the surface of the knitted fabric 1 may appear and appear. If the jet pressure of the water streams 5, 5,... Is too high, even if the air permeability of the knitted fabric 1 is low, the water streams 5, 5,. There is a risk of penetration. Furthermore, when the air permeability of the knitted fabric 1 is too low, the water flow that collides with the fiber web 22 and becomes low energy becomes difficult to pass through the knitted fabric 1. In this case, since water stays on the back surface of the knitted fabric 1, the constituent fibers 3, 3,... Of the fiber web 22 are easily flown in any direction, and the constituent fibers 3, 3,.・ There is a risk of uneven distribution.

  And after hydroentanglement processing, the water currently hold | maintained at the knitted fabric 1 and the fiber fleece 2 is dried and removed, and the skin material which concerns on this invention is obtained. Such a skin material may be stretched as it is on the surface of the seat body or the inner surface of the door body. If it does so, the seat and door inner surface which the surface consists of knitted fabrics, such as a moquette and a tricot, will be obtained. Further, a foam may be laminated on the back surface of the fiber fleece 2 in order to give cushioning properties to the seat surface and the door inner surface. In order to laminate the foam, it may be bonded to the back surface of the fiber fleece 2 with an adhesive or the like.

  Further, in the present invention, it is preferable to laminate a polyurethane foam on the back surface of the fiber fleece 2 by applying a mold foaming method. That is, an unfoamed polyurethane resin is applied to the back surface of the fiber fleece 2 of the skin material according to the present invention. And this is introduce | transduced in a metal mold | die and it heats in the state which maintained the predetermined type | mold. Then, the unfoamed polyurethane resin is foamed, and a part thereof enters the fiber fleece 2. Therefore, the polyurethane foam 7 and the fiber fleece 2 are firmly integrated. This is preferable because the peel strength between the skin material and the polyurethane foam 7 is high and it is difficult to peel. And if the seat or door inner surface of the vehicle has a structure in which the polyurethane foam 7 is stretched along the seat main body surface or the door main body inner surface, the seat or door inner surface excellent in cushioning properties can be obtained.

  The skin material according to the present invention has a fiber fleece laminated on the back surface of a knitted fabric such as a moquette or tricot. The constituent fibers of the fiber fleece and the constituent yarns of the knitted fabric are entangled with each other. Therefore, since the constituent yarn of the knitted fabric is fixed with the constituent fiber of the fiber fleece, the dimensional stability of the entire skin material is excellent. In addition, since the constituent fibers of the fiber fleece are not substantially exposed on the surface of the knitted fabric, the pattern and texture of the surface of the knitted fabric are maintained as they are at the beginning, and there is an effect that they are not easily damaged.

  Moreover, the skin material which concerns on this invention is using the fiber fleece as a backing material, without using the backing material which consists of a synthetic resin layer. The fiber fleece is composed of a large number of constituent fibers, and these constituent fibers are entangled with constituent yarns of the knitted fabric to give dimensional stability to the knitted fabric. The fiber fleece has voids between a large number of constituent fibers and does not have any voids unlike the synthetic resin layer, so that its weight is lighter than that of the synthetic resin layer. Therefore, if the skin material according to the present invention is used, the weight of the skin material can be reduced, and consequently the weight of the vehicle can be reduced.

  Furthermore, the fiber fleece of the skin material according to the present invention has a large number of gaps between the constituent fibers. Therefore, when the polyurethane foam is laminated on the back surface of the fiber fleece, it is possible to laminate the polyurethane foam so that a part of the polyurethane foam enters the fiber fleece. With such a laminated state, the laminated integration of the skin material and the polyurethane foam becomes strong, and is difficult to peel off from each other. Therefore, the seat and the inner surface of the door using the polyurethane foam-equipped skin material are less likely to peel off the skin material and the polyurethane foam, so that the skin material can be prevented from floating with use. Play.

[Example 1]
First, a moquette (air permeability: 15.3 cc / cm ² / sec) that is generally used for automobile seats was prepared as a knitted fabric. A fiber web having a basis weight of 30 g / m ² composed of 100% by weight of a polyester fiber having a fineness of 1.6 dtex and a fiber length of 38 mm (product number “Tetron TT02A” manufactured by Teijin Fibers Limited) was laminated on the back of the moquette. And from the fiber web side, the water flow of the ejection pressure of 20 Mpa was given using the conventionally well-known hydroentanglement processing apparatus. As a result, a skin material excellent in dimensional stability in which the back surface of the moquette was backed with a fiber fleece was obtained. In addition, since the fiber fleece has a large number of gaps between the constituent fibers, if the polyurethane foam is laminated and integrated by the mold foaming method, a part of the polyurethane foam enters well. .

[Example 2]
The same method as in Example 1 was used except that a moquette having an air permeability of 5.2 cc / cm ² / sec was used instead of the moquette used in Example 1 (air permeability of 15.3 cc / cm ² / sec). The skin material was obtained. As a result, basically, it had the same characteristics as the skin material obtained in Example 1, but the constituent fibers in the fiber fleece were unevenly distributed.

[Example 3]
The same method as in Example 1 was used except that a moquette having an air permeability of 33.8 cc / cm ² / sec was used instead of the moquette used in Example 1 (air permeability of 15.3 cc / cm ² / sec). The skin material was obtained. As a result, basically, it had the same characteristics as the skin material obtained in Example 1, but on the surface of the knitted fabric, the constituent fibers of the fiber fleece are not substantially revealed, A slight manifestation was seen.

The physical properties of each skin material obtained as described above were as follows.
[Table 1]
━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━
Tensile elongation (%) Tensile strength (N) Taber abrasion
━━━━━━━━━━━━━━━━━━━
Freshly scallops ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━
Example 1 31 36 1910 1154 Class 4 Example 2 26 34 856 953 Class 3 Example 3 45 46 1396 724 Class 4 ━━━━━━━━━━━━━━━━━━━━━━ ━━━━━━━━━━

In addition, the measuring method regarding tensile elongation (%), tensile strength (N), and Taber abrasion in Table 1 is as follows.
[Tensile elongation (%)]
Three test pieces having a length of 200 mm and a width of 50 mm were collected so that the vertical direction of each skin material coincided with the length direction. Three test pieces each having a length of 200 mm and a width of 50 mm were collected so that the weft direction of each skin material coincided with the length direction. And about each test piece, the tensile elongation (%) of the length direction was measured with the holding | grip space | interval of 100 mm and the tensile speed of 300 mm / min using the tensile tester. In Table 1, the average value of the tensile elongation (%) of three test pieces whose vertical direction is the length direction is the “vertical” term, and the horizontal direction is the length direction. The average value of the tensile elongation (%) of the three test pieces is shown in the section “Wide”. The tensile elongation (%) is calculated by the following formula. That is, tensile elongation (%) = [(maximum displacement / grip interval) × 100]. Maximum displacement (mm) is the amount of elongation at maximum load.

[Tensile strength (N)]
In the measurement of the tensile elongation (%) described above, the average value of the maximum load was defined as the tensile strength (N).

[Taber wearability]
Three circular test pieces having a diameter of 130 mm were collected from each skin material, and a 6 mm hole was made in the center of the test piece. This test piece was attached to a Taber type abrasion tester, and a wear wheel No. 1 equipped with a 500 g weight was attached. With H38, the surface of each skin material (the surface of the knitted fabric) was worn 1500 times. After this wear, the fine dust of the fiber generated by the wear was completely removed by brushing or suction, and the surface state of the test piece was observed. And the surface state was evaluated by the following grades.
Grade 5: The fiber was not dropped at all and was in the initial state.
4th grade: Almost no fibers dropped out, almost in the original state.
Grade 3 ... Some amount of fiber has fallen off, but it was almost in its original state.
2nd grade: The fibers are falling off and it was not the original state.
First grade: A large amount of fibers were dropped, and the initial state was not maintained at all.

It is a typical side view of the skin material which concerns on an example of this invention. It is the schematic diagram which looked at the state where the hydroentanglement process is performed from the front. It is the typical side view which showed the state by which the foam (especially polyurethane foam) was laminated | stacked and integrated with the skin material which concerns on an example of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Knitted fabric 2 Fiber fleece 3 Fiber fleece constituent fiber 4 Knitted fabric constituent yarn 5 Water flow 6 Water entanglement processing device 7 Polyurethane foam 22 Fiber web

Claims (5)

  A fiber fleece is laminated on the back side of a knitted fabric such as a moquette or tricot, the constituent fibers of the fiber fleece and the constituent yarns of the knitted fabric are entangled with each other, and the constituent fibers of the fiber fleece are: A skin material for an inner surface of a vehicle seat or door, which is substantially not exposed on the surface of the knitted fabric. The skin material of the inner surface of a vehicle seat or door according to claim 1, wherein the air permeability of the knitted fabric is 6 to 30 cc / cm ² / sec as measured by the Frazier method specified in JIS L 1096. Basis weight of the fiber fleece, the skin material of the vehicle seat or the door inner surface according to claim 1, wherein a 10 to 60 g / m ^2.   A fiber web is laminated on the back surface of a knitted fabric such as a moquette or tricot, and a hydroentanglement treatment is applied from the fiber web side to interlace the constituent fibers of the fiber web to form a fiber fleece. A skin material for an inner surface of a vehicle seat or door, wherein the fiber and the constituent yarn of the knitted fabric are also entangled, and the constituent fiber is not substantially exposed on the surface of the knitted fabric. Production method.   The fiber fleece of the vehicle seat or door inner skin material according to claim 1, wherein a polyurethane foam is laminated on the rear surface of the vehicle seat or door inner skin material. A vehicle seat structure or a door inner surface structure, characterized in that a polyurethane foam is laminated on the side, and a part of the polyurethane foam enters the fiber fleece on the laminated surface.

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