JP2007145280A - Vehicular interior material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a vehicular interior material with superior environment property, high rigidity, light weight and superior molding workability in which there is no fear that a glass fiber is scattered at overhauling of the vehicle. <P>SOLUTION: The vehicular interior material is constituted by a film, a net-like knitted article and a hard polyurethane foam. Further, the net-like knitted article is arranged between the hard polyurethane foam and the film. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a vehicle interior material.

  The vehicle interior material is required to have good decorativeness and touch feeling. In particular, a vehicle interior material used as a ceiling material needs rigidity and light weight in order to be stretched on the ceiling. Conventionally, a composite of a rigid fiber such as glass fiber and a resin such as polyurethane foam has been used so as to satisfy these requirements. As such a composite, for example, JP-A-4-21416 discloses a molded part for an automobile in which a polyurethane foam is sandwiched between two glass fibers and one side is covered with a film. Japanese Examined Patent Publication No. 63-7777 discloses a composite panel for the automobile industry having a structure of polyethylene sheet / glass fiber / polyurethane / glass fiber / polyethylene sheet.

  In the first place, glass fiber is a fibrous inorganic fiber, which stimulates the skin during handling, so that workability is poor and the trim mold used for trimming is easily worn. In addition, highly irritating glass fibers are scattered at the time of dismantling of automobiles and are incombustible when incinerated as waste, and there is a problem in waste disposal by sticking to the furnace wall. In addition, asbestos (asbestos), which is a fibrous inorganic fiber, has a problem of carcinogenicity, and there is a very high level of concern about the fibrous inorganic fiber not only from the manufacturing environment but also from the aspect of the living environment. Alternative material technology that eliminates the use of glass fibers has been strongly expected.

JP-A-4-21416 Japanese Examined Patent Publication No. 63-7777

  An object of the present invention is to provide an interior material for a vehicle that is excellent in working environment, has high rigidity, is light in weight, and has excellent molding processability without fear of scattering of glass fibers when the vehicle is disassembled.

  That is, the present invention is a vehicle interior material composed of a film, a net-like knitted fabric, and a rigid polyurethane foam.

  ADVANTAGE OF THE INVENTION According to this invention, there is no fear that glass fiber may be scattered at the time of vehicle disassembly, it is possible to provide an interior material for a vehicle that is excellent in work environment, has high rigidity, is light, and has excellent moldability.

Hereinafter, embodiments of the present invention will be described in detail.
[Net-like woven / knitted fabric]
As the net-like woven / knitted fabric, a net-like woven / knitted fabric made of synthetic fibers is used. As long as it is a net-like woven or knitted fabric, it may be a woven fabric or a knitted fabric. Preferably, a woven fabric with open eyes is used. As synthetic fibers constituting the net-like woven or knitted fabric, for example, polyester fibers, nylon fibers, vinylon fibers, aramid fibers, and polyolefin fibers can be used. These synthetic fibers are preferably long fibers, particularly long fiber yarns having a total thickness of 150 to 2000 dt.

As the open woven fabric of the net-like woven or knitted fabric, a woven fabric made of multifilament, monofilament or spun yarn is preferably used. The fiber spacing of the synthetic fibers in this fabric is preferably 1 to 20 mm in order to ensure rigidity. In other words, it is preferable to use a woven fabric having an opening of 1 to 20 mm as the net-like woven or knitted fabric. If the mesh opening is less than 1 mm, the basis weight may be unnecessarily high, which is not preferable, and if it exceeds 20 mm, the effect of improving the rigidity may be insufficient. The weight per unit area of the net-like woven / knitted fabric, that is, the basis weight, is preferably 5 to 200 g / m ² , more preferably 30 to 120 g / m ² . If it is less than 5 g / m ² , the rigidity tends to be inferior, and if it exceeds 200 g / m ² , the lightness tends to be impaired.

  The net-like knitted and knitted fabric is constituted by combining long fiber yarns arranged in at least two axial directions of the fiber structure. For example, long fiber yarns arranged in biaxial, triaxial, or tetraaxial directions or more according to the required direction of reinforcement may be used. As a method for arranging long fiber yarns, a net-like woven fabric or knitted fabric is generally used. However, in order to maximize the effects of the present invention, a plurality of long fiber yarns may be used without knitting. It is preferable to use a braided fabric structure that is overlapped in the axial direction because the spacing between the filaments can be freely selected and the elongation can be reduced. A net-like woven or knitted fabric having this braid structure is preferably integrated with a synthetic resin because a high reinforcing effect can be obtained and the handleability is excellent.

  The net-shaped knitted or knitted fabric may be coated and impregnated with a synthetic resin when processed into a net shape. Thereby, accumulation | storage of the water | moisture content in the convergence part of fiber, a cross | intersection part, or a single fiber can be prevented, and the fall of the interlayer contact | adhesion force by external temperature change can be suppressed. As a synthetic resin used for coating / impregnation, for example, an acrylate resin, an epoxy resin, a urethane resin, or a polyvinyl alcohol resin can be used.

[the film]
In the present invention, a film made of a synthetic resin is used as the film. For example, a synthetic resin film such as olefin, nylon, or polyester can be used.
The thickness of the film is, for example, 10 to 250 μm, preferably 20 to 200 μm, and more preferably 50 to 188 μm. If it is thinner than 10 μm, sufficient rigidity will not be obtained after molding, and if it exceeds 250 μm, wrinkles are likely to occur during molding.
Hereinafter, the case where a polyester film is used as the film will be described as an example.

  Examples of the main repeating unit of the polyester film include ethylene terephthalate, tetramethylene terephthalate, ethylene-2,6-naphthalate, and tetramethylene-2,6-naphthalate. Among these, a polyester having an ethylene terephthalate unit as a main constituent component is preferable because it can maintain good mold followability, adhesion, and corrosion resistance even after heat history. Here, “the ethylene terephthalate unit is a main constituent” means that the terephthalic acid component is at least 75 mol% of the total dicarboxylic acid component and the ethylene glycol component is at least 75 mol% of the total diol component.

  As the polyester film, it is preferable to use a biaxially stretched film rather than an unstretched film because of high heat resistance and strength and high rigidity after bonding. The plane orientation coefficient of the biaxially stretched polyester film is preferably 0.05 to 0.16, more preferably 0.06 to 0.15, and particularly preferably 0.07 to 0.14. When the plane orientation coefficient is less than 0.05, the rigidity and heat resistance of the film are likely to be inferior, which is not preferable. If it exceeds 0.16, the moldability of the film may deteriorate, which is not preferable.

  The polyester film preferably has a melting point of 210 to 270 ° C. because of its high heat resistance and moldability. As the polyester, a mixture of two or more kinds of polyesters may be used. In this case, if two or more melting points are measured, the melting point on the high temperature side is preferably 210 to 270 ° C.

  As a copolymerization component of the copolymerized polyethylene terephthalate, diphthalic acid components such as isophthalic acid, orthophthalic acid, 2,6-naphthalenedicarboxylic acid, 2,7-naphthalenedicarboxylic acid, 1,4-naphthalenedicarboxylic acid, 4,4 ′ As preferred diol components, such as aromatic dicarboxylic acid components such as biphenylene dicarboxylic acid, alicyclic dicarboxylic acid components such as cyclohexane-1,4-dicarboxylic acid, and aliphatic dicarboxylic acid components such as succinic acid, adipic acid, and sebacic acid Are aliphatic diol components such as propylene glycol, trimethylene glycol, tetramethylene glycol and neopentyl glycol, alicyclic diol components such as cyclohexane-1,4-dimethanol, aromatic diol components such as bisphenol A, diethylene glycol Ether-condensed diol components such as polyethylene glycol, polytetramethylene glycol and the like, and preferred components other than dicarboxylic acid and diol components include p-hydroxybenzoic acid, ω-hydroxybutyric acid, ω-hydroxyvaleric acid, lactic acid, etc. And a tricarboxylic acid component such as trimellitic acid, pyromellitic acid, and glycerin. Among these, isophthalic acid, 2,6-naphthalenedicarboxylic acid or neopentyl glycol, cyclohexane- from the ease of exhibiting various properties, the availability of raw materials, the ease of production of copolymerized polyesters, and the like. 1,4-dimethanol and diethylene glycol are particularly preferred. The ratio of these copolymer components may be adjusted so that the melting point of the copolymer polyester is in the range of 210 to 270 ° C. For example, when isophthalic acid is copolymerized with polyethylene terephthalate, The proportion of isophthalic acid occupied is preferably in the range of approximately 0 to 18 mol%.

  The polyester film may be a single layer film or a laminated film composed of two or more layers. In the case of a laminated film, it is preferable that the layer made of the copolyester is 50% or more of the total thickness. The other layers of the copolymer polyester may be made of homopolyethylene terephthalate or may be made of another copolymer polyester.

It is preferable that the polyester film contains particles having an average particle diameter of 2.5 μm or less because appropriate slipperiness can be obtained, and as a result, the handleability and molding processability of the film are excellent. Examples of the particles include inorganic fine particles such as silica, alumina, titanium oxide, calcium carbonate, and kaolin, precipitated fine particles of catalyst residues, and / or organic fine particles such as silicone, polystyrene cross-linked product, and acrylic cross-linked product.
In addition to the above-described particles, various additives such as a stabilizer, an antistatic agent, a dye, a pigment, and a flame retardant may be contained within a range not impairing the effects of the present invention.

  The polyester film may be transparent or concealed. When concealing properties are imparted, suitable particles can be added, foamed by adding incompatible components, or a concealing layer can be provided by coating or printing a paint. In this case, suitable particles for blending are titanium oxide, barium sulfate and zinc sulfide. As the incompatible component, for example, when the film is polyester, a polyolefin compound such as trimethylpentene or polypropylene can be used. In the case of coating or printing, an organic paint such as acrylic, polyurethane, or polyester containing the above-described particles and an appropriate organic solvent or aqueous solvent may be used.

[Rigid polyurethane foam]
As the rigid polyurethane foam in the present invention, it is excellent in heat insulation, and those conventionally used for vehicle interior materials can be used as they are. Of the rigid polyurethane foams, ether-based polyurethane foams obtained using polyether polyols are preferred because they are difficult to hydrolyze.

The density of the polyurethane foam is preferably 5 to 50 kg / m ³ , more preferably 7 to 40 kg / m ³ , and particularly preferably 10 to ³⁰ kg / m ³ . If the density is less than 10 kg / m ³ , the rigidity tends to be poor, and if it exceeds 60 kg / m ³ , the lightness is impaired, which is not preferable.

  The thickness of the rigid polyurethane foam is preferably 3 to 20 mm, more preferably 4 to 15 mm, and particularly preferably 5 to 10 mm. If it is less than 3 mm, the rigidity tends to be inferior, and if it exceeds 20 mm, the lightness is impaired.

[Paste]
The automobile interior material of the present invention preferably has a configuration in which a net-like woven or knitted fabric is disposed between a rigid polyurethane foam and a film. For example, a configuration of film / net woven / rigid polyurethane foam (/ skin), film / net woven / rigid polyurethane foam / net woven / polyurethane foam / net woven knitted (/ skin) is preferable.

  The automobile interior material of the present invention can be manufactured by laminating a film, a net-like knitted fabric, and a rigid polyurethane foam. Bonding may be performed when creating a rigid polyurethane foam, may be performed when heat treatment is performed in a separate process, or may be performed when molding a skin material, a base material, or a back surface material. Good.

  In pasting, the film, the net-like knitted fabric, and the rigid polyurethane foam may each be a single layer, or any of them may be a multilayer, or some may be a multilayer. A structure in which a rigid polyurethane foam is sandwiched between films may be used, and it is preferable that at least one layer in which a net-like woven or knitted fabric is sandwiched between the film and the rigid polyurethane foam is provided.

In some cases, it is possible to use the same material without using an adhesive, and bonding can be done only by thermocompression bonding, but various adhesives are used on one or both sides when creating or bonding rigid polyurethane foam. By doing so, stronger adhesion becomes possible. As an adhesive, a thermosetting adhesive such as an epoxy resin, an isocyanate resin, or a diallyl phthalate resin, a thermoplastic adhesive having a melting point of 100 to 160 ° C., or an adhesive using these adhesive polymers is used. Sheets are preferred. Basis weight of these adhesives or adhesive sheet is preferably 20 to 100 g / ^{m 2,} more preferably 30 to 80 g / ^{m 2,} particularly preferably 40 to 60 g / ^{m 2.}

[Skin material]
A skin material may be provided on the surface of the vehicle interior material of the present invention. As a skin material, what has air permeability is good, and specifically, a nonwoven fabric or a woven fabric made of polyester fiber, polypropylene fiber or the like, a knit, or a raised knit can be exemplified. Of these, polyester fibers are preferable.
The automotive interior material of the present invention may be added with known functional processing such as water repellent processing, flameproof processing, flame retardant processing, and negative ion generation processing.

  Hereinafter, the present invention will be described in more detail with reference to examples. The characteristics were measured and evaluated by the following methods.

(1) Melting Point Using a scanning differential thermal analyzer type 910 manufactured by Du Pont Instruments, a sample amount of 20 mg was measured at a heating rate of 20 ° C./min, and the endothermic peak temperature was taken as the melting point.

(2) Plane orientation factor Plane orientation factor obtained from the refractive index in the longitudinal direction, width direction, and thickness direction (nMD, nTD, and nZ, respectively) using an Abbe refractometer with sodium D line (wavelength 589 nm) as a light source Ns = (nMD + nTD) / 2−nZ was calculated and obtained.

(3) Fiber fineness It measured by the method as described in JIS L 1015 7.5.1 A method.

(4) Bending strength of laminate Using a test piece having a size of 50 mm (width) x 150 mm (length) according to JIS K7203, with a bending speed of 10 mm / min at a span of 100 mm, The maximum bending strength was measured and evaluated according to the following criteria.
○: 20N or more Δ: 15N or more, less than 20N ×: less than 15N

(5) Heat resistance Three horizontal 50 × 250 mm test pieces were cut out from the vertical and horizontal directions of the base material, fixed 50 mm with the polyurethane foam side down, and overhanged 200 mm. After leaving it in a hot air drying oven at 80 ° C. for 24 hours, it was taken out from the drying oven, the amount of sagging at the tip when the substrate was at room temperature was measured to obtain an average value, and evaluated according to the following criteria.
○: Less than 10 mm Δ: 10 mm or more, less than 30 mm ×: 30 mm or more

(6) Molding workability An adhesive spunbond sheet and a skin material are laminated on a film and polyurethane foam, and the skin material is pressed for 180 seconds using a 10 mm thick spacer in a press set at 150 ° C. A vehicle interior material in which the base material / back surface material was laminated and integrated was produced. The film surface was heat-drawn at 160 ° C. for 180 seconds with the film surface inside, and formed into a case having an inner diameter of 60 mm × height of 20 mm × thickness of 5 mm. The appearance of the film in the trunk of this case was observed and evaluated according to the following criteria.
○: No change in appearance.
Δ: Some peeling of the film is observed and / or the film is not peeled, but whitening is observed in the film.
X: Remarkable peeling of the film is observed.

[Example 1]
Polyethylene (terephthalate-isophthalate) copolymer (terephthalic acid (TA) component / isophthalic acid (IA) component molar ratio) of an intrinsic viscosity of 0.65 (measured in o-chlorophenol at 35 ° C., the same applies hereinafter) = 88/12) pellets (containing 0.1% by weight of spherical silica particles having an average particle size of 1.5 μm) were supplied to an extruder and melt-extruded on a rotating cooling drum maintained at 20 ° C. to obtain an unstretched film Got. Next, the unstretched film is stretched 3.0 times in the MD direction, both ends along the MD direction of the unstretched film are gripped and stretched 3.2 times in the TD direction, and the both ends are gripped. While being given 5% relaxation in the TD direction, heat treatment was performed at 190 ° C. to obtain a biaxially stretched polyester film having a thickness of 100 μm. The film had a melting point of 228 ° C. and a plane orientation coefficient of 0.113. Next, warps and wefts having a fineness of 1300 dtex using 192 filaments of polyethylene terephthalate resin having a single fiber fineness of 6 dtex were prepared, and these were impregnated with an acrylic resin and coated at 90 ° C. in a biaxial direction. A net-like woven or knitted fabric with a fiber spacing of 5 mm was prepared. The basis weight was 60 g / m ² . Further, an adhesive sheet having a basis weight of 40 g / m ^{2 made} of a thermoplastic copolymer polyester having a melting point of 110 ° C. was used as the adhesive sheet. On the other hand, a polyether foam having a density of 25 kg / m ³ and a thickness of 6 mm was used as the rigid polyurethane foam.

  Next, film, net-like knitted fabric, adhesive sheet, and polyurethane foam are stacked in this order, and press processing is performed with a hot press machine so that the thickness is 5 mm at 150 ° C for 5 minutes on a flat plate. And car interior material was obtained. The obtained automobile interior material had a bending strength of 23 N and a heat resistance of 7 mm. The evaluation results are shown in Table 1.

[Example 2]
An automobile inner layer material was produced in the same manner as in Example 1 except that the thickness of the film was 188 μm. The obtained automobile interior material had a bending strength of 27 N and a heat resistance of 4 mm. The evaluation results are shown in Table 1.

[Example 3]
The composition is in the order of film, net-like woven / knitted fabric, adhesive sheet, polyurethane foam, adhesive sheet, net-like woven / knitted fabric, the thickness of the film is 50 μm, and the rigid polyurethane foam has a density of 15 kg / m ³ and a thickness of 6 mm. A car interior material was manufactured in the same manner as in Example 1 except that a Teflon (registered trademark) sheet for preventing fusion was applied and pressure-processed, and the sheet was peeled and removed. The obtained automobile interior material had a bending strength of 32 N and a heat resistance of 2 mm. The evaluation results are shown in Table 1.

[Example 4]
The net-like woven or knitted fabric is made of warp and weft having a fineness of 1500 dtex using 72 filaments of single fiber fineness of 20 dtex made of polyethylene terephthalate resin, and these are plain woven (weight per unit area 70 g / m ² ), and the fiber spacing is 5 mm. An automobile interior material was manufactured in the same manner as in Example 1 except that the net-like woven / knitted fabric was changed. The obtained automobile interior material had a bending strength of 21 N and a heat resistance of 9 mm. The evaluation results are shown in Table 1.

[Comparative Example 1]
An automobile interior material was manufactured in the same manner as in Example 1 except that the net-like woven / knitted fabric was not used. The obtained automobile interior material had a bending strength of 9 N and a heat resistance of 19 mm. The evaluation results are shown in Table 1.

[Comparative Example 2]
An automobile interior material was produced in the same manner as in Example 1 except that no film was used. In order for the adhesive sheet to cause fusion in the press machine, a Teflon (registered trademark) sheet was sandwiched between the press machine and the sample. The obtained automobile interior material had a bending strength of 6 N and a heat resistance of 36 mm. These evaluation results are shown in Table 1.

[Reference Example 1]
Car interior material in the same manner as in Example 1 except that the film contains 0.1% by weight of spherical silica particles having an intrinsic viscosity of 0.65 and an average particle diameter of 1.5 μm, and is changed to unstretched polyethylene terephthalate having a thickness of 188 μm. Manufactured. The obtained automobile interior material had a bending strength of 17 N and a heat resistance of 31 mm. The evaluation results are shown in Table 1.

[Comparative Example 3]
A net-like woven or knitted fabric is made of warp and weft having a fineness of 1500 dtex using 72 filaments made of polyethylene terephthalate resin and having a single-fiber fineness of 20 dtex. An automobile interior material was manufactured in the same manner as in Example 1 except that the amount was changed to 7 g / m ² ). The obtained automobile interior material had a bending strength of 13 N and a heat resistance of 15 mm. The evaluation results are shown in Table 1.

[Reference Example 2]
A rotating cooling drum in which the film was supplied to an extruder with polyethylene terephthalate pellets (containing 0.1% by weight of spherical silica particles having an average particle diameter of 1.5 μm) having an intrinsic viscosity of 0.65 and maintained at 20 ° C. An unstretched film was obtained by melt extrusion. Next, the unstretched film is stretched 3.6 times in the MD direction, both ends along the MD direction of the unstretched film are gripped and stretched 3.9 times in the TD direction, and the both ends are gripped. While being given 3% relaxation in the TD direction, heat treatment was performed at 235 ° C. to obtain a biaxially stretched polyester film having a thickness of 100 μm. The film had a melting point of 257 ° C. and a plane orientation coefficient of 0.165. The procedure was the same as Example 1 except that this film was used. The obtained sample had a bending strength of 27 N and a heat resistance of 5 mm. These evaluation results are shown in Table 1.

  The vehicle interior material of the present invention can be used as a vehicle interior material such as a molded ceiling, a door trim, a quarter trim, a package tray trim, and a floor mat.

Claims (4)

  Vehicle interior material composed of film, net-like knitted fabric and rigid polyurethane foam.   The vehicle interior material according to claim 1, wherein the net-like woven or knitted fabric is disposed between the rigid polyurethane foam and the film.   The vehicle interior material according to claim 1 or 2, wherein the fiber spacing of the net-like woven or knitted fabric is 1 to 20 mm.   The vehicle interior material according to any one of claims 1 to 3, wherein the film and the net-like woven / knitted fabric are made of polyester.