JP2006116833A - Molding for interior finish of vehicle and skin material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an excellent molding for the interior finish of a vehicle which is free from problems including the oozing of an adhesive and has a good texture and cushioning properties although a skin material is adhered directly to a substrate layer without using polyurethane foam, and the skin material used in the molding. <P>SOLUTION: In the molding for an interior finish of a vehicle, the skin material is directly adhered/integrated to/with the substrate layer 12 for an interior finish. The skin material comprises a pile part 13a formed from specified synthetic fibers A and a non-pile part 13b formed from specified synthetic fibers B. The sum of the size of the synthetic fibers A and the size of the synthetic fibers B is 60-140 decitex. The weight of the synthetic fibers A is greater than that of the synthetic fibers B. The skin material is composed of a pile texture 13 in which the number of courses, the number of wales, basis weight, and thickness are set up to be 40-80/2.54 cm, 35-65/2.54 cm, 100-300 g/m<SP>2</SP>, and 1-10 mm, respectively. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a molded product for vehicle interior used for an automobile roof trim, door trim and the like, and a skin material used therefor.

  Conventionally, as automotive interior trims such as automobile roof trims and door trims, the base material layer is mainly composed of a rigid foam with sound absorption and impact resistance. The thing of the structure which joined and integrated the provided flexible skin layer is used. For example, as shown in FIG. 4, as the base material layer 1, a hard polyurethane foam or the like 3 in which a glass mat with an adhesive 2 or the like is laminated on the front and back surfaces is used, and as the skin layer 4, a knitted fabric, non-woven fabric, suede-like synthetic leather A material in which a flexible polyurethane foam 6 is laminated on the back surface of a skin material 5 such as the above is disclosed (see Patent Document 1). This is a state in which the release paper (not shown) provided on the surface of the glass mat with adhesive 2 of the base material layer 1 is peeled off and laminated between the skin layers 4 and pressed between dies, It can be shaped into the desired shape.

Further, in the skin layer 4, the flexible polyurethane foam 6 is not used, and instead, as shown in FIG. 5, a nonwoven fabric 7 such as a low-melting-point polyester having some cushioning properties and a knitted fabric, a nonwoven fabric, a synthetic leather, etc. A laminate of a skin material 5 'has also been proposed (see Patent Document 2).
JP 2003-245969 A JP 2000-95036 A

  However, in the molded article for vehicle interior shown in FIG. 4, it takes very troublesome work to obtain the skin layer 4 by laminating the flexible polyurethane foam 6 on one surface of the skin material 5, and the manufacturing cost is high. Have. Moreover, since the flexible polyurethane foam 6 is very flammable, in order to use it for the skin layer 4, many expensive flame retardants must be mix | blended and there also exists a problem that material cost becomes high. Further, since the flexible polyurethane foam 6 has poor light resistance and easily discolors, when combined with a light pale skin material 5, the discolored color of the flexible polyurethane foam 6 on the back side can be seen through from the top of the skin material 5. There is a problem that is bad.

  On the other hand, in the molded article for vehicle interior shown in FIG. 5, the problem derived from the flexible polyurethane foam 6 can be solved, but the cushioning property of the nonwoven fabric 7 is not so good and a good feeling cannot be obtained. There is. In addition, the adhesive (not shown) used for laminating and integrating the nonwoven fabric 7 and the skin material 5 'oozes out during molding, creating irregularities on the surface of the skin material 5' and deteriorating the appearance. There is.

  The present invention has been made in view of such circumstances, and there is a problem such as bleeding of an adhesive even though the skin material is directly bonded to the base material layer without using a flexible polyurethane foam. In addition, an object of the present invention is to provide an excellent molded article for vehicle interior having a good texture and cushioning properties and a skin material used therefor.

In order to achieve the above object, the present invention is a molded article for vehicle interior in which a skin material is directly joined and integrated with a base material layer for interior, and the skin material is formed of the following synthetic fiber A A pile portion and a non-pile portion formed of the following synthetic fiber B, and the total fineness of the synthetic fiber A and the synthetic fiber B is 60 to 140 dtex, and the synthetic fiber A and the synthetic fiber B Consists of pile fabric with weight ratio A> B, number of courses 40-80 / 2.54 cm, number of wells 35-65 / 2.54 cm, basis weight 100-300 g / m ² , thickness 1-10 mm The molded article for vehicle interior is a first gist.
A: Synthetic fiber mainly composed of polyester, having a total fineness of 30 to 110 dtex and a single yarn fineness of 0.5 to 2.5 dtex.
B: Synthetic fiber mainly composed of polyester, having a total fineness of 30 to 110 dtex and a single yarn fineness of 1 to 5 dtex.

Further, the present invention is a skin material used for the molded article for vehicle interior, comprising a pile portion formed of the following synthetic fiber A and a non-pile portion formed of the following synthetic fiber B, The total fineness of the synthetic fiber A and the synthetic fiber B is 60 to 140 dtex, the weight ratio of the synthetic fiber A and the synthetic fiber B is A> B, the number of courses is 40 to 80 / 2.54 cm, and the number of wells is 35. A skin material composed of a pile fabric set to ˜65 / 2.54 cm, a basis weight of 100 to 300 g / m ² , and a thickness of 1 to 10 mm is defined as a second gist.
A: Synthetic fiber mainly composed of polyester, having a total fineness of 30 to 110 dtex and a single yarn fineness of 0.5 to 2.5 dtex.
B: Synthetic fiber mainly composed of polyester, having a total fineness of 30 to 110 dtex and a single yarn fineness of 1 to 5 dtex.

  And this invention makes the 3rd summary the skin material by which the average friction coefficient of the surface which consists of a non-pile part of the said pile cloth is set to 0.1-0.4 among the said skin materials especially. To do.

  That is, in the molded product for vehicle interior of the present invention, since the skin material is composed of a special pile fabric, it is directly bonded to the base material layer without using a flexible polyurethane foam. There is no problem such as bleeding of the adhesive, and it has a good texture and cushioning properties. And since the flexible polyurethane foam is not used, not only can the manufacturing process be reduced, but there is also no need to use a lot of expensive flame retardants, and this has the advantage that it can be provided at low cost. .

  Next, an embodiment of the present invention will be described.

  FIG. 1 schematically shows an embodiment of a molded product for vehicle interior according to the present invention so that the configuration before molding can be understood. That is, the molded product for vehicle interior includes a base material layer 12 in which a glass nonwoven fabric 11 is laminated and integrated on the front and back surfaces of a lightweight cushioning material 10 such as rigid polyurethane foam, and a special pile fabric 13 that is a skin material. It is configured to be directly joined and integrated through the adhesive layer 14.

  The structure of the base material layer 12 may be any conventionally known material. Examples of the lightweight cushioning material 10 include hard polyurethane foam, various hard foams that can be molded such as hard polyethylene foam, and the like. It is done. Further, the glass nonwoven fabric 11 laminated and integrated on the front and back surfaces of the lightweight cushioning material 10 is not necessarily required. However, when the lightweight cushioning material 10 and another member are joined, the adhesive strength by the adhesive is strengthened. In order to make it appear, it is preferable to provide a layer that assists the penetration of the adhesive. As such a layer, in addition to the glass nonwoven fabric 11, various types of nonwoven fabrics, woven and knitted fabrics, paper, porous sheets and the like can be used.

  The adhesive layer 14 provided between the glass nonwoven fabric 11 and the pile fabric 13 may also be any conventionally known one. However, if the adhesiveness to the glass nonwoven fabric 11 and the pile fabric 13 is taken into consideration, an isocyanate layer 14 is used. Preferable are hot-melt adhesives such as system adhesives, copolymerized polyesters, copolymerized polyacids, and polyolefins, ethylene vinyl acetate, acrylic resin-based emulsion adhesives, and the like.

  Note that an adhesive is applied in advance to the front surface of the glass nonwoven fabric 11 or the back surface of the pile fabric 13, and the coated surface is covered with a release paper, and the base material layer 12 and the pile fabric 13 as a skin material are joined. During the work, the release paper may be peeled off and joined.

  On the other hand, the pile fabric 13 to be joined to the base material layer 12 has one surface formed in the pile portion 13a and the other surface formed in the non-pile portion 13b.

The pile portion 13a must be formed of a synthetic fiber A mainly composed of polyester, having a total fineness of 30 to 110 dtex and a single yarn fineness of 0.5 to 2.5 dtex, and the non-pile portion 13b. Must be formed of synthetic fiber B having polyester as a main component, total fineness of 30 to 110 dtex and single yarn fineness of 1 to 5 dtex. The total fineness of the synthetic fiber A and the synthetic fiber B is 60 to 140 dtex, the weight ratio of the synthetic fiber A and the synthetic fiber B is A> B, and the number of courses is 40 to 80 / 2.54 cm. It should be set to several 35 to 65, a basis weight of 100 to 300 g / m ² , and a thickness of 1 to 10 mm.

  That is, the pile fabric 13 limited as described above realizes an excellent cushioning property and a high-quality texture with the pile portion 13a being plump. And the non-pile part 13b is a dense knitted fabric, and the adhesive which comprises the said adhesive bond layer 14 does not ooze out to the surface side (pile part 13a side).

  The synthetic fibers A and B are both composed mainly of polyester fiber from the viewpoint of weather resistance, heat resistance, and cost, and it is desirable that the whole is composed of polyester fiber. Other fibers such as polyamide fibers may be used for a part of them. As the mixing form, it is possible to mix the yarn itself by blending, mixing and spinning, mixing the yarn made of polyester fiber and the yarn made of other fiber, or knitting the yarn and mixing them with the pile fabric 13. it can.

  And it is suitable for the average friction coefficient of the back surface of the said pile fabric 13, ie, the surface which consists of a non-pile part 13b, to be set to 0.1-0.4. That is, if the average friction coefficient is less than 0.1, the air permeability may be lost and the sound absorption performance may be deteriorated. Conversely, if it is greater than 0.4, it is necessary to increase the amount of adhesive used. This is because it may ooze into the pile fabric 13 which is a material and deteriorate the quality.

  In addition, the synthetic fibers A and B constituting the pile fabric 13 can be blended with appropriate additives such as a flame retardant, an antibacterial agent, and an ultraviolet absorber as necessary. Examples of the flame retardant include phosphorus flame retardants and inorganic flame retardants. Examples of the antibacterial agent include inorganic antibacterial agents such as silver and zinc, and examples of the ultraviolet absorber include benzotriazole, benzophenone, and triazine.

  The molded product for vehicle interior according to the present invention has a laminate obtained by joining and integrating the non-pile portion 13b of the pile fabric 13 with the base material layer 12 through the adhesive layer 14, and is loaded into a predetermined mold. Can be obtained by compression pressing.

  The molded article for vehicle interior according to the present invention obtained in this way is obtained by directly bonding the base material layer 12 without using a flexible polyurethane foam because the skin material is composed of a special pile fabric 13. In spite of this, there are no problems such as bleeding of the adhesive, and it has a good texture and cushioning properties. And since the flexible polyurethane foam is not used, it is not necessary to use many expensive flame retardants, and it has the advantage that this can be provided cheaply.

  In the above example, the pile fabric 13 and the base material layer 12 are joined and integrated via the adhesive layer 14, and then loaded into a predetermined mold and molded by a compression press. Depending on the material of the surface layer of the material layer 12 (the glass nonwoven fabric 11 in the above example), the pile fabric 13 and the base material layer 12 are directly press-formed without the adhesive layer 14 interposed therebetween. Can do. Further, in the molded product for vehicle interior according to the present invention, only the base material layer 12 is first molded into a predetermined shape, and then the pile fabric 13 is pasted on the surface via the adhesive layer 14. There is no problem.

  Next, examples will be described together with comparative examples.

[Example 1]
To prepare a 56T / 48-DND polyester yarn (manufactured by Kanebo Gosei Co., Ltd.) containing 1.3% by weight of titanium oxide as a yarn (synthetic fiber A) for forming a pile portion, and to form a non-pile portion As a yarn (synthetic fiber B), a 33T / 48-DND polyester yarn (manufactured by Kanebo Gosei Co., Ltd.) containing 1.3% by weight of titanium oxide was prepared. Then, a tricot knitting was knitted using a 28-gauge scissor with a 2-pole tricot knitting machine manufactured by Meyer, so that the weight ratio of both yarns was 3: 1. The number of courses of this knitted fabric was 50 / 2.54 cm, and the number of wells was 56 / 2.54 cm.

Next, this knitted fabric was refined and dyed, and a finishing set was performed at 170 ° C. At that time, 5% by weight of a flame retardant (Nikka Chemical Co., Ltd., Nikka Fine P-205) was attached to the surface composed of the non-pile part. The number of courses after finishing of the pile fabric thus obtained was 64 / 2.54 cm, the number of wells was 52 / 2.54 cm, the basis weight was 195 g / m ² , and the thickness was 3 mm.

Next, 15 g / m ² of an isocyanate-based adhesive (manufactured by Dainippon Ink & Chemicals, Hydran ADS) and 10 g / m ² of the same flame retardant as described above are attached to this pile fabric, and both sides of the rigid polyurethane foam are adhered. It was made to adhere to the single side | surface of the base material (thickness 4mm) by which the glass nonwoven fabric was laminated | stacked and integrated. And this was loaded into the shaping | molding die, and the target molded article for vehicle interior was obtained by the compression press process. In addition, as shown in FIG. 1, this has a structure of a pile fabric 13 + an adhesive layer 14 + a base material layer 12.

[Examples 2-7, Comparative Examples 1-4]
As shown in Tables 1 to 3 below, the conditions of the pile fabric were changed. Other than that was carried out similarly to the said Example 1, and obtained the target molded article for vehicle interior.

[Comparative Example 5]
To prepare 44T / 18-DND polyester yarn (manufactured by Kanebo Gosei Co., Ltd.) containing 1.3% by weight of titanium oxide as a yarn (synthetic fiber A) for forming a pile portion, and to form a non-pile portion As a yarn (synthetic fiber B), a 33T / 12-SOD polyester yarn (Kanebo Gosei Co., Ltd.) containing 0.4% by weight of titanium oxide was prepared. Then, a tricot knitting was knitted using a 28-gauge scissors with a Meyer single tricot knitting machine so that the used weight ratio of both yarns was 73:27. The number of courses of this knitted fabric was 70 / 2.54 cm, and the number of wells was 28 / 2.54 cm.

Next, after raising the knitted fabric with a French raising machine, the knitted fabric was refined and dyed, and finished at 170 ° C. The number of courses after finishing the pile fabric was 55 / 2.54 cm, the number of wells was 62 / 2.54 cm, the basis weight was 120 g / m ² , and the thickness was 1 mm.

  Next, a soft polyurethane foam (thickness 2 mm) was heat-sealed to the back surface (the surface not brushed) of the knitted fabric, and this surface was laminated to obtain a skin material. Next, on the back surface (soft polyurethane foam surface) of the skin material, the same isocyanate adhesive and flame retardant as in Example 1 were attached with the same basis weight as in Example 1, and this was applied to both surfaces of the rigid polyurethane foam. The glass nonwoven fabric was adhered to one side of a base material (thickness 4 mm) integrated and laminated. And this was loaded into the shaping | molding die, and the target molded article for vehicle interior was obtained by the compression press process. In addition, as shown in FIG. 2, this has a configuration of a raised cloth 15 + a flexible polyurethane foam layer 16 + an adhesive layer 14 + a base material layer 12.

[Comparative Example 6]
The flexible polyurethane foam was not heat-sealed on the back side. Other than that was carried out similarly to the comparative example 1, and obtained the molded object for vehicle interiors. In addition, this thing has the structure of the raising cloth 15 + adhesive layer 14 + base material layer 12, as shown in FIG.

[Comparative Example 7]
A soft polyurethane foam (thickness 2 mm) was heat-sealed to the back surface (the surface not brushed) of the same pile fabric as in Example 1, and this surface was laminated to obtain a skin material. Next, the same isocyanate adhesive and flame retardant as in Example 1 are attached to the back surface (soft polyurethane foam surface) of this skin material with the same basis weight as in Example 1, and this is applied to both surfaces of the rigid polyurethane foam. The glass nonwoven fabric was adhered to one side of a base material (thickness 4 mm) integrated and laminated. And this was loaded into the shaping | molding die, and the target molded article for vehicle interior was obtained by the compression press process. In addition, as shown in FIG. 2, this has a configuration of a raised cloth 15 + a flexible polyurethane foam layer 16 + an adhesive layer 14 + a base material layer 12.

  The following items were measured or evaluated for these molded products for vehicle interior, and the results are shown in Tables 1 to 3 below.

[Average friction coefficient]
It measured using the surface testing machine (the Kato tech company make, KES-FB4). Regarding the measurement, in accordance with the measurement standard of KES (Kawabata Evaluation System: Kawabata Evaluation System), standard load: 0.490 N, contact area 5 mm × 5 mm = 25 mm ² , contact moving speed: 1 mm / second, sample tension: The test was performed at 0.196 N / cm, sensitivity: sens 2 × 5. A skin material having a size of 20 cm × 20 cm was prepared as a sample, and the back surface was measured three times in the longitudinal direction and the weft direction, and the average value was obtained.

[Cushioning]
The compression characteristics were measured using a compression tester (KES-FB3, manufactured by Kato Tech Co., Ltd.), and cushioning properties were evaluated. For the measurement, in accordance with the measurement criteria of KES, pressure movement speed: 1 mm / 50 seconds, pressurized area: 2 cm ^2, sensitivity: was performed in sens 2 × 5. In the compression characteristics, the compression recovery property was evaluated as x when the RC value was less than 40%, ○ when the RC value was 40% or more and less than 50%, and ◎ when 50% or more.

[Flame Retardant Performance]
In accordance with JIS D 1201 “Combustion test method for organic materials for automobile interiors”, the flame retardancy was evaluated. In the test, those that were completely burned were evaluated as “x”, those that were partially burned, “Δ” that self-extinguished in the middle, and “◯” that did not burn at all.

[Surface quality of molded products]
The surface quality in the longitudinal and weft directions was visually observed from two directions perpendicular to the angle of about 10 to 20 ° with respect to the molded product. When the entire skin is wavy in an uneven state, the quality is good when viewed from the vertical direction, but the part that appears to be partially convex when viewed from the diagonal direction is △, and the vertical direction is also from the diagonal direction The case where no irregularities were seen at all was evaluated as ○.

[Texture]
A combined evaluation of sensory evaluation by hand feeling and compression stiffness: LC value in compression characteristics by a compression tester (KES-FB3, manufactured by Kato Tech Co., Ltd.) was performed. The LC value can be measured simultaneously with the compression recovery property RC value in the cushioning evaluation. And in the tactile sensation evaluation, the feeling is bad and the compression stiffness is less than 0.3 non or 0.7 non or more, and the tactile sensation evaluation is not good in touch, but the compression stiffness is not less than 0.3 non and less than 0.7 non. Although the feel is good in the sensory evaluation or the tactile sensory evaluation, the compression stiffness is less than 0.3 non or 0.7 non or more, the touch is good in the sensory sensory evaluation, the compression stiffness is 0.3 non or more and less than 0.7 non Were rated as ○.

(Abrasion resistance)
The abrasion resistance was evaluated by F method (method using a universal type testing machine) of JIS L 1076 “Pilling test method for woven fabrics and knitted fabrics”. Evaluations were made with items less than 3 ×, items 3 and 4 or less as Δ, and items over 4 as ○.

[Manufacturing cost]
It can be said that the smaller the number of steps, the lower the manufacturing cost and the lower the probability of quality defects. Therefore, among the four steps a to d shown below, the number of steps required was counted, and three or less were evaluated as ◯ and the others were evaluated as ×. a: Manufacturing process of skin material.
b: A step of laminating the skin material and the flexible urethane foam. c: Manufacturing process of lightweight cushioning material.
d: A step of bonding the skin material and the lightweight cushioning material.

  From the above results, it can be seen that all of the examples are of good quality. On the other hand, at least some of the evaluation items of the comparative example products are defective and are not practical or preferable.

It is typical explanatory drawing which shows the structure of one Example of this invention. 10 is a schematic explanatory diagram showing a configuration of Comparative Example 5. FIG. 10 is a schematic explanatory diagram showing a configuration of Comparative Example 6. FIG. It is typical explanatory drawing which shows the structure of an example of a conventional product. It is typical explanatory drawing which shows the structure of the other example of a conventional product.

Explanation of symbols

12 Base material layer 13 Pile fabric 13a Pile part 13b Non-pile part

Claims (3)

It is a molded article for vehicle interior in which a skin material is directly joined and integrated with a base material layer for interior, and the skin material is composed of a pile portion formed by the following synthetic fiber A and the following synthetic fiber B A non-pile portion formed, the total fineness of the synthetic fiber A and the synthetic fiber B is 60 to 140 dtex, the weight ratio of the synthetic fiber A and the synthetic fiber B is A> B, and the number of courses is 40 to 40 Molding for vehicle interior, characterized in that it is made of pile fabric set to 80 pieces / 2.54 cm, number of wells 35 to 65 pieces / 2.54 cm, basis weight 100 to 300 g / m ² , thickness 1 to 10 mm. Goods.
A: Synthetic fiber mainly composed of polyester, having a total fineness of 30 to 110 dtex and a single yarn fineness of 0.5 to 2.5 dtex.
B: Synthetic fiber mainly composed of polyester, having a total fineness of 30 to 110 dtex and a single yarn fineness of 1 to 5 dtex. A skin material used for a molded article for vehicle interior according to claim 1, comprising a pile part formed of the following synthetic fiber A and a non-pile part formed of the following synthetic fiber B, The sum of the fineness of fiber A and synthetic fiber B is 60 to 140 dtex, the weight ratio of synthetic fiber A and synthetic fiber B is A> B, the number of courses is 40 to 80 / 2.54 cm, and the number of wells is 35 to 65. A skin material characterized in that it is composed of a pile fabric set to a book / 2.54 cm, a basis weight of 100 to 300 g / m ² , and a thickness of 1 to 10 mm.
A: Synthetic fiber mainly composed of polyester, having a total fineness of 30 to 110 dtex and a single yarn fineness of 0.5 to 2.5 dtex.
B: Synthetic fiber mainly composed of polyester, having a total fineness of 30 to 110 dtex and a single yarn fineness of 1 to 5 dtex.   The skin material according to claim 2, wherein an average friction coefficient of a surface formed of a non-pile portion of the pile fabric is set to 0.1 to 0.4.

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