JP2008013090A - Manufacturing method of interior material and felt base material for interior material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a felt base material for an interior material having a surface skin that provides piloerection feeling and smooth feel to the touch, and a manufacturing method of the interior material used for a trunk room, a luggage room, or a seat back lining material of an automobile. <P>SOLUTION: The felt base material for the interior material has a fabric gluing layer and at least one felt body layer. The fabric gluing layer is integrated with the felt body layer, constituent fabrics are partly melted in a granular state by a preheating process, and the granularly melted elements are dispersed and bonded to the entire surface of the fabric gluing layer. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a felt base material for an interior material having a skin with good nap and feel, and relates to a method for producing an interior material used for an automobile trunk room, luggage room, seat back and the like.

  A number of interior materials are attached to automobiles. For example, in an interior material used in a trunk room or luggage room, a soft velor-like or diloer-like felt skin material is often used in order to improve touch and design. Conventionally, this skin material has been adhered to a plastic or felt sheet by spraying adhesive powder. It is desirable that this seat has a high sound absorbing property in order to reduce noise entering from the trunk room into the vehicle interior, and also has a high rigidity and formability in order to obtain a desired shape with a certain strength.

  As another example of manufacturing automobile interior materials, as shown in Japanese Patent Publication No. 7-1000034, when molten polypropylene is extruded from a T die, and a skin material is laminated on the molten sheet, it is subjected to hot press molding into a predetermined shape. , Lamination and press molding can be performed consistently, so productivity is excellent. As an example of improving this method, Japanese Patent Application Laid-Open No. 9-300514 further adheres a sound absorbing material to the back side of a plastic sheet. In JP-A-11-342801, a two-layer nonwoven fabric in which a skin material is intertwined, the first skin is a polypropylene fiber that is easily welded to a polypropylene sheet, and the second skin is a polyester having a higher melting point than the first skin. Nylon fiber is used.

Further, the present applicant has already sold an interior material obtained by hot press molding after tangling and integrating a plain type skin material and a felt sheet by needle punching. On the other hand, JP-A-11-99869 discloses a method in which a skin material layer obtained by laminating a skin on a dense layer is bonded to a base material layer of a felt sheet, and the dense layer is mainly a resin such as polyethylene or rubber. It may be a material or a fiber material.
Japanese Patent Publication No.7-100349 Japanese Patent Laid-Open No. 9-300514 JP-A-11-99869 JP-A-11-342801

  In the conventional manufacturing method for automotive interior materials, when spraying adhesive powder and bonding the skin material to the plastic sheet, the fine powder of resin often scatters at the manufacturing plant, which degrades the product quality by fouling the production line It is easy to make, and the working environment is remarkably deteriorated. In the case of hot press molding immediately after laminating a skin material on a molten polypropylene sheet, even if the productivity is good, the sound absorption and breathability of the interior material are impaired, and the polypropylene may ooze out depending on the mold.

  As for the interior material, when the heat press molding is performed after entanglement and integration of the polypropylene fiber skin material and the felt sheet, the surface temperature of the heat press at around 170 ° C. and the pressure directly act on the surface of the skin material. A part of the material melts to form a sheet, and the feel is remarkably lowered. As shown in Japanese Patent Application Laid-Open No. 11-99869, if the skin is composed of 80% normal polyester fiber and 20% heat-sealable polyester fiber, even if the melting is not noticeable, the nap of the skin is formed by hot press molding. Will fall asleep, and the touch and aesthetics will still decline.

  The present invention has been proposed to improve the above-mentioned problems associated with conventional interior materials mainly used in automobiles, and can be used for interior materials that do not affect the skin material by being able to adhere the skin material at room temperature. The object is to provide a felt substrate. Another object of the present invention is to provide a method for producing an interior material that is less prone to thermal deformation of a skin material having a nap, and that has excellent surface feel and aesthetics.

  The felt base material for interior materials according to the present invention is a felt base material capable of bonding a skin material having a feeling of napping at room temperature. This felt base material has a fiber adhesive layer and at least one felt body layer. The fiber adhesive layer is integrated with the felt body layer, and the constituent fibers are partially granular by the heat pretreatment. The granular melt is dispersed and fixed to the entire surface of the fiber adhesive layer.

In the felt base material for interior materials of the present invention, the fiber adhesive layer is preferably mainly composed of a polypropylene component or a copolymerized polyamide component. Moreover, the fiber adhesive layer is a spunbonded nonwoven fabric, and its basis weight is preferably 10 to 70 g / m ² . Desirably, the felt body layer has a multilayer structure of two or more layers, both of which are formed by needle punching a fiber wrap.

  In the interior material manufacturing method according to the present invention, at least one felt body layer is used, and a thin fiber layer is placed on the felt body layer and entangled with a needle punch. Furthermore, by subjecting the obtained felt base material to heat pretreatment at a temperature higher than the melting point of the constituent fibers of the fiber thin layer, the fiber thin layer becomes a fiber adhesive layer in which the constituent fibers are partially melted in a granular form, Next, the skin material is placed on the reheated fiber adhesive layer and formed into a desired shape by cold pressing.

  In the method of the present invention, it is also possible to place a skin material directly on a thin fiber layer and directly mold it with a cold press for a felt base material heat-treated at a temperature higher than the melting point of the constituent fibers. In this case, the felt base material may be heat-treated at a temperature higher than the melting point of the constituent fibers of the thin fiber layer, and then a skin material may be placed on the thin fiber layer and molded.

  The present invention will be described with reference to the drawings. FIG. 1 shows an example of a felt substrate 1 according to the present invention. In the felt substrate 1, the felt body layer 2 is a single layer as shown in FIG. 1 or two layers as shown in FIG. 2, and a multilayer structure of three or more layers is also possible. The thin fiber layer 3 is integrated with the felt main body layer 2 and may be laminated on both the front and back sides of the felt main body layer 2 depending on the application.

  For the felt body layer 2, synthetic and / or natural fibers are generally mixed uniformly by a well-known wrap forming method using a card machine, and then spread and laminated, but a wrap manufactured by a method other than the card method is used. It is also possible. Examples of synthetic and / or natural fibers to be used include synthetic fibers such as polyester, polypropylene, acrylic, and nylon, natural fibers such as wool and cotton, chemical fibers such as acetate, and fibers obtained by mixing these fibers. From this point, polyester fiber is preferable. This raw fiber may partially use bristles (collected recycled cotton).

  When blending the raw material fibers, it is possible to add an appropriate amount of heat-fusible fibers having a melting point of about 40 to 70 ° C. or lower than the fibers. Addition of heat-fusible fibers makes it easier to form a three-dimensional shape when the obtained felt main body layer 2 is heat-treated. Examples of the heat-fusible fiber include low-melting point polyester fiber, low-melting point polyamide, polyethylene, and polypropylene, and may be a copolymer with ethylene or butene. As long as the heat-fusible fiber has a lower melting point than that of a normal fiber, a known fiber, a resin filament, or a mixture thereof having a melting point of 90 to 170 ° C. can be used. A composite fiber may be used.

  As illustrated in FIG. 2 or FIG. 4, the felt body layer 2 can have a multilayer structure of two or more layers in which fiber wraps are needle punched. When the felt body layer is composed of two layers, generally, the amount of heat-fusible fiber added in the intermediate layer 5 is increased as compared with the outer layer 7 to improve the moldability of the felt body layer 2 and the overall elasticity. Is preferable. Moreover, when the felt main body layer is three or more layers, a layer for improving air permeability and a layer for improving heat insulation are interposed.

Felt body layer 2 is formed by needle punching the desired fiber wrap, this needle punching, needle density of 20 to 200 present / cm ² preferably 80 to 150 present / cm ² using a conventional locking needle To do. When the felt main body layer is two layers, needle punching is performed for each layer, the intermediate layer 5 is usually performed at a needle density of 50 to 200 needles / cm ² , and the needle density is increased as compared with the outer layer 7 and felt. It is preferable to increase the rigidity of the main body layer 2.

The felt body layer 2 preferably has a thickness of 1 to 10 mm and a basis weight of 300 to 1500 g / m ² as a whole. If the thickness of the felt body layer 2 is less than 1 mm, predetermined moldability and rigidity cannot be obtained, and if the thickness exceeds 10 mm, the quality is not improved, which is uneconomical. Further, if the basis weight is less than 300 g / m ² , the predetermined moldability and rigidity cannot be obtained, and if it exceeds 1500 g / m ² , it becomes too heavy and hinders the weight reduction of the automobile.

The upper thin fiber layer 3 needs to be integrated with the felt main body layer 2 by an arbitrary method, and is normally intertwined and integrated by a needle punch as is apparent from FIG. When integrating with a needle punch, needle punching is performed from above and below using a normal rocking needle, preferably at a needle depth of 6 to 16 mm and a needle density of 20 to 100 / cm ² . When the needle depth is 6 mm and the needle density is less than 100 / cm ² , the fiber adhesive layer 8 is easily peeled off, and when the needle depth is 16 mm and the needle density exceeds 100 / cm ² , the adhesive property at the time of melting. Is unfavorable because it decreases.

The fiber thin layer 3 preferably has a basis weight of 10 to 70 g / m ² . Cost The basis weight is difficult to obtain a predetermined adhesive is less than 10 g / m ^2, whereas, adhesion even exceed 70 g / m ² is not improved, the felt base material 1 becomes heavy Only rises.

  As is clear from the photograph of FIG. 3, the fiber thin layer 3 needs to be partially melted by heating pretreatment at 150 to 200 ° C., and for this purpose, a polypropylene component or copolymer polyamide that can be melted at that temperature. It is desirable that the main component is a component or the like, and some other fibers may be included. The fiber thin layer 3 is generally a spunbond nonwoven fabric, needle punched nonwoven fabric, woven fabric or knitted fabric having a thickness of 0.1 to 0.5 mm, and a spunbond nonwoven fabric of polypropylene fibers is particularly preferable.

  The fiber adhesive layer 8 (FIG. 3) is formed by pre-heating the felt substrate 1 as shown in FIG. For example, the felt base material 1 is run at a processing temperature of 150 to 240 ° C., preferably 170 to 210 ° C. at a processing speed of 8.5 m / min. After performing 15, the felt base material 1 having the fiber adhesive layer 8 is wound up. In the fiber adhesive layer 8, the constituent fibers in the fiber thin layer 3 are partially melted in a granular form, and the granular melt 12 is dispersed and fixed to the entire surface of the fiber adhesive layer 8.

  When the felt base material 1 is reheated at 160 to 220 ° C., the fiber adhesive layer 8 melts the surface in a shorter heating time than the original fiber thin layer 3 and firmly adheres the skin material 14 (FIG. 4). Is possible. In addition, if this felt base material is heat-treated at a temperature higher than the melting point of the constituent fibers of the fiber thin layer 3 for a slightly longer time than the pre-heating treatment, the surface of the fiber thin layer is melted, and the fiber adhesive layer 8 is It is also possible to directly bond the skin material 14 without going through.

  The felt base material 1 is pre-heated in FIG. 6 and then formed into a desired shape with a cold press 16 or other forming machine as shown in FIG. For example, in the cold press 16, the cushion felt 20 is laid on the lower plate 18, and the skin material 14 is set face down. On the other hand, the felt base material 1 is reheated at 160 to 240 ° C. for 1 minute in an oven (not shown), then taken out from the oven, and the outer surface of the melt is the fiber adhesive layer 8 (or the fiber thin layer 3) facing down. The material 14 is placed. By pressing with the upper plate 22 of the cold press 16, the interior material 24 (FIG. 4) can be obtained and simultaneously formed into a desired sheet shape or three-dimensional shape.

  When the interior material 24 is molded into a three-dimensional shape as illustrated in FIG. 8, it can be attached to the trunk room 28 or the luggage room of the automobile 26. Examples of places where this interior material can be attached include the back of the seat in a car, the kerchits that are both sides of the seat, and the trim lower that is inside and below the door, as well as the car tray trim, station wagon, and van. It may be used for quarter trim and rear floor.

  The felt base material for interior material according to the present invention may be heated alone and fed into a cold press or the like, and can be formed into a desired shape at the same time that the skin material is bonded to the felt base material at room temperature. The felt base material for interior materials according to the present invention can be molded by cold pressing, so that the surface of the skin material is not heated / pressurized, and does not affect the skin material during the bonding / molding process. Interior material that retains the color and the feeling of napping can be obtained.

  Since the interior material manufactured by the method of the present invention is cold-formed during molding, the outer skin material has a color and a raised feeling at the time of production, and also has a cushioning property, and retains its feel and aesthetics. Yes. This interior material has a good feeling of nap and touch of the skin, and is suitable for use in a trunk room or luggage room. In addition, this interior material can be easily fitted to the seat frame when cutting and sewing and assembling on the back of the seat, etc., and can prevent wrinkles from occurring in the corner portion of the seat. It is possible to attach a sound absorbing material on the back side of this interior material, so that the surface will not be torn during sewing or assembly of the seat, and when the automobile is discarded and incinerated, it will be a source of pollution from the interior material. No toxic gases such as chlorine gas are generated.

Next, the present invention will be described based on examples, but the present invention is not limited to the examples. In order to produce the felt base material 1 shown in FIG. 2, as the outer layer 7 of the felt main body layer 2, 60% normal polyethylene terephthalate fiber having a fineness of 17 dtex and 40% low-melting polyester fiber having a fineness of 4.4 dtex And needle felt having a basis weight of 720 g / m ² was obtained by needle punching. As the intermediate layer 5, a needle felt having a fineness of 4.4 dtex and a low melting point polyester fiber of 100% and a basis weight of 150 g / m ² was obtained.

The intermediate layer 5 and the outer layer 7 are overlapped, and a polypropylene spunbond nonwoven fabric having a basis weight of 30 g / m ² is overlapped on the intermediate layer as the fiber thin layer 3. The needle punch was applied to the whole, and 3 layers were compounded integrally. Furthermore, the composite felt base material 1 was pre-heated at 180 ° C. for 2 minutes as shown in FIG. 6 to obtain the felt base material 1 having the fiber adhesive layer 8. The spunbonded nonwoven fabric that is the fiber adhesive layer 8 was melted in a granular form on the surface of the substrate as shown in the photograph of FIG. 3, and the granular melt 12 was dispersed and fixed.

  As shown in FIG. 7, when the felt base material 1 and the skin material 14 having a feeling of napping are bonded and simultaneously formed, only the felt base material 1 is reheated at 200 ° C. for 1 minute, and the fiber adhesive layer 8 And the skin material 14 and the back surface were superposed and bonded, and at the same time, the skin material 14 was molded by a molding die. The obtained interior material 24, which is a molded product, maintained the feeling of napping of the skin, and the adhesion between the felt base material 1 and the skin material 14 was sufficient, and there was no problem with moldability.

The felt body layer 2 includes 30% of ordinary polyethylene terephthalate fiber having a fineness of 17 dtex, 40% of recycled polypropylene fiber having a fineness of 3.3 to 11.6 dtex, and 30% of low melting point polyester fiber having a fineness of 4.4 dtex. And a needle felt having a basis weight of 870 g / m ² was obtained by needle punching. Moreover, as the fiber thin layer 3, a spunbond nonwoven fabric made of polypropylene having a basis weight of 30 g / m ² was overlapped, and both layers were integrally combined by needle punch.

  Subsequently, the composite felt base material 1 was pre-heated at 180 ° C. for 2 minutes to obtain a felt base material 1 having a fiber adhesive layer 8. When this felt base material 1 was reheated and molded in the same manner as in Example 1, it was possible to obtain an interior material 24 that was a molded product that had a sufficient adhesion and maintained the nap feeling of the skin. did it.

In Example 1, it processed similarly except having used the polyamide adhesion nonwoven fabric of 30 g / m < ² > of fabric weights instead of the polypropylene spunbond nonwoven fabric, and the felt base material 1 which has the fiber contact bonding layer 8 was obtained. When this felt base material 1 was reheated and subjected to molding processing, it was possible to obtain an interior material 24 that was a molded product that maintained the nap feeling of the skin and had sufficient adhesion as in Example 1. did it.

Comparative Example 1
A molding substrate was obtained in the same manner as in Example 1 except that heat treatment was not performed at 180 ° C. for 2 minutes. Molding was performed at the same temperature and time as in Example 1, but the adhesion between the skin material and the molding substrate was insufficient. At this time, when the molding process was performed for a longer time than in Example 1, the skin material and the molding substrate were sufficiently bonded, but the feeling of napping of the skin was somewhat impaired.

Comparative Example 2
In Example 3, the needle felt of the base material layer and the polyamide-bonded nonwoven fabric were superposed and heat-treated at 180 ° C. for 2 minutes without needle punching. In the obtained base material for molding, the polyamide as the fiber adhesive layer was not sufficiently fixed on the surface of the base material layer, and spilled off when touched by hand.

Comparative Example 3
About the felt main body layer which consists of a needle felt of Example 2, the molded article was produced simultaneously with the skin material by press molding using polyethylene powder. The obtained molded product had a poor design property due to the loss of nap in the skin due to heat during molding, and the working environment was deteriorated by the scattered powder.

It is a schematic sectional drawing which expands and shows the felt base material for interior materials which concerns on this invention. It is an expanded sectional view which shows the modification of this invention. It is a 50 times magnified photograph which shows the fiber adhesion layer surface of the felt base material at the time of heat processing. It is an expanded sectional view showing an example of the interior material manufactured by the method of the present invention. It is a schematic side view which shows the manufacturing process of a felt base material. It is a schematic side view which shows the formation process of a fiber contact bonding layer about a felt base material. It is a schematic side view which shows the cold press used for shaping | molding of a felt base material. It is a fragmentary sectional view which shows the rear part of the motor vehicle which is the usage example of an interior material.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Felt base material for interior material 2 Felt main body layer 3 Fiber thin layer 5 Intermediate layer 7 Outer layer 8 Fiber adhesive layer 12 Granular melt 14 Skin material 24 Interior material

Claims (6)

  A felt base material capable of adhering a skin material having a nap feeling at room temperature, comprising a fiber adhesive layer and at least one felt body layer, wherein the fiber adhesive layer is integrated with the felt body layer. And a felt base material for interior materials in which the constituent fibers are partially melted in a granular form by heating pretreatment, and the granular melt is dispersed and fixed to the entire surface of the fiber adhesive layer.   The felt base material according to claim 1, wherein the fiber adhesive layer mainly comprises a polypropylene component or a copolymerized polyamide component. Bonded fiber layers is a spunbonded nonwoven, according to claim 1 or 2 felt substrate according its basis weight is 10~70g / m ^2.   The felt base material according to claim 1, wherein the felt body layer has a multilayer structure of two or more layers, both of which are formed by needle punching a fiber wrap.   Using at least one felt body layer, a thin fiber layer is placed on the felt body layer and entangled and integrated with a needle punch. From the melting point of the constituent fibers of the thin fiber layer, the obtained felt base material is obtained. The fiber thin layer becomes a fiber adhesive layer in which the constituent fibers are partially melted in a granular form by heating pretreatment at a higher temperature, and then the skin material is placed on the reheated fiber adhesive layer and cooled. A method of manufacturing interior materials that are molded into a desired shape by hot pressing.   The manufacturing method according to claim 5, wherein the felt base material is heat-treated at a temperature higher than the melting point of the constituent fibers of the thin fiber layer, and then a skin material is placed on the thin fiber layer and molded.

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