JP2005088873A - Foam sheet for interior material of automobile - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a foam sheet for an interior material of automobile capable of forming to a required shape while maintaining excellent sound absorption performance. <P>SOLUTION: The foam sheet A for the interior material of automobile is composed of only an open cell layer mainly comprising the open cell. Denatured polyphenylene ether-based resin sheets 3, 3 are integrally laminated on both sides of the denatured polyphenylene ether-based resin foamed sheet 1 having a continuous bubble fraction of 50% or more, and a hole part reaching from the surface of the denatured polyphenylene ether-based resin sheet 1 within the denatured polyphenylene ether-based resin foam sheet 1 is formed. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a foam sheet for automobile interior materials used for automobile interior materials such as automobile ceiling materials and door members.

  Conventionally, various automobile interior materials have been proposed. As such an automobile interior material, for example, Patent Document 1 discloses an automobile interior material composed of a skin material and a foam laminate, in which the foam laminate is a modified polyphenylene ether type. It has a structure in which a non-foamed layer made of a thermoplastic resin is laminated on both surfaces of a foamed layer made of a resin as a base resin, and the foaming ratio of the foamed layer exceeds 20 times and is 100 times or less. Automotive interior materials have been proposed.

  However, the above-mentioned automobile interior material increases the degree of freedom of vibration of the non-foamed layer laminated on the foamed layer by making the foamed layer highly foamed, and utilizes the sound interference effect due to the vibration of the non-foamed layer. Since the sound absorbing performance is exhibited by the shape of the automobile interior material, the degree of freedom of vibration of the non-foamed layer is affected by the molded shape of the automobile interior material. There is a problem in that a certain sound absorbing performance cannot be maintained, or if a certain sound absorbing performance is maintained, the shape of the automobile interior material is limited.

JP 2000-283482 A

  The present invention provides a foam sheet for automobile interior materials that can be molded into a desired shape while maintaining excellent sound absorption performance.

  The modified polyphenylene ether-based resin constituting the modified polyphenylene ether-based resin foam sheet 1 of the foam sheet A for automobile interior materials of the present invention is not particularly limited, and is a polyphenylene ether represented by the following chemical formula 1 and a polystyrene-based resin. A mixture, a modified polyphenylene ether obtained by graft copolymerization of a styrene monomer with the polyphenylene ether, a mixture of the modified polyphenylene ether and a polystyrene resin, a phenol monomer represented by the following chemical formula 2 and a styrene monomer: Examples thereof include a block copolymer obtained by oxidative polymerization in the presence of a catalyst such as an amine complex of II), a mixture of this block copolymer and a polystyrene resin, and the like. The modified polyphenylene ether resin may be used alone or in combination.

（Ｒ₁ 、Ｒ₂ は炭素数が１〜４のアルキル基又はハロゲン原子を示し、ｎは重合度を示す。）

(R ₁ and R ₂ represent an alkyl group having 1 to 4 carbon atoms or a halogen atom, and n represents the degree of polymerization.)

  Examples of the polyphenylene ether represented by the above chemical formula 1 include poly (2,6-dimethylphenylene-1,4-ether), poly (2,6-diethylphenylene-1,4-ether), poly (2, 6-dichlorophenylene-1,4-ether), poly (2,6-dibromophenylene-1,4-ether), poly (2-methyl-6-ethylphenylene-1,4-ether), poly (2- Chloro-6-methylphenylene-1,4-ether), poly (2-methyl-6-isopropylphenylene-1,4-ether), poly (2,6-di-n-propylphenylene-1,4-ether) ), Poly (2-bromo-6-methylphenylene-1,4-ether), poly (2-chloro-6-bromophenylene-1,4-ether), poly (2-chloro-6-ether) Rufeniren 1,4 ether) and the like, which may be used in combination be used alone, also the degree of polymerization n is usually that of 10 to 5000 is used.

（Ｒ₃ 、Ｒ₄ は炭素数が１〜４のアルキル基又はハロゲン原子を示す。）

(R ₃ and R ₄ represent an alkyl group having 1 to 4 carbon atoms or a halogen atom.)

  Examples of the phenolic monomer represented by the above chemical formula 2 include 2,6-dimethylphenol, 2,6-diethylpheninol, 2,6-dichlorophenol, 2,6-dibromophenol, 2-methyl-6- Ethylphenol, 2-chloro-6-methylphenol, 2-methyl-6-isopropylphenol, 2,6-di-n-propylphenol, 2-bromo-6-methylphenol, 2-chloro-6-bromophenol, Examples thereof include 2-chloro-6-ethylphenol, and these may be used alone or in combination.

  Examples of the polystyrene resin mixed with the polyphenylene ether, the modified polyphenylene ether, or the block copolymer include polystyrene, a copolymer of styrene and a vinyl monomer copolymerizable therewith, and high impact polystyrene. And polystyrene is preferred. In addition, the polystyrene-based resin may be used alone or in combination.

  Examples of the vinyl monomer include methyl methacrylate, acrylonitrile, methacrylonitrile, and butyl acrylate. Moreover, as high impact polystyrene, rubber components such as styrene-butadiene copolymer and styrene-butadiene-styrene block copolymer are added to polystyrene or a copolymer of styrene and a vinyl monomer copolymerizable therewith. The thing formed by adding 1 to 20 weight% is mentioned.

  Examples of the styrene monomer that is graft copolymerized with polyphenylene ether or block copolymerized with a phenol monomer include styrene; α-methylstyrene, 2,4-dimethylstyrene, p-methylstyrene, ethylstyrene, p- Examples thereof include alkylated styrene such as t-butylstyrene; halogenated styrene such as monochlorostyrene and dichlorostyrene.

  The modified polyphenylene ether resin is preferably a modified polyphenylene ether resin in which the phenylene ether component is 15 to 60% by weight and the styrene component is 85 to 40% by weight, and the phenylene ether component is 20 to 60% by weight. A modified polyphenylene ether resin having a styrene component of 80 to 40% by weight is more preferable, and a modified polyphenylene ether resin having a phenylene ether component of 25 to 50% by weight and a styrene component of 75 to 50% by weight is particularly preferable. In addition, when the polystyrene resin is mixed with the polyphenylene ether resin, the content of the phenylene ether component and the styrene component refers to the content including the polystyrene resin.

  This is because if the amount of the phenylene ether component in the modified polyphenylene ether-based resin is small, the heat resistance of the foamed sheet may be lowered, while if it is large, a good-quality foamed sheet may not be obtained.

  Then, the open cell ratio of the entire modified polyphenylene ether resin foam sheet 1 of the foam sheet A for automobile interior materials, that is, a modified polyphenylene ether resin foam sheet in which the hole 2 is formed (hereinafter referred to as “hole-processed”). If the overall open cell ratio of 1) is low, the sound absorbing property of the foam sheet for automobile interior materials may be lowered, so it is limited to 50% or more, and 60% or more On the other hand, if it is high, the mechanical strength of the foam sheet for automobile interior materials may be lowered, so 60 to 90% is more preferable, and 60 to 85% is particularly preferable.

  In addition, the open cell rate of the modified polyphenylene ether-based resin foam sheet 1 subjected to hole processing refers to that measured in accordance with ASTM D2856-87. More specifically, a plurality of planar square sheet-like test pieces each having a side of 25 mm are cut out from the hole-processed modified polyphenylene ether resin foam sheet 1 over the entire length in the thickness direction of the foam sheet 1. A laminate is formed by stacking a plurality of test pieces in the thickness direction so that the total thickness is about 25 mm.

Next, after accurately measuring the apparent volume of the laminate using a caliper, the volume is measured by the 1-1 / 2-1 atmospheric pressure method using an air-comparing hydrometer, and the open cell ratio is calculated by the following formula: Is calculated. In addition, the volume of the laminated body by the 1-1 / 2-1 atmospheric pressure method is measured using the air comparison type hydrometer which is marketed with the brand name "air comparison type hydrometer 1000 type | mold" from Tokyo Science, for example. be able to. Further, the apparent volume of the laminate does not include the volume of the hole 2 portion described later, which is included in the laminate.
Open cell ratio (%) = 100 × (apparent volume−volume of laminate by air comparison type hydrometer) / apparent volume

  On the other hand, if the average cell diameter of the modified polyphenylene ether-based resin foam sheet 1 subjected to hole processing in the foam sheet A for automobile interior materials is small, the foam sheet 1 may become soft and the mechanical strength may decrease. If it is large, the surface smoothness of the foamed sheet 1 may decrease or become brittle, so 0.2 to 1.3 mm is preferable, and 0.3 to 1.0 mm is more preferable. In addition, the average cell diameter of the modified polyphenylene ether-based resin foam sheet 1 subjected to hole processing refers to that measured in accordance with the test method of ASTM D2842-69.

When the density of the modified polyphenylene ether-based resin foam sheet 1 subjected to hole processing in the foam sheet A for automobile interior materials is small, the mechanical strength of the foam sheet for automobile interior materials may be reduced. 0.03 to 0.30 g / cm ³ is preferable, and 0.035 to 0.20 g / cm ³ is preferable because the foamed sheet for interior material may be deteriorated and may be damaged with respect to bending. cm ³ is more preferable. In addition, the density of the modified polyphenylene ether resin foam sheet 1 subjected to hole processing refers to a density measured according to the method described in JIS K7222: 1999 “Measurement of foamed plastic and rubber-apparent density”.

  Further, when the thickness of the modified polyphenylene ether-based resin foam sheet 1 in which holes are processed in the foam sheet A for automobile interior materials is thin, the thickness of the automobile interior material obtained by molding the foam sheet A for automobile interior materials is thin. In other words, the sound absorbing property of the automobile interior material may be lowered. On the other hand, if it is thick, the moldability of the foam sheet A for the automobile interior material may be lowered, so 2 to 10 mm is preferable, and 3 to 8 mm is more preferable.

  The modified polyphenylene ether-based resin foamed sheet 1 in which holes are processed in the foamed sheet A for automobile interior materials preferably has an open cell layer mainly composed of open cells. Such a modified polyphenylene ether is preferable. The resin-based resin foam sheet 1 is (1) a foam sheet consisting only of an open cell layer mainly composed of open cells and having an overall open cell ratio of 50% or more, and (2) mainly composed of open cells. Examples include those in which closed cell layers 12 and 12 mainly composed of closed cells are formed on both surfaces of the open cell layer 11 and the total open cell rate is 50% or more.

  The foamed sheet 1 of the above (1), that is, a modified polyphenylene ether resin foamed sheet 1 having a hole processed and comprising only an open cell layer mainly composed of open cells and having an overall open cell ratio of 50% or more, The closed cell layer mainly composed of closed cells does not exist, and as a whole, it is composed of the open cell layer 1A mainly composed of open cells. In addition, non-foamed layers 13, 13, so-called skin layers, may be formed on the entire surfaces of both sides of the modified polyphenylene ether-based resin foam sheet 1 subjected to the hole processing described in (1).

  The hole-processed modified polyphenylene ether resin foam sheet 1 is entirely composed of open cells. Therefore, the hole-modified modified polyphenylene ether resin foam sheet 1 is generally homogeneous. ing.

  Accordingly, even when the foam sheet for automobile interior material is compression-molded when being molded into the automobile interior material, the modified polyphenylene ether-based resin foam sheet 1 subjected to the hole processing is compressed substantially uniformly in the thickness direction. Since it is molded into a desired shape, the strength of the modified polyphenylene ether-based resin foamed sheet 1 that has been subjected to hole processing is not partially reduced, and a predetermined strength is maintained.

  In addition, the open cell layer 1A of the modified polyphenylene ether resin foamed sheet 1 having been subjected to the hole processing has only to be mainly composed of open cells, and it is not necessary that all the cells are open cells. It is preferable that 70% or more of the contained bubbles are open cells, that is, the open cell ratio of the open cell layer 1A is 70% or more. Note that the open cell rate of the open cell layer 1A refers to that measured by the above-described method for measuring the open cell rate.

  Next, the modified polyphenylene ether-based resin foam sheet 1 of (2) above, that is, has an open cell layer 11 mainly composed of open cells at the center, and is independent on both sides of the open cell layer 11. Hole-modified modified polyphenylene ether-based resin foam in which closed cell layers 12 and 12 mainly composed of cells are continuously and integrally formed and the total open cell rate is 50% or more. The sheet 1 will be described. The open cell layer 11 and the closed cell layer 12 do not have a clear boundary at the interface, but the open cell layer 11 and the closed cell layer 12 are mixed. Non-foamed layers 13 and 13, so-called skin layers, may be formed on the entire surface of the closed cell layers 12 and 12.

  In addition, the open cell layer 11 of the modified polyphenylene ether resin foamed sheet 1 that has been subjected to the hole processing is only required to be composed of open cells, and it is not necessary that all the cells are open cells, but the open cell layer 11 It is preferable that 80% or more of the bubbles contained in the above are open cells, that is, the open cell rate of the open cell layer 11 is 80% or more. The open cell rate of the open cell layer 11 is measured by the above-described method for measuring the open cell rate.

  Similarly, the closed cell layer 12 of the modified polyphenylene ether-based resin foamed sheet 1 that has been subjected to the hole processing only needs to be mainly composed of closed cells, and not all the cells need to be closed cells. It is preferable that 60% or more of the bubbles contained in 12 are closed cells, that is, the closed cell ratio of the closed cell layer 12 is 60% or more. The closed cell rate of the closed cell layer 12 is a value obtained by subtracting the open cell rate measured by the above-mentioned open cell rate measuring method and the ratio of the resin from 100 (%).

Closed cell ratio (%) = 100 × [(volume of laminate by air comparison hydrometer)
-(Mass of laminate / density of resin)] / apparent volume

  Furthermore, if the thickness of each closed cell layer 12 of the modified polyphenylene ether-based resin foamed sheet 1 subjected to the hole processing is large, the sound absorbing property of the foamed sheet A for automobile interior material may be lowered. 30% or less of the total thickness of the modified polyphenylene ether-based resin foam sheet 1 is preferable, and if it is too thin, the air barrier property of the foam sheet A for automobile interior material is lowered, and the air inside the vehicle passes through the foam sheet for automobile interior material. There is a problem that the dirt contained in the air becomes airy and the dirt contained in the air is filtered by the skin material 5 described later laminated and integrated on the surface of the foam sheet for automobile interior material, and the dirt of the skin material 5 becomes conspicuous. Since it will generate | occur | produce or the mechanical strength of the foam sheet A for motor vehicle interior materials will fall, 2 to 25% is more preferable. When the non-foamed layer (skin layer) 13 is formed on the entire surface of the closed cell layer 12, “the thickness of the closed cell layer 12” refers to the thickness including the thickness of the non-foamed layer 13.

  Here, in the present invention, a closed cell refers to a bubble that is surrounded by a bubble wall and is not in communication with other bubbles. On the other hand, the term “open cell” refers to all bubbles other than closed cells. Specifically, a through-hole is formed in the bubble wall, and the bubble is in communication with other bubbles through the through-hole.

  Further, in the modified polyphenylene ether resin foamed sheet 1 subjected to the hole processing, the distinction between the open cell layer mainly composed of open cells and the closed cell layer mainly composed of closed cells is determined as follows. The

  First, a flat square sheet-shaped test piece having a side of 40 mm is cut out from the modified polyphenylene ether-based resin foam sheet 1 having been subjected to the hole processing over the entire length in the thickness direction of the foam sheet 1.

On the other hand, 300 g of distilled water and 3 cm ³ of water-based red ink for fountain pens were supplied into a beaker to prepare a red aqueous solution, and a test piece was pressed into the red aqueous solution from above with a wire mesh to center the vertical direction in the red aqueous solution. It is set as the state completely immersed in the part. Examples of the water-based red ink for the fountain pen include those sold by the pilot company under the trade name “Pilot Ink Red”.

Thereafter, the beaker in which the test piece is immersed is placed in a decompressor and the pressure is reduced to 5.3 × 10 ⁴ Pa for 30 seconds. Next, after returning the inside of the pressure reducer to normal pressure, the test piece is taken out from the pressure reducer, and the red aqueous solution adhering to the surface of the test piece is removed with a water absorbent towel.

  And by excising the surface of all the cut surfaces of the test piece when cut out from the foam sheet 1, that is, excising the outer peripheral edge of the flat four sides from the test piece over the entire length in the thickness direction, that is, a rectangular frame shape By cutting out over the entire length in the thickness direction, a colored square test piece having a side of 38 mm is cut out. Next, the colored state of each cross section of the colored test piece was observed with a video microscope at a magnification of 50 times, and the colored portion was an open cell layer mainly composed of open cells, while the non-colored portion was mainly closed cells. A closed cell layer consisting of

  Furthermore, the thickness of the closed cell layer 12 of the modified polyphenylene ether-based resin foam sheet 1 subjected to hole processing is measured in the following manner. That is, a colored test piece is prepared in the same manner as described above from any five locations of the modified polyphenylene ether resin foamed sheet 1 that has been subjected to hole processing.

  Next, the cross section of each colored specimen is observed at a magnification of 50 times using a video microscope, and the maximum thickness and the minimum thickness in the closed cell layer 12 are measured for each colored specimen, and the addition of these thicknesses is measured. The average value is calculated. Then, the arithmetic average value calculated for each colored test piece is taken as the thickness of the closed cell layer 12 of the modified polyphenylene ether-based resin foamed sheet 1 subjected to hole processing. The video microscope is commercially available, for example, from SCARA Co., Ltd. under the trade name “Video Microscope VMS-300”.

  Furthermore, as shown in FIGS. 1 and 3, modified polyphenylene ether resin sheets 3 and 3 are laminated on both surfaces of the modified polyphenylene ether resin foam sheet 1 in which holes are formed in the foam sheet A for automobile interior materials. It may be integrated. The modified polyphenylene ether resin constituting the modified polyphenylene ether resin sheet 3 is the same as the modified polyphenylene ether resin constituting the foamed sheet 1, but the phenylene ether component is 10 to 50% by weight. Further, a modified polyphenylene ether resin having a styrene component of 90 to 50% by weight is preferable, a modified polyphenylene ether resin having a phenylene ether component of 10 to 40% by weight and a styrene component of 90 to 60% by weight is more preferable. A modified polyphenylene ether-based resin having an ether component of 10 to 35% by weight and a styrene component of 90 to 65% by weight is particularly preferable. In addition, when the polystyrene resin is mixed with the polyphenylene ether resin, the content of the phenylene ether component and the styrene component refers to the content including the polystyrene resin.

  This is because if the amount of the phenylene ether component in the modified polyphenylene ether-based resin is small, the heat resistance and rigidity of the modified polyphenylene ether-based resin sheet 3 may decrease, and if it is large, the fluidity of the molten resin decreases. This is because the extrudability decreases.

  The recovered product of the foam sheet A for automobile interior materials may be mixed in the modified polyphenylene ether resin constituting the modified polyphenylene ether resin sheet 3, and in this case, the weight of the modified polyphenylene ether resin is 100 parts by weight. On the other hand, 100 parts by weight or less of the recovered product of the foam sheet A for automobile interior materials is preferable. This is because if too much of the recovered product of the foam sheet A for automobile interior materials is mixed in the modified polyphenylene ether-based resin sheet 3, mechanical strength such as bending strength of the modified polyphenylene ether-based resin sheet 3 may be lowered. Because.

  Furthermore, the glass transition temperature Tg of the modified polyphenylene ether resin constituting the modified polyphenylene ether resin sheet 3 is the glass transition temperature of the modified polyphenylene ether resin constituting the hole-modified modified polyphenylene ether resin foamed sheet 1. It is preferable that it is 10-40 degreeC lower than Tg.

  This is due to the following reasons. That is, the bubble film of the modified polyphenylene ether-based resin foamed sheet 1 that has been subjected to hole processing is easily melted with a small amount of heat compared to the modified polyphenylene ether-based resin sheet 3 made of the same material, because the thickness is thin. Deformation causes bubbles on the surface portion of the foam sheet 1 to be crushed by the molding pressure.

  On the other hand, the modified polyphenylene ether-based resin sheet 3 laminated and integrated on both surfaces of the modified polyphenylene ether-based resin foamed sheet 1 that has been subjected to the hole processing is extremely non-foamed, as compared with the foam film of the foamed sheet 1. Therefore, it is excellent in form retention as compared with the foam sheet 1.

  Therefore, the glass transition temperature Tg of the modified polyphenylene ether resin constituting the modified polyphenylene ether resin sheet 3 is determined from the glass transition temperature Tg of the modified polyphenylene ether resin constituting the perforated modified polyphenylene ether resin foam sheet 1. The modified polyphenylene ether-based resin foam sheet 1 that has been subjected to hole processing has a heat resistance superior to that of the modified polyphenylene ether-based resin sheet 3, and the foamed sheet 1 of the foamed sheet 1 is formed at the time of molding the foamed sheet A for automobile interior materials. This is because the bubbles on the surface portion are prevented from being crushed by the molding pressure under heating by molding heat, and a molded product having a desired thickness can be obtained.

  Further, a colorant may be contained in the modified polyphenylene ether resin sheet 3, and such a colorant is not particularly limited, and examples thereof include carbon black, titanium oxide, zinc oxide, iron oxide, aluminum oxide, and the like. Inorganic fillers, cyanine blue, cyanine green, miloli blue, selenium blue, cadmium red, cadmium yellow, cadmium orange, petals, ultramarine blue, phthalocyanine blue, etc. Is preferable, and carbon black is more preferable.

  Further, a rubber component may be added to the modified polyphenylene ether resin sheet 3 in order to prevent embrittlement. Examples of such a rubber component include high impact polystyrene and styrene-butadiene copolymer. Examples thereof include a styrene-butadiene-styrene block copolymer, and high impact polystyrene is preferable.

  If the content of the rubber component in the modified polyphenylene ether resin sheet 3 is small, the effect of preventing embrittlement of the modified polyphenylene ether resin sheet 3 may not be exhibited. Since the bending strength and rigidity of No. 3 may be lowered, 1 to 20 parts by weight is preferable with respect to 100 parts by weight of the modified polyphenylene ether resin.

  The modified polyphenylene ether-based resin sheets 3 and 3 are formed by directly perforating the modified polyphenylene ether-based resin foam 1 without interposing an adhesive layer on both sides of the hole-modified modified polyphenylene ether-based resin foamed sheet 1. The sheet is firmly laminated and integrated by heat fusion between the modified polyphenylene ether resin constituting the sheet 1 and the modified polyphenylene ether resin constituting the modified polyphenylene ether resin sheet 3.

  That is, the modified polyphenylene ether-based resin sheet 3 and the modified polyphenylene ether-based resin foam sheet 1 subjected to the hole processing are the same type of resin constituting both, that is, by thermal fusion between the modified polyphenylene ether-based resins. The foamed sheet A for automobile interior materials is accurately integrated into a complicated shape without the modified polyphenylene ether-based resin sheet 3 being peeled off from the surface of the modified polyphenylene ether-based resin foamed sheet 1 that has been perforated. And it can shape | mold reliably.

  Furthermore, when the thickness of the modified polyphenylene ether-based resin sheet 3 is thin, the mechanical strength of the foam sheet A for an automotive interior material may be reduced. On the other hand, when the thickness is large, the moldability of the foam sheet A for an automotive interior material and Since lightness may fall, 50-300 micrometers is preferable and 70-200 micrometers is more preferable.

  As shown in FIGS. 1 to 3, the modified polyphenylene ether-based resin foam sheet 1 includes a modified polyphenylene ether-based resin sheet laminated and integrated on the surface or the surface of the modified polyphenylene ether-based resin foam sheet. .. Are formed on the surface, and the foam sheet A for automobile interior material is thus configured.

  By forming a large number of holes 2 in this way, vibration energy of sound generated on the opening side of the holes 2 is smoothly guided into the foam sheet 1 through the holes 2, The vibration of sound is converted into thermal energy and absorbed by vibrating the bubble wall, effectively preventing the reflection of sound by the foam sheet A for automobile interior materials, and the sound absorbing performance superior to the foam sheet A for automobile interior materials Is granted.

  First, in the case where the modified polyphenylene ether resin foam sheet 1 having been subjected to perforation includes only the open cell layer 1A mainly composed of open cells and the total open cell ratio is 50% or more, the modified polyphenylene subjected to perforation processing. Modified polyphenylene ether resin sheets 3 and 3 are laminated and integrated on both sides of the ether-based resin foam sheet 1, and the hole 2 is modified polyphenylene laminated and integrated on both surfaces of the modified polyphenylene ether resin foam sheet 1. It suffices if the modified polyphenylene ether-based resin foam sheet 1 is formed so as to reach the inside of the foamed sheet in a state of being opened on the surfaces of the ether-based resin sheets 3 and 3.

  The depth of the hole 2 is not particularly limited, but if the depth of the hole 2 is shallow, the vibration energy of sound is not efficiently induced in the open cells of the open cell layer, and the foam sheet A for automobile interior materials. On the other hand, if the depth is too deep, when the hole 2 is formed in the foamed sheet 1, there is a risk of forming a through hole in the foamed sheet 1, or the foamed sheet A for automobile interior materials. Therefore, the thickness is preferably 10 to 95%, more preferably 30 to 90% of the thickness of the modified polyphenylene ether-based resin foam sheet 1 subjected to hole processing.

  Next, the modified polyphenylene ether-based resin foam sheet 1 having been subjected to hole processing is formed such that closed cell layers 12 and 12 mainly composed of closed cells are formed on both surfaces of the open cell layer 11 mainly composed of open cells and When the overall open cell ratio is 50% or more, the hole 2 is opened on the surface 1a of the modified polyphenylene ether resin foam sheet 1 or the modified polyphenylene ether resin foam sheet. In the state of opening on the surface 3a of the modified polyphenylene ether resin sheet 3 laminated and integrated on both sides of the foam 1, the foaming penetrates one closed cell layer 12a (and skin layer 13a) in the modified polyphenylene ether resin foam sheet 1. It is only necessary to reach the open cell layer 11 of the sheet 1, and the other closed cell layer 12b of the modified polyphenylene ether resin foam sheet 1 is sufficient. It may not reach even been reached.

  That is, as shown in FIGS. 2 and 3, the hole 2 is formed with the bottom 21 reaching the interface between the open cell layer 11 and the closed cell layer 12a in the modified polyphenylene ether resin foam sheet 1. 4 or 5, as shown in FIGS. 4 and 5, the bottom 21 has entered the open cell layer 11 of the modified polyphenylene ether-based resin foam sheet 1, preferably in FIGS. As shown, the bottom 21 is formed so as to reach the interface between the open cell layer 11 and the other closed cell layer 12b in the modified polyphenylene ether resin foam sheet 1.

  And the vibrational energy of sound can be smoothly guided into the open cell layer 11 of the foam sheet 1 through the hole 2, so that the bottom 21 of the hole 2 reaches the inside of the open cell layer 11 of the modified polyphenylene ether resin foam sheet 1. Preferably, the bottom portion 21 of the hole 2 is formed so as to reach the interface between the open cell layer 11 and the other closed cell layer 12b in the modified polyphenylene ether resin foamed sheet 1. More preferably.

  The opening end shape of the hole 2 formed in the modified polyphenylene ether-based resin foam sheet 1 is not particularly limited as long as it can induce the vibration energy of sound into the open cells of the foam sheet 1. In addition to a circle and an ellipse, polygonal shapes such as a triangle and a quadrangle are listed, and a true circle is preferable.

  The cross-sectional shape along the surface of the foam sheet A for automobile interior materials in the hole 2 may be the same shape without changing over the entire length in the depth direction, or in the depth direction. It may change.

When the opening end area of the hole 2 is small, the sound absorption of the foam sheet A for automobile interior material may be reduced. On the other hand, when the area is large, the mechanical strength of the foam sheet A for automobile interior material is reduced. Therefore, 0.2 to 40 mm ² is preferable, and 0.3 to 30 mm ² is more preferable.

  Further, the form of formation of the hole 2 is not particularly limited, but the mechanical strength of the foam sheet A for automobile interior materials may be non-uniform. As shown in Fig. 5, the intersection points 41, 41, ... of the virtual lattice 4 drawn on the surface 1a of the modified polyphenylene ether resin foam sheet 1 or on the surface 3a of the modified polyphenylene ether resin sheet 3 are the same. The open end having a diameter is formed into a perfectly circular hole 2a, 2a ... in a state where the centers 21a, 21a are matched, and the open end has a perfect circular shape having the same diameter as the hole 2a. A plurality of holes are formed by forming the holes 2b, 2b,... So that their centers 21b, 21b are aligned with the diagonal intersections 42a, 42a,... Of the square frame 42 of the virtual lattice 4. Form parts 2, 2 (2a, 2b) ... in a staggered pattern Rukoto is more preferable. Note that only the hole 2a may be formed without forming the hole 2b.

  In addition, if the ratio of the total opening area of the hole 2 to the surface of the foam sheet A for automobile interior materials is small, the sound absorbing property of the foam sheet A for automobile interior materials may be reduced. Since the mechanical strength of the foamed sheet A may be lowered, 2 to 50% is preferable, 3 to 50% is more preferable, and 3 to 40% is particularly preferable.

  Here, the total opening area ratio of the hole part 2 with respect to the surface of the foam sheet A for automobile interior materials refers to that measured in the following manner. That is, a measurement frame having a flat square shape with a side of 10 cm is defined at an arbitrary location on the surface 1a (3a) of the foam sheet A for automobile interior materials.

  And the sum total of the opening edge area of the hole part 2 contained in this measurement frame is calculated | required, the percentage of the sum total of the opening edge area of the hole part 2 with respect to the area of a measurement frame is calculated, and the value of this percentage is used for automobile interior It is set as the total opening area ratio of the hole part 2 with respect to the surface of the foam sheet A for materials. When only a part of the opening end of the hole 2 is in the measurement frame, only the area of the opening end portion of the hole 2 in the measurement frame is targeted.

  Specifically, as shown in FIG. 9, in the case where the hole portions 2 having a perfect circular opening end are formed in a staggered pattern, for example, a virtual space is formed so that a plurality of hole portions 2 can be inserted. A plane square-shaped measurement frame 43 is defined along the lattice 4, and the sum of the opening end areas of the hole portions 2 contained in the measurement frame 43 (shaded portion) is calculated, and the hole portion 2 with respect to the area of the measurement frame 43 is calculated. What is necessary is just to calculate the percentage of the sum total of the opening edge area.

  In addition, when the foam sheet for automobile interior materials is subjected to secondary foaming to obtain a molded product, the opening end shape, the opening end area, and the total opening area ratio of the hole 2 in the secondary foamed molded product satisfy the above-described conditions. In such a case, the hole 2 of the foam sheet for automobile interior material before secondary foaming does not necessarily satisfy the above-mentioned opening end shape, opening end area, and total opening area ratio.

  Next, the manufacturing method of the foam sheet A for automobile interior materials will be described. First, as a method for producing a modified polyphenylene ether-based resin foam sheet (hereinafter referred to as “raw modified polyphenylene ether-based resin foam sheet”) before forming the hole, a conventionally used production method is used, By adjusting the extrusion foaming temperature of the modified polyphenylene ether resin, the temperature of the mold attached to the extruder or the surface cooling degree of the foamed sheet immediately after being extruded from this mold, the raw material having a desired open cell ratio The modified polyphenylene ether-based resin foam sheet can be obtained.

  Specific examples of the method for producing the raw modified polyphenylene ether resin foam sheet include, for example, (1) supplying the modified polyphenylene ether resin to an extruder and melt-kneading the volatile foaming agent in the extruder. A method for producing a foam sheet that is extruded from a mold attached to an extruder and then foamed, (2) A modified polyphenylene ether resin is impregnated with a volatile foaming agent and then supplied to the extruder and melted. Examples thereof include a method for producing a foamed sheet which is kneaded and extruded from a mold attached to an extruder and foamed.

  The volatile blowing agent is not particularly limited as long as it is conventionally used. For example, organic blowing agents such as ethane, propane, isobutane, normal butane, pentane, and dimethyl ether, carbon dioxide, water, Examples include inorganic foaming agents such as nitrogen, and these may be used alone or in combination.

  Further, the kind and amount of the volatile foaming agent are adjusted so that the amount of residual foaming agent remaining in the modified polyphenylene ether resin foamed sheet 1 processed with holes is 0.3 to 4.0% by weight. It is preferable. This is because if the amount of residual foaming agent in the hole-modified modified polyphenylene ether resin foam sheet 1 is small, a good foam sheet 1 cannot be obtained, and if it is large, the heat resistance of the foam sheet 1 and It is because dimensional stability may fall.

  When the modified polyphenylene ether resin sheets 3 and 3 are laminated and integrated on both surfaces of the raw modified polyphenylene ether resin foam sheet 1 obtained as described above, the raw modified polyphenylene ether resin foam sheet is processed. As a method of laminating and integrating a modified polyphenylene ether-based resin sheet on both sides of, for example, (1) superposing a modified polyphenylene ether-based resin sheet on both sides of a raw modified polyphenylene ether-based resin foamed sheet, (2) Laminating a modified polyphenylene ether resin sheet immediately after being extruded from an extruder on both surfaces of a raw modified polyphenylene ether resin foam sheet, This sheet is made of raw modified polyphenylene ether resin foam (3) A method of laminating and integrating a modified polyphenylene ether resin sheet on both sides of a raw modified polyphenylene ether resin foam sheet by coextrusion, etc. .

  A hole 2 is formed in the raw modified polyphenylene ether resin foam sheet thus obtained to produce a foam sheet A for automobile interior materials. The method for forming the hole 2 is not particularly limited. For example, (1) an unprocessed modified polyphenylene ether-based resin foam sheet, or an unprocessed material in which modified polyphenylene ether-based resin sheets are laminated and integrated on both sides The modified polyphenylene ether-based resin foam sheet is supplied between a pair of rolls arranged in parallel so that the rotation axes are parallel to each other with a predetermined interval and a large number of pins are implanted on one roll surface. The pin is pierced from one side of the raw modified polyphenylene ether resin foam sheet so as to reach the open cell layer 11 (1A) of the foam sheet. (2) Raw modified polyphenylene ether resin foam sheet, or modified polyphenylene ether resin sheet laminated and integrated on both sides, unprocessed Pressing a flat plate in which a large number of pins are planted on one side of the modified polyphenylene ether-based resin foam sheet, and the open-cell layer 11 of the foamed sheet from one side of the raw modified polyphenylene ether-based resin foam sheet ( A method of forming a large number of holes 2, 2... By piercing them to reach 1A) can be mentioned.

  In addition, the foam sheet A for automobile interior materials is usually laminated on the surface where the hole 2 is opened with a skin material 5 disposed on the vehicle interior side through an adhesive layer (not shown). In addition to being integrated, the noise prevention layer 6 is laminated and integrated on the other surface (see FIG. 10), and then molded into a desired shape by thermoforming and used as an automobile interior material.

  Note that the adhesive layer for laminating and integrating the skin material 5 and the foam sheet A for automobile interior materials is used for automobile interior materials so that the adhesive layer does not inhibit the sound vibration energy from entering the open cell layer. It is preferable not to close the upper end opening of the hole 2 of the foam sheet A.

  Accordingly, as a procedure for laminating and integrating the skin material 5 on one surface of the foam sheet A for automobile interior materials via an adhesive layer, for example, (1) the hole 2 on one surface of the foam sheet A for automobile interior materials After spraying a powdery adhesive so as not to close the upper end opening of the sheet and laminating the skin material 5 on one surface of the foam sheet A for automobile interior material, the foam sheet A for automobile interior material is melted at the melting point of the adhesive. A method of pressing and integrating the foam sheet A for automobile interior materials and the skin material 5 after heating as described above, (2) a powder adhesive on the surface of the skin material 5 facing the foam sheet A for automotive interior materials The skin material 5 is heated to a temperature equal to or higher than the melting point of the adhesive and then pressed from both sides to fix the adhesive to the surface of the skin material 5. Thereafter, the surface of the skin material 5 is laminated on one surface of the foam sheet A for automobile interior material with the surface to which the adhesive is fixed facing the foam sheet A for automobile interior material, and then the foam sheet A for automobile interior material is formed. A method of heating and heating the adhesive to a temperature at which the adhesive melts, and pressing and integrating the foam sheet A for automobile interior materials and the skin material 5; (3) the upper end opening of the hole 2 on one surface of the foam sheet A for automobile interior materials A method of applying an adhesive so as not to clog, and integrating the foam sheet A for automobile interior materials and the skin material 5 through the adhesive, (4) One side of the raw sheet of the modified polyphenylene ether resin foam After the adhesive is applied to the entire surface, the hole 2 is formed as described above to form the foam sheet A for automobile interior material, and the skin material 5 is laminated on one surface of the foam sheet A for automobile interior material via the adhesive. How to integrate, (5) Shape with adhesive After the skin material is laminated on one surface of the foam sheet A for automobile interior material through the nonwoven fabric or web having air permeability, the automobile interior material foam sheet A is heated to a temperature at which the adhesive melts. Examples thereof include a method in which the foam sheet A for interior material and the skin material 5 are pressed and integrated.

  Examples of the skin material 5 include non-woven fabrics, woven fabrics, and knitted fabrics, and preferably have air permeability. Note that a flame retardant may be included in order to impart flame resistance to the skin material 5.

  The fibers constituting the skin material 5 include polyesters such as polyethylene terephthalate, synthetic fibers such as polyamide and polyacrylonitrile, polyester fibers are preferred, and polyethylene terephthalate fibers are more preferable in terms of excellent heat resistance. preferable. In addition, the fiber which comprises the said skin material 5 may be used independently, or may be used together.

  The adhesive layer is not particularly limited as long as the skin material 5 and the foam sheet A for automobile interior materials can be bonded and integrated. For example, a thermoplastic adhesive, a hot melt adhesive, a rubber adhesive , Thermosetting adhesives, monomer-reactive adhesives, inorganic adhesives, natural material-based adhesives, and the like. Hot melt adhesives are preferred because they can be easily bonded.

  Examples of the hot melt adhesive include polyolefin, modified polyolefin, polyurethane, ethylene-vinyl acetate copolymer, polyamide, polyester, thermoplastic elastomer, styrene-butadiene copolymer, styrene- The thing which uses resin, such as an isoprene copolymer system as a component, is mentioned, These may be used independently or may be used together.

  Further, the noise preventing layer 6 is laminated and integrated on the other surface of the foam sheet A for automobile interior materials, that is, the surface where the hole 2 is not formed (opened). It is for reducing the friction noise generated when the foam sheet A for automobile interior materials is slidably contacted with a steel plate constituting a car body of an automobile. A polyolefin resin film or a nonwoven fabric is preferably used, and a nonwoven fabric is more preferably used. .

  Examples of the polyolefin resin film include polyolefin resin films such as a polyethylene film and a polypropylene film, which are excellent in heat resistance and stably generate frictional noise over a long period of time regardless of ambient temperature changes. An unstretched polypropylene film is preferable in that it can be reduced. In addition, as for the said polyolefin resin film, the thing whose thickness is 10-100 micrometers normally 25-35 micrometers is normally used preferably.

  Further, the fibers constituting the nonwoven fabric used for the noise preventing layer 6 are not particularly limited, and examples thereof include synthetic resin fibers such as polyester fibers, polyethylene fibers, polypropylene fibers, polyamide fibers, and polyacrylonitrile fibers. .

  Finally, in FIG. 2 to FIG. 7 and FIG. 10, the interface between the open cell layer 11 and the closed cell layer 12, the closed cell layer 12 and the non-foamed layer (skin layer) in the modified polyphenylene ether resin foamed sheet 1 that has been perforated. ) For the sake of convenience, the boundary line is described at the interface with 13, but the interface between the open cell layer 11 and the closed cell layer 12 and the independent cell layer in the modified polyphenylene ether-based resin foam sheet 1 in which the hole is processed according to the present invention. There is no clear boundary line at the interface between the bubble layer 12 and the non-foamed layer (skin layer) 13.

  Next, as described above, the foam sheet A for automobile interior material is laminated and integrated with the skin material 5 on one side and the noise prevention layer 6 is laminated and integrated on the other side, and then the desired shape is formed by thermoforming. It is formed into a car interior material.

  As a thermoforming method of the foam sheet A for automobile interior materials, a general-purpose method has been conventionally used. For example, the foam sheet A for automobile interior materials preferably has a double-sided temperature (the foam sheet 1 is constituted). Glass transition temperature Tg of modified polyphenylene ether resin Tg−25 ° C.) to (Glass transition temperature Tg of modified polyphenylene ether resin constituting foamed sheet 1 + 15 ° C.), more preferably, modified glass foam temperature 1 The glass transition temperature Tg of the polyphenylene ether resin Tg-20 ° C.) to (the glass transition temperature of the modified polyphenylene ether resin Tg constituting the foamed sheet 1 + 10 ° C.), particularly preferably (the modification constituting the foamed sheet 1). Glass transition temperature Tg-20 ° C. of polyphenylene ether-based resin to (modified foam sheet 1) General purpose molding such as vacuum molding and pressure molding of the foamed sheet A for automobile interior materials after the secondary foaming by heating to a glass transition temperature Tg + 5 ° C. of the rephenylene ether resin. What is necessary is just to thermo-mold using a method.

  The reason why it is preferable to adjust the heating temperature of the foam sheet A for automobile interior materials to be within the above temperature range is that, if low, residual distortion occurs during thermoforming of the foam sheet A for automobile interior materials, and the dimensional change rate is On the other hand, if it is high, excessive heat is applied to the foam sheet A for automobile interior material, causing the foam sheet A to shrink, resulting in a decrease in mechanical strength of the foam sheet A for automobile interior material or a poor shape. It is because it may produce.

  The glass transition temperature Tg of the modified polyphenylene ether resin constituting the foam sheet A for automobile interior materials is a value measured in accordance with the method described in JIS K7121: 1987 “Method for measuring plastic transition temperature”. Specifically, it can be measured under the condition of a heating rate of 10 ° C./min using a differential scanning calorimeter marketed by Seiko Electronics Industry under the trade name “DSC200 type”.

  As vacuum forming and pressure forming, for example, plug forming, free drawing forming, plug and ridge forming, matched mold forming, straight forming, drape forming, reverse draw forming, air slip forming, plug assist forming, plug Examples include assist reverse draw molding. In the molding method, it is preferable to use a mold whose temperature can be adjusted.

Further, the clearance of the mold preferably satisfies the following formula 3 and more preferably satisfies the following formula 4 when the initial thickness of the foamed sheet A for automotive interior materials is T.
0.7T ≦ clearance of mold ≦ 0.98T ・ ・ ・ Formula 3
0.8T ≤ mold clearance ≤ 0.95T ... Formula 4

  This is because if the mold clearance is narrow, the ratio of the thickness of the open cell layer 11 to the total thickness of the foam sheet A for automobile interior materials may be reduced, and sound absorption may be reduced. This is because it may not be possible to obtain a car interior material having a proper shape.

  The foam sheet for automobile interior material according to the present invention is a modified polyphenylene ether resin foam sheet configured as described above or a structure in which a modified polyphenylene ether resin sheet is laminated and integrated on both surfaces of the modified polyphenylene ether resin foam sheet. Since the hole part reaching the open cell layer from the surface or reaching the open cell layer is formed, the modified polyphenylene ether resin foamed sheet in which the vibration energy of sound is processed through the hole part It smoothly guides into the open cell layer and vibrates the cell wall of the open cell that constitutes the open cell layer, thereby converting vibration energy into heat energy and exhibiting excellent sound absorption.

  In the foam sheet for automobile interior materials, when the open cell ratio of the modified polyphenylene ether resin foam sheet is 60 to 90%, the cell walls of the open cells in the open cell layer of the foam sheet are more effectively By vibrating, the vibration energy of sound can be efficiently converted into thermal energy, and the sound absorbing property of the foam sheet for automobile interior materials can be further improved.

  Furthermore, in the said foam sheet for automotive interior materials, when the total opening area ratio of the hole part with respect to the surface of a foamed sheet is 2 to 50%, maintaining the mechanical strength excellent in the foam sheet for automotive interior materials Excellent sound absorption can be given.

(Example 1)
A mixture of polyphenylene ether and polystyrene resin (trade name “NORYL EFN4230” manufactured by GE Plastics, polyphenylene ether: 70% by weight, polystyrene resin: 30% by weight) and polystyrene (trade name, manufactured by Toyo Styrene Co., Ltd.) “HRM-26”) modified polyphenylene ether resin mixed with 50 parts by weight (polyphenylene ether component: 35 wt%, polystyrene resin component: 65 wt%, glass transition temperature: 132 ° C.) and talc 0.65 Part by weight is supplied to the first extruder and melt kneaded, and 3.9 parts by weight of a volatile blowing agent consisting of 35% by weight of isobutane and 65% by weight of normal butane is injected into the first extruder and melted at 300 ° C. After kneading, the molten resin is continuously fed to the second extruder connected to the tip of the first extruder. Fed to it after adjusting so that the resin temperature is 206 ° C., circular die attached to the tip of the second extruder (temperature: 155 ° C.) was extruded from a cylindrical shape. The cylindrical foam was continuously cut between the inner and outer surfaces in the extrusion direction and developed to obtain a raw modified polyphenylene ether resin foam sheet. The raw modified polyphenylene ether-based resin foam sheet has an open cell layer 11 mainly composed of open cells, and an open cell layer 12a mainly composed of closed cells on the other surface of the open cell layer 11. The closed cell layer 12b mainly composed of closed cells was formed.

  Next, a flat plate in which a large number of pins are planted on one side is prepared, and the pin of this flat plate is pierced from the closed cell layer 12a side of the raw modified polyphenylene ether resin foam sheet, and the modified polyphenylene ether type Only on one side of the resin foam sheet, the open end reaching from the surface 1a into the open cell layer 11 is a flat circular hole 2, that is, open to the surface 1a and the bottom 21 is located in the open cell layer 11 A large number of flat circular holes 2 were formed at the open ends to obtain a foam sheet A for automobile interior materials.

In addition, the modified polyphenylene ether resin foamed sheet 1 in which the hole-formed modified foaming sheet A constituting the obtained automotive interior foaming sheet A has a thickness of the open cell layer 11 of 3.6 mm and a thickness of the closed cell layer 12a. The thickness of the closed cell layer 12b was 0.6 mm, and the basis weight was 250 g / m ² .

The modified polyphenylene ether-based resin foam sheet 1 processed with holes has a density of 0.048 g / cm ³ , an overall open cell ratio of 61.3%, and a ratio of open cells contained in the open cell layer 11. 93.0%, the ratio of closed cells contained in the closed cell layer 12 was 85%, and the average cell diameter was 0.54 mm.

Further, the holes 2 of the modified polyphenylene ether-based resin foamed sheet 1 subjected to the hole processing are uniformly formed in a staggered pattern as shown in FIG. 8, and the opening end area of each hole 2 is 3. 14 mm ² , the depth is 3.7 mm, the ratio of the total opening area of the hole 2 to the surface of the foam sheet A for automobile interior materials is 9.8%, and the length d of the square frame 42 of the virtual lattice 4 is 8 mm. there were.

(Example 2)
Mixture of polyphenylene ether and polystyrene resin (trade name “NORYL EFN4230” manufactured by GE Plastics, polyphenylene ether: 70 wt%, polystyrene resin: 30 wt%) and polystyrene (trade name “HRM- manufactured by Toyo Styrene Co., Ltd.”) 26 ”) and high impact polystyrene (trade name“ E641N ”manufactured by Toyo Styrene Co., Ltd.) and a modified polyphenylene ether resin (glass transition temperature Tg: 116 ° C.) and a carbon black masterbatch (manufactured by Dainichi Seika Co., Ltd.) as a colorant. Trade name “PS-M SSC 98H822A, carbon black: 40 wt%), polyphenylene ether component 20 wt%, styrene resin component 77.6 wt%, rubber component 2 wt%, carbon black 0.4% by weight The mixed resin mixed while adjusting was supplied to each of the two extruders, and a modified polyphenylene ether resin sheet in a molten state immediately after being extruded from one of the extruders was produced in the same manner as in Example 1. Immediately after being unfolded, it is laminated on one surface of a raw modified polyphenylene ether-based resin foamed sheet and integrated by heat fusion. Laminated on the other side of the processed modified polyphenylene ether resin foam sheet and integrated by heat fusion, and then the entire surface of the unmodified modified polyphenylene ether resin foam sheet is colored black with carbon black in the thickness direction. The modified polyphenylene ether resin sheets 3 and 3 having a thickness of 95 μm were laminated and integrated directly by heat fusion.

Thereafter, a modified polyphenylene ether resin sheet was laminated and integrated on both sides in the same manner as in Example 1 except that the opening end area of the hole 2 was adjusted to 2.54 mm ^2, and unprocessed Only on one side of the modified polyphenylene ether-based resin foam sheet, a large number of holes 2 having openings on the surface of the modified polyphenylene ether-based resin sheet and the bottom portion 21 located in the open cell layer 11 and having an open end of a flat circular shape. The foamed sheet A for automobile interior materials was obtained.

In addition, the modified polyphenylene ether-based resin foamed sheet 1 in which the obtained foamed sheet A for automobile interior materials has been subjected to hole processing has a thickness of 5.1 mm, a basis weight of 450 g / m ² , and a thickness of the open cell layer 11 of 3. 5 mm, the thickness of one closed cell layer 12a is 0.6 mm, the thickness of the other closed cell layer 12b is 1.0 mm, the density is 0.088 g / cm ³ , the open cell rate is 73.3%, the open cell layer 11 The ratio of open cells contained in the inside was 94.6%, the ratio of closed cells contained in the closed cell layer 12 was 85%, and the average cell diameter was 0.54 mm.

Further, the holes 2 of the modified polyphenylene ether resin foam sheet 1 are uniformly formed in a staggered pattern as shown in FIG. 8, and the opening end area of each hole 2 is 2.54 mm ² , deep. The total opening area ratio of the hole 2 with respect to the surface of the foam sheet A for automobile interior materials was 7.9%, and the length d of the square frame portion 42 of the virtual lattice 4 was 8 mm.

(Example 3)
Mixture of polyphenylene ether and polystyrene resin (trade name “NORYL EFN4230” manufactured by GE Plastics, polyphenylene ether: 70 wt%, polystyrene resin: 30 wt%) and polystyrene (trade name “HRM- manufactured by Toyo Styrene Co., Ltd.”) 26 ”) and high impact polystyrene (trade name“ E641N ”manufactured by Toyo Styrene Co., Ltd.) and a modified polyphenylene ether resin (glass transition temperature Tg: 113 ° C.) and a carbon black masterbatch (manufactured by Dainichi Seika Co., Ltd.) as a colorant. Trade name “PS-M SSC 98H822A, carbon black: 40% by weight), polyphenylene ether component 16.8% by weight, styrene resin component 81.2% by weight, rubber component 2.6% by weight Carbon black is 0.4% by weight The mixed resin mixed while adjusting so as to be supplied to each of the two extruders.

  On the other hand, the volatile foaming agent is changed to 3.5 parts by weight instead of 3.9 parts by weight, the resin temperature is adjusted to 203 ° C. instead of 206 ° C. in the second extruder, and the temperature of the circular mold is set to 155 ° C. Except that the temperature was changed to 180 ° C. instead of the above, it was extruded from one of the above-mentioned extruders onto one surface of a raw modified polyphenylene ether resin foamed sheet immediately after being developed in the same manner as in Example 1. The molten modified polyphenylene ether-based resin sheet immediately after the lamination is laminated and integrated by heat fusion, and the molten modified polyphenylene ether-based resin sheet immediately after being extruded from the other extruder is replaced with the unmodified modified polyphenylene. Laminated on the other side of the ether-based resin foam sheet and integrated by heat-sealing, the entire thickness of the unmodified polyphenylene ether-based resin foam sheet on both sides The modified polyphenylene ether-based resin sheet 3,3 95μm thick colored in black were directly laminated and integrated by thermal fusion by to carbon black.

Thereafter, both sides of the hole portion 2 were prepared in the same manner as in Example 1 except that the opening end area of the hole portion 2 was 0.50 mm ² and the length d of the square frame portion 42 of the virtual lattice 4 was 4 mm. The modified polyphenylene ether-based resin sheet is laminated and integrated, and only on one side of the raw modified polyphenylene ether-based resin foam sheet, the surface of the modified polyphenylene ether-based resin sheet opens and the modified polyphenylene ether-based resin foam sheet is continuous. A large number of holes 2 reaching the bubble layer were formed to obtain a foam sheet A for automobile interior materials.

The resulting modified polyphenylene ether resin foamed sheet 1 in which the foamed sheet A for automobile interior materials is perforated is composed of only the open cell layer 1A mainly composed of open cells, and on both sides of the open cell layer 1A. A non-foamed layer 13 having a thickness of 0.1 mm was formed. Moreover, the modified polyphenylene ether resin foamed sheet 1 having a hole processed has a thickness of 5.3 mm, a basis weight of 500 g / m ^{2 and a} density of 0.094 g / cm ³ , and an open cell ratio of the entire foamed sheet of 79.6%. The open cell ratio of the open cell layer 1A was 92.2%, and the average cell diameter was 0.49 mm.

Further, the holes 2 of the modified polyphenylene ether-based resin foam sheet 1 subjected to the hole processing are uniformly formed in a staggered pattern as shown in FIG. 50 mm ² , the depth is 4.0 mm, the ratio of the total opening area of the hole 2 to the surface of the foam sheet A for automobile interior materials is 6.3%, and the length d of the square frame 42 of the virtual lattice 4 is 4 mm. there were.

Example 4
The foamed sheet A for automobile interior materials was obtained in the same manner as in Example 3 except that the flat circular holes 2 of the modified polyphenylene ether-based resin foamed sheet 1 subjected to the hole processing were uniformly formed in a lattice shape. . The opening end area of each hole 2 is 0.50 mm ² , the depth is 4.0 mm, the ratio of the total opening area of the hole 2 to the surface of the foam sheet A for automobile interior materials is 3.6%, and the virtual lattice 4 The length d of the square-shaped frame part 42 was 5.3 mm.

(Example 5)
As a modified polyphenylene ether resin, 57.1 parts by weight of a mixture of polyphenylene ether and polystyrene resin (trade name “NORYL EFN4230” manufactured by GE Plastics, polyphenylene ether: 70 wt%, polystyrene resin: 30 wt%), , Polystyrene (trade name “HRM-26” manufactured by Toyo Styrene Co., Ltd.) 42.9 parts by weight of modified polyphenylene ether resin (polyphenylene ether component: 40% by weight, polystyrene resin component: 60% by weight, glass Transition temperature: 137 ° C), the volatile blowing agent was 3.5 parts by weight instead of 3.9 parts by weight, and the resin temperature was adjusted to 208 ° C instead of 206 ° C in the second extruder. Except that the temperature of the circular mold was changed to 185 ° C. instead of 155 ° C. In the same manner as in Example 3, the modified polyphenylene ether-based resin sheet was directly heat-sealed and integrated on both sides of the raw modified polyphenylene ether-based resin foamed sheet in the same manner as in Example 3. In the same manner as in No. 3, a hole was formed in the raw modified polyphenylene ether-based resin foam sheet to obtain a foam sheet A for automobile interior materials.

In addition, the modified polyphenylene ether-based resin foamed sheet 1 in which the hole-processed foam sheet A for automobile interior materials is obtained is composed of only the open cell layer 1A mainly composed of open cells, and is formed on both surfaces of the open cell layer 1A. A non-foamed layer 13 having a thickness of 0.1 mm was formed. In addition, the modified polyphenylene ether-based resin foam sheet having a hole processed has a thickness of 5.4 mm, a basis weight of 500 g / m ^{2 and a} density of 0.093 g / cm ³ , and an open cell ratio of the entire foam sheet of 79.6%, The open cell layer 1A had an open cell ratio of 92.6% and an average cell diameter of 0.55 mm.

Further, the holes 2 of the modified polyphenylene ether-based resin foamed sheet 1 subjected to the hole processing are uniformly formed in a staggered pattern as shown in FIG. 50 mm ² , the depth is 4.0 mm, the ratio of the total opening area of the hole 2 to the surface of the foam sheet A for automobile interior materials is 6.3%, and the length d of the square frame 42 of the virtual lattice 4 is 4 mm. there were.

(Example 6)
A foamed sheet for automobile interior materials in the same manner as in Example 5, except that the thickness of the modified polyphenylene ether-based resin sheet laminated and integrated on both surfaces of the raw modified polyphenylene ether-based resin foamed sheet was 119 μm instead of 95 μm. Got.

(Example 7)
As a modified polyphenylene ether resin, 64.3 parts by weight of a mixture of polyphenylene ether and polystyrene resin (trade name “NORYL EFN4230” manufactured by GE Plastics, polyphenylene ether: 70 wt%, polystyrene resin: 30 wt%), , Modified polyphenylene ether resin mixed with 35.7 parts by weight of polystyrene (trade name “HRM-26” manufactured by Toyo Styrene Co., Ltd.) (polyphenylene ether component: 45% by weight, polystyrene resin component: 55% by weight, glass Transition temperature: 142 ° C), the volatile blowing agent was 3.5 parts by weight instead of 3.9 parts by weight, and the resin temperature was adjusted to 212 ° C instead of 206 ° C in the second extruder. Example 1 except that the temperature of the circular mold was changed to 189 ° C. instead of 155 ° C. Immediately after being developed in the same manner, the modified polyphenylene ether resin sheet is directly laminated on both sides of the raw modified polyphenylene ether resin foam sheet in the same manner as in Example 3 by heat fusion. Furthermore, in the same manner as in Example 3, holes were formed in the raw modified polyphenylene ether resin foam sheet to obtain a foam sheet A for automobile interior materials.

The resulting modified polyphenylene ether resin foamed sheet 1 in which the foamed sheet A for automobile interior materials is perforated is composed of only the open cell layer 1A mainly composed of open cells, and on both sides of the open cell layer 1A. A non-foamed layer 13 having a thickness of 0.1 mm was formed. Moreover, the modified polyphenylene ether resin foamed sheet 1 in which the holes are processed has a thickness of 5.4 mm, a basis weight of 500 g / m ^{2 and a} density of 0.093 g / cm ³ , and an open cell ratio of the entire foamed sheet of 78.6%. The open cell ratio of the open cell layer 1A was 92.7%, and the average cell diameter was 0.49 mm.

Further, the holes 2 of the modified polyphenylene ether-based resin foam sheet 1 subjected to the hole processing are uniformly formed in a staggered pattern as shown in FIG. 50 mm ² , the depth is 4.0 mm, the ratio of the total opening area of the hole 2 to the surface of the foam sheet A for automobile interior materials is 6.3%, and the length d of the square frame 42 of the virtual lattice 4 is 4 mm. there were.

(Example 8)
30 g of powdered ethylene-vinyl acetate copolymer hot melt adhesive (melting point: 97 ° C.) is applied to one surface of the skin material 5 (Curehatech's basis weight: 130 g / m ² ) composed of a nonwoven fabric made of polyethylene terephthalate fiber. / M ² uniformly sprayed.

  After that, after heating the skin material 5 to a temperature equal to or higher than the melting point of the hot melt adhesive, the skin material 5 is sandwiched from both sides with a pressure of 0.7 MPa, and the hot melt adhesive is applied to one surface of the skin material 5. A part thereof was fixed so as to be impregnated in the skin material 5.

  And the said skin material 5 was piled up on the hole 2 formation surface of the foam sheet A for automobile interior materials obtained in Example 3 so that the adhesive fixing surface is on the foam sheet A side for automobile interior materials. Thereafter, the foam sheet A for automobile interior materials was heated to the melting point or higher of the hot melt adhesive, and the foam sheet A for automobile interior materials and the skin material 5 were pressed and integrated from both sides.

(Comparative Example 1)
Unmodified modified polyphenylene ether resin in the same manner as in Example 1 except that the resin temperature in the second extruder was adjusted to 202 ° C. and the amount of the volatile foaming agent was 3.3 parts by weight. A foam sheet 1 was obtained. This raw modified polyphenylene ether-based resin foam sheet has a closed cell layer 12a mainly composed of closed cells on one surface of the open cell layer 11 mainly composed of open cells. A closed cell layer 12b composed mainly of closed cells was formed. Next, a number of holes 2 were formed in the raw modified polyphenylene ether resin foam sheet in the same manner as in Example 1 to obtain a foam sheet A for automobile interior materials.

  In addition, in the modified polyphenylene ether resin foamed sheet 1 subjected to hole processing constituting the foamed sheet A for automobile interior material, the thickness of the open cell layer 11 is 1.8 mm, and the thickness of the closed cell layer 12a is The thickness of 1.0 mm and the closed cell layer 12b was 1.2 mm.

Moreover, the modified polyphenylene ether resin foamed sheet 1 processed with holes has a thickness of 4.0 mm, a basis weight of 210 g / m ² , a density of 0.053 g / cm ³ , and an overall open cell ratio of 48.1%. The ratio of open cells contained in the open cell layer 11 was 90.6%, the ratio of closed cells contained in the closed cell layer 12 was 81%, and the average cell diameter was 0.49 mm.

  About the sound absorption property of the foamed sheet for automobile interior materials and the foamed sheet for automobile interior materials obtained by the secondary foaming of the foamed sheet for automobile interior materials obtained as described above, and the moldability of the foamed sheet for automobile interior materials The measurement was performed in the following manner, and the results are shown in Tables 1 to 3 and FIGS.

(Sound absorption)
The sound absorption properties of the foamed sheet A for automobile interior materials and the foamed sheet A for automotive interior materials obtained by secondary foaming are measured by the transfer function method based on the normal incident sound absorption coefficient test of ASTM E1050. Under the condition of no layer, a sound wave having a frequency of 500 to 6300 Hz was incident on the foam sheet A for automobile interior material and the secondary foamed molded product from the opening side of the hole 2 to measure the normal incident sound absorption coefficient. The sound absorbing property of the foam sheet A for automobile interior materials is shown in Table 1 and FIG. 12, and the sound absorbing property of the secondary foamed molded product is shown in Table 2 and FIG.

  The secondary foamed molded product was obtained as follows. That is, the foam sheet A for automobile interior material was heated to the surface temperature shown in Table 3 and freely subjected to secondary foaming. And when the surface temperature of the foam sheet A for automobile interior materials reaches the surface temperature shown in Table 3, the heating of the foam sheet A for automobile interior materials is finished, and the foam sheet A for automobile interior materials after secondary foaming. The thickness of was measured. In addition, the said point was repeated 3 times and let the arithmetic mean of the thickness after secondary foaming of the foam sheet A for three automotive interior materials be thickness after secondary foaming.

  Next, the foam sheet A for automobile interior materials is heated until the surface temperature thereof reaches the surface temperature shown in Table 3, and then the foam sheet A for automobile interior materials is formed as a pair of flat plates having opposing surfaces formed on smooth surfaces. The plate-shaped mold is clamped after being placed between the molds, and the foam sheet A for automobile interior materials is the only open-cell layer until the one with the closed-cell layer is 90% of the thickness after secondary foaming. The glass transition of the modified polyphenylene ether resin in which the foam temperature of the foam sheet A for automobile interior materials constitutes the foam sheet is cooled while being compression-molded in the thickness direction until 95% of the thickness after secondary foaming. When the temperature became lower by 50 ° C. than the temperature Tg, the pair of flat plate molds were opened to obtain a secondary foam molded product. In addition, in the above-mentioned point, about the foam sheet A for automobile interior materials of Example 8, the temperature of the surface on which the skin material was not laminated was measured.

  And the total thickness of the secondary foam molded product, the thickness of the open cell layer, the thickness of the closed cell layer, the opening end area of the hole, and the total open area ratio of the hole to the surface of the secondary foam molded product Are shown in Table 3. In addition, the measurement about the said evaluation item of a secondary foaming molded product is performed in the same way as the measuring method in the foam sheet for automotive interior materials. In Table 3, the thickness of the closed cell layer is the closed cell layer 12a, the closed cell. Listed in the order of layer 12b. Moreover, about Example 8, the skin material was peeled and removed from the surface of the secondary foamed molded article, and the above items were measured.

(Formability)
30 g of powdery ethylene-vinyl acetate copolymer hot melt adhesive (melting point: 97 ° C.) is applied to one surface of the skin material 5 (made by Kurehatech, basis weight: 130 g / m ² ) composed of a nonwoven fabric made of polyethylene terephthalate fiber. / M ² uniformly sprayed.

  After that, after heating the skin material 5 to a temperature equal to or higher than the melting point of the hot melt adhesive, the skin material 5 is sandwiched from both sides with a pressure of 0.7 MPa, and the hot melt adhesive is applied to one surface of the skin material 5. A part thereof was fixed so as to be impregnated in the skin material 5.

  Then, the skin material 5 is overlaid on the hole 2 forming surface of the foam sheet A for automobile interior material such that the adhesive fixing surface is on the foam sheet A side for automobile interior material, and the foam sheet for automobile interior material On the other side of A, the noise preventing material 6 (trade name “Ecule 6151A” manufactured by Toyobo Co., Ltd.) composed of a non-woven fabric made of polyethylene terephthalate fiber is substantially uniformly attached to the entire surface of one side of the noise preventing material 6. A laminated body was prepared by laminating the hot-melt adhesive powder so as to face the foam sheet A for automobile interior materials. In addition, about the foam sheet A for automotive interior materials of Example 8, the noise prevention material 6 was laminated | stacked on the other way only on the other side, and the laminated body was produced.

  Thereafter, the laminated body is supplied between a pair of polytetrafluoroethylene belts whose surface temperature is maintained at 135 to 145 ° C., and the laminated body is heated and compressed in the thickness direction from both sides thereof, so that an automobile interior material is obtained. The skin material 5 was laminated on one side of the foam sheet A for use, and the noise preventing material 6 was laminated and integrated on the other side.

  A test piece of a predetermined shape is cut out from the foam sheet A for automobile interior material in which the skin material 5 and the noise preventing material 6 are laminated and integrated, and the temperature of both surfaces of the test piece is as shown in Table 3. As shown in FIG. 11, a molded product B having a shape in which the flange portion was extended outward from the entire circumference of the upper end edge of the bottomed cylindrical body in the horizontal direction was obtained. And the external appearance of the molded article B was visually observed and evaluated according to the following criteria. In addition, it shape | molded so that the skin material 5 of the foam sheet A for motor vehicle interior materials might become inside. In FIG. 11, the detailed layer structure of the molded product B is omitted.

A: The molded product B was not torn and the thickness was substantially uniform.
X: The molded product B was broken and the thickness was varied.

It is the model vertical end view which showed the foam sheet for motor vehicle interior materials of this invention. It is the model longitudinal end view which showed other examples of the foam sheet for motor vehicle interior materials of this invention. It is the model longitudinal end view which showed other examples of the foam sheet for motor vehicle interior materials of this invention. It is the model longitudinal end view which showed other examples of the foam sheet for motor vehicle interior materials of this invention. It is the model longitudinal end view which showed other examples of the foam sheet for motor vehicle interior materials of this invention. It is the model longitudinal end view which showed other examples of the foam sheet for motor vehicle interior materials of this invention. It is the model longitudinal end view which showed other examples of the foam sheet for motor vehicle interior materials of this invention. It is the top view which showed an example of the formation aspect of a hole part. It is the top view which showed an example of the formation aspect of a hole part. It is the model vertical end view which showed the state which laminated | stacked and integrated the skin material and the noise prevention material on both surfaces of the foam sheet for automotive interior materials of this invention. It is the model longitudinal cross-sectional view which showed the molded article obtained in the Example. It is the graph which showed the result of the sound absorptivity of the foam sheet for automotive interior materials. It is the graph which showed the sound absorptivity result of the secondary foaming molding.

Explanation of symbols

1,1A modified polyphenylene ether resin foam sheet
11 Open cell layer
12 closed cell layer
13 Non-foamed layer (skin layer)
2 Hole 3 Modified polyphenylene ether resin sheet 5 Skin material 6 Anti-noise material A Foam sheet for automobile interior material B Molded product

Claims (5)

The modified polyphenylene ether resin sheet is formed by laminating and integrating a modified polyphenylene ether resin sheet on both sides of a modified polyphenylene ether resin foam sheet mainly composed of an open cell layer composed of open cells and having an open cell ratio of 50% or more. A foamed sheet for automobile interior materials, wherein a hole reaching from the surface of the ether-based resin sheet into the modified polyphenylene ether-based resin foamed sheet is formed. A modified polyphenylene ether-based resin foam sheet having a closed cell layer mainly composed of closed cells formed on both sides of an open cell layer mainly composed of open cells and having an open cell rate of 50% or more is formed from the surface. A foam sheet for automobile interior material, wherein a hole reaching the open cell layer is formed. Modified polyphenylene on both sides of a modified polyphenylene ether-based resin foamed sheet in which closed cell layers mainly composed of closed cells are formed on both sides of an open cell layer mainly composed of open cells and the open cell ratio is 50% or more A vehicle interior material characterized in that an ether resin sheet is laminated and integrated, and a hole is formed from the surface of the modified polyphenylene ether resin sheet to the open cell layer of the modified polyphenylene ether resin foam sheet. Foam sheet. The foamed sheet for automobile interior materials according to any one of claims 1 to 3, wherein the open cell ratio of the modified polyphenylene ether-based resin foamed sheet is 60 to 90%. The foamed sheet for automobile interior materials according to any one of claims 1 to 4, wherein the ratio of the total opening area of the holes to the surface of the foamed sheet is 2 to 50%.

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