JP2009120060A - Foamed laminated sheet for automobile interior material and automobile interior material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a light and rigid foamed sheet for automobile interior material, structured of only plastic material without using an inorganic material, and having superior sound absorbing performance, isotropic dimensional stability, and environmental adaptability, and also to provide an automobile interior material using the same. <P>SOLUTION: This foamed laminated sheet is formed by laminating a non-foamed layer having a non-crystal thermoplastic resin as a base material resin on both surfaces of a continuous open cell foam layer having a heat resistant resin as a base material resin. At least the non-foamed layer on the interior side is formed by laminating a non-woven fabric having 50 g/m<SP>2</SP>or less of basis weight comprising a non-melting organic fiber and a crystal resin film. Then, a hole is provided from the surface of an interior side laminated body to the foamed layer. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a foam laminated sheet for automobile interior materials and an automobile interior material using the sheet. More specifically, the present invention relates to a foam sheet for automobile interior material that is lightweight, highly rigid, and further excellent in sound absorption and dimensional stability, and an automobile interior material using the sheet.

  In order to ensure the quietness in the automobile, it is one of the important qualities to impart sound absorption to the automobile interior material. In recent years, the use of an open-cell foamed sheet as a base material has been activated in order to impart sound absorption characteristics to automobile interior materials, due to market demands for further weight reduction of automobiles (for example, Patent Document 1).

  Further, there is a strict requirement for dimensional stability for automobile interior materials, particularly automobile ceiling materials. In order to satisfy this requirement, glass fiber is generally used (for example, Patent Document 2). However, when glass fiber is used, there arises a problem of waste disposal, and in recent years, there is a tendency to be avoided from the viewpoint of environmental problems.

  Therefore, in consideration of environmental compatibility, in order to improve dimensional stability (suppression of the linear expansion coefficient), studies have been made by combining an organic fiber nonwoven fabric and a resin (for example, Patent Document 3). However, in these studies, there is room for improvement in the anisotropy related to the linear expansion coefficient, and it is necessary to design a mold that pays attention to the magnitude of this anisotropy when used as an automobile interior material. .

As described above, no materials that satisfy all of these market requirements have been found, satisfying practical characteristics, excellent sound absorption, glass-free, low linear expansion, low anisotropy, and The emergence of lightweight and inexpensive new automotive interior materials is awaited.
JP 2005-88873 A Japanese Patent Application Laid-Open No. 60-113747 JP 2005-199891 A

  It is an object of the present invention to provide a foam laminated sheet for automobile interior materials that is excellent in lightness, heat resistance, dimensional stability, and quietness in a vehicle, and an automobile interior material using the sheet. To do.

As a result of intensive studies to solve the above-mentioned problems, the present inventor has made a foam lamination for automobile interior materials in which a non-foamed layer using an amorphous thermoplastic resin as a base resin is laminated on both sides of an open-cell foamed layer. In the sheet, the following was found and the present invention was achieved.
(1) A non-woven fabric obtained by subjecting at least the indoor non-foamed layer of the non-foamed layer made of an amorphous thermoplastic resin to a cross-web capable of adjusting the fiber orientation by high-pressure columnar water flow processing or needling processing. And anisotropy in the coefficient of linear expansion of the resulting automobile interior material can be improved by laminating the crystalline resin film.
(2) By using non-melting organic fibers as the fibers constituting the nonwoven fabric, the linear expansion coefficient calculated by the dimensional change of the automobile interior material at 0 ° C. to 80 ° C. can be reduced.
(3) The melting point of the crystalline resin film laminated on the non-foamed layer is 130 ° C. or less, which is assumed to be the lower limit of the heating temperature during molding, and the constituent fibers of the nonwoven fabric are mainly included in the crystalline resin film. This reduces the internal strain that occurs during molding and reduces the deformation of the molded body that occurs when placed under high temperatures.
As will be described later, by using a crystalline resin film, there is a possibility that the dimensional stability is inferior due to crystal shrinkage or the like, but the rigidity of the crystalline resin film having a melting point of 130 ° C. or less is the present invention. Since it is overwhelmingly lower than the rigidity of the amorphous resin, it is possible to ignore the influence of crystal shrinkage of the crystalline resin film.
(4) By forming a hole that reaches the inside of the foamed layer from one non-foamed layer surface side, it is possible to effectively utilize the open cell part to provide high sound absorption performance.

That is, the present invention
[1] A foam-laminated sheet in which a non-foamed layer using an amorphous thermoplastic resin as a base resin is laminated on both sides of an open-cell foamed layer in which holes are formed in the thickness direction,
A film having an organic fiber nonwoven fabric and a crystalline thermoplastic resin as a base resin is laminated on at least the indoor non-foamed layer, and has a hole reaching the inside of the foamed layer from the surface of the indoor laminated body. Characteristic foam laminate sheet for automobile interior materials,
[2] The foamed laminated sheet for automobile interior materials according to [1], wherein the foamed layer comprises a thermoplastic resin foamed sheet having an open cell ratio of 60 to 98%.
[3] The automobile according to [1] or [2], wherein the heat-resistant resin constituting the foamed layer is a modified polyphenylene ether resin composed of a mixed resin of a polystyrene resin and a polyphenylene ether resin. Foam laminated sheet for interior materials,
[4] The thermoplastic resin constituting the foam layer is 25 to 70 parts by weight of a polyphenylene ether resin and 75 to 30 parts by weight of a polystyrene resin (the total of the polyphenylene ether resin and the polystyrene resin is 100 parts by weight. The foamed laminated sheet for automobile interior materials according to any one of [1] to [3], which is a modified polyphenylene ether resin
[5] The amorphous thermoplastic resin constituting the non-foamed layer is at least one selected from the group consisting of polystyrene resins, heat-resistant polystyrene resins and polyphenylene ether resins. ] The foaming laminated sheet for automotive interior materials of any one of [4],
[6] The automobile according to any one of [1] to [5], wherein the glass transition temperature of the amorphous thermoplastic resin constituting the non-foamed layer is 85 ° C. or higher and 130 ° C. or lower. Foam laminated sheet for interior materials,
[7] The automobile according to any one of [1] to [6], wherein the organic fiber nonwoven fabric is a nonwoven fabric obtained by subjecting a cross web to high-pressure columnar water flow processing or needling processing. Foam laminated sheet for interior materials,
[8] The foam laminated sheet for automobile interior materials according to any one of [1] to [7], wherein the organic fibers constituting the nonwoven fabric are non-meltable organic fibers,
[9] The foam laminated sheet for automobile interior materials according to any one of [1] to [8], wherein the organic fiber constituting the nonwoven fabric is rayon fiber,
[10] The organic fiber constituting the nonwoven fabric is formed by mixing 10 to 30% by weight of a heat-fusible binder fiber when the total organic fiber is 100% by weight. [1] to [9] ] The foaming lamination sheet for automotive interior materials of any one of these,
[11] The foam laminated sheet for automotive interior materials according to any one of [1] to [10], wherein the basis weight of the organic fiber nonwoven fabric is 50 g / m ² or less.
[12] The foamed laminated sheet for automobile interior materials according to any one of [1] to [11], wherein the crystalline thermoplastic resin has a melting point of 130 ° C. or lower.
[13] The foamed laminated sheet for automobile interior materials according to any one of [1] to [12], wherein the crystalline thermoplastic resin is a linear low density polyethylene resin, and [14] ] It is related with a motor vehicle interior material obtained by shape | molding the foaming lamination sheet for motor vehicle interior materials of any one of [1]-[13].

  The foam laminated sheet for automobile interior materials of the present invention is composed of only a plastic material without using an inorganic material, and is lightweight and heat-resistant, and further excellent in sound absorption, dimensional stability (isotropic) and bending rigidity, In addition, it is possible to provide a foam sheet for automobile interior materials that can be thermally recycled. Furthermore, by molding using the sheet, an automotive interior material having the above characteristics can be provided.

  The foamed laminated sheet for automobile interior materials and the automobile interior material of the present invention will be described with reference to the drawings.

  FIG. 1 shows a configuration of a foam laminated sheet (27) for automobile interior material according to one embodiment of the present invention, and an open-cell foamed layer having holes in the thickness direction using a thermoplastic resin as a base resin. A non-foamed layer (12) and a non-foamed layer (13) using an amorphous thermoplastic resin as a base resin are laminated on both surfaces of (11). The non-foamed layer (12) is formed by laminating an organic fiber nonwoven fabric layer (14) and a crystalline resin film layer (16). Furthermore, the hole which reaches the inside of a foamed layer from the indoor side non-foamed layer surface is provided. Moreover, a non-foaming layer (13) is laminated | stacked by the organic fiber nonwoven fabric layer (15).

  FIG. 2 shows the configuration of a foamed laminated sheet (28) for automobile interior materials according to one embodiment of the present invention. An open-cell foamed layer (11 having a hole in the thickness direction using a thermoplastic resin as a base resin). ) Are laminated with a non-foamed layer (12) and a non-foamed layer (13) using an amorphous thermoplastic resin as a base resin. The non-foamed layer (12) and the non-foamed layer (13) are formed by laminating an organic fiber nonwoven fabric layer (14, 15) and a crystalline resin film layer (16, 17). Furthermore, the hole which reaches the inside of a foamed layer from the indoor side non-foamed layer surface is provided.

  FIG. 3 shows the configuration of a foam laminated sheet (27) for automobile interior materials according to one embodiment of the present invention, and an open-cell foamed layer having pores in the thickness direction using a thermoplastic resin as a base resin. A non-foamed layer (12) and a non-foamed layer (13) using an amorphous thermoplastic resin as a base resin are laminated on both surfaces of (11). The non-foamed layer (12) is formed by laminating an organic fiber nonwoven fabric layer (14) and a crystalline resin film layer (16). Furthermore, the hole which reaches the inside of a foaming layer from the indoor side non-foamed layer (12) surface is provided, and a skin material layer (26) is laminated | stacked on the indoor side non-foamed layer surface.

As the open-cell foamed layer (11) in the present invention, a material obtained by partially or wholly foaming any material of a thermoplastic resin and a thermosetting resin as long as it has three-dimensional air permeability. I do not care.
Note that “having air permeability” means that gas is allowed to permeate in the three-dimensional direction, and mechanically breathable, such as by forming a hole in the post-processing in a direction that does not have air permeability when foaming. May be given. For example, a thermosetting resin or a thermoplastic resin foamed so as to have a high open cell ratio and imparted air permeability, or a perforated process was applied to the thickness direction of the foam (through) For example, the air permeability is further increased by providing holes.

  In the present invention, since the open-cell foamed layer has “breathability”, it not only exhibits sound absorption, but also reduces the amount of VOC (particularly the amount of toluene) caused by volatile components in the base resin. it can.

  From the viewpoint of sound absorption, the open cell ratio before pores are formed in the thickness direction of the foamed layer (11) in the present invention is preferably 60% to 98%, more preferably 70 to 85%. preferable. When the open cell ratio of the foamed layer (1) is less than 60%, the air permeability becomes small, the effective sound absorbing property cannot be expressed, and the quietness in the vehicle may not be improved. When the open cell ratio exceeds 98%, the bending rigidity of the sheet is extremely lowered, so that even if a non-foamed layer having bending rigidity is laminated, the practical characteristics as the interior material may not be satisfied.

  In the present invention, the “open cell ratio” is the ratio of the cells (closed cells) in which the foamed cells are completely isolated from the other foamed cells by the cell membrane and are independent (closed cell rate). The value was calculated as open cell ratio (%) = 100−closed cell ratio (%) after measurement according to ASTM D-2859 using a multi-pycnometer (manufactured by Beckman).

  As the base resin for the open-cell foamed layer (11) in the present invention, it is preferable to use a thermoplastic resin from the viewpoint of environment such as recycling.

  Specific examples of the thermoplastic resin include, for example, polyolefin resins such as polyethylene and polypropylene, polyamide resins, polyester resins such as polybutylene terephthalate (PBT) and polyethylene terephthalate (PET), vinyl chloride, polyphenylene ether (PPE), polystyrene ( PS), acrylic resin, acrylonitrile / butadiene / styrene resin (ABS), polycarbonate and the like. These resins may be used alone or in combination of two or more.

  Among these, a modified PPE resin is preferable because it has excellent quality such as heat resistance and rigidity, and is easy to process and manufacture. Examples of the modified PPE resin include a mixture of a PPE resin and a PS resin, a styrene / phenylene ether copolymer such as a graft copolymer of a styrene monomer to PPE, and the like. The modified PPE resin is low in cost, and by changing the mixing ratio, it is easy to obtain a resin with excellent quality such as heat resistance and rigidity, and having changed workability. A mixed resin of a resin and a PS resin is preferable.

  Examples of PPE used in the modified PPE resin include poly (2,6-dimethylphenylene-1,4-ether), poly (2-methyl-6-ethylphenylene-4-ether), poly (2, 6-diethylphenylene-1,4-ether), poly (2,6-diethylphenylene-1,4-ether), poly (2-methyl-6-n-propylphenylene-1,4-ether), poly ( 2-methyl-6-n-butylphenylene-1,4-ether), poly (2-methyl-6-chlorophenylene-1,4-ether), poly (2-methyl-6-bromophenylene-1,4) -Ether), poly (2-ethyl-6-chlorophenylene-1,4-ether), and the like. These may be used alone or in combination of two or more.

  In the modified PPE resin, a polystyrene resin (hereinafter sometimes abbreviated as “PS resin”) that forms a mixed resin with the PPE resin is styrene or a derivative thereof such as α-methylstyrene, 2,4- A resin mainly composed of dimethyl styrene, monochloro styrene, dichloro styrene, p-methyl styrene, ethyl styrene or the like. Accordingly, the PS-based resin is not limited to a homopolymer composed only of styrene or a styrene derivative, but may be a copolymer obtained by copolymerizing with another monomer.

  Specific examples of the styrene monomer that is polymerized on the PPE resin, preferably graft polymerized, include styrene, α-methylstyrene, 2,4-dimethylstyrene, monochlorostyrene, dichlorostyrene, p- Examples include methyl styrene and ethyl styrene. These may be used alone or in combination of two or more. Of these, styrene is preferable from the viewpoint of versatility and cost.

  In the present invention, when a modified PPE resin is used as the thermoplastic resin used in the open cell foam layer (11), the PPE resin is 25 to 70% by weight and the PS resin is 75 to 30% by weight. The PPE resin is preferably 35 to 60% by weight and the PS resin is 65 to 40% by weight. If the PPE resin in the modified PPE resin is less than 25% by weight, the heat resistance tends to be inferior. If the PPE resin exceeds 70% by weight, the viscosity at the time of heat flow increases and foam molding becomes difficult. Tend.

  The foam sheet used in the present invention may be a single foam layer, or may be a sheet formed by laminating two or more foam layers.

  The resin constituting the open-cell foamed layer of the present invention has various additives as necessary, for example, a nucleating agent, an antioxidant, a heat stabilizer, as long as the object of the present invention is not significantly impaired. An antistatic agent, a conductivity imparting agent, a weathering agent, an ultraviolet absorber, a flame retardant, an inorganic filler, and the like can be added.

  In order to efficiently obtain an open-cell foamed sheet layer using a thermoplastic resin, a method of obtaining a foamed sheet by extrusion foaming using a circular die is preferable from the viewpoint of processability.

  Extrusion foaming using a circular die is, for example, after mixing a base resin and another type of resin used as necessary, additives in a blender, and then supplying the extruder to the resin composition by melt-kneading, A foaming agent is injected under high temperature and high pressure, mixed, cooled to a suitable foaming temperature, and extruded and foamed from a circular die, which is a mold having an annular slit under atmospheric pressure, to obtain a cylindrical foam. A method of stretching and cooling with an annular cooling mandrel installed on the inner side of the cylindrical foam so as to cool from the inner surface side of the foam, and then cutting it and taking it up into a sheet shape. Examples of the extruder used for extrusion foaming include a one-stage type of one extruder and a two-stage type (tandem type) in which two extruders are connected in series. Among these, the two-stage system is particularly preferable for efficiently performing the plasticization of the resin, the mixing of the resin and the additive, and the cooling step of the resin, followed by the extrusion.

  Here, in the extrusion process, in order to increase the open cell ratio of the open cell foamed sheet made of a thermoplastic resin, for example, (i) the temperature condition in the extruder and (ii) the amount of the foaming agent may be adjusted. . More specifically, regarding (i), by setting the cooling temperature in the second-stage extruder to the high temperature side, an open cell layer can be provided as a whole in the thickness direction of the sheet. With regard to (ii), the foaming agent press-fitting amount may be set to about 1.5 to 2.0 times the normal use amount with respect to 100 parts by weight of the base resin. However, if the foaming agent press-fitting amount is too large, plasticization proceeds and shear heat generation between the polymers is less likely to occur, so that the open cell ratio may decrease. These (i) to (ii) may be combined.

  In the present invention, by forming holes in the thickness direction of the open-cell foamed sheet made of thermoplastic resin, the space in the traveling direction of the incident sound wave increases, so the sound wave vibrates the material efficiently. It will be easier to communicate. Therefore, it tends to develop a sound absorbing effect.

  As a method of forming holes in the thickness direction with respect to the foamed sheet, a method of passing the foamed sheet between a roll or flat plate provided with a large number of needles, a method of contacting with a hot needle, a method of opening by irradiating a laser , Etc. are examples.

  The depth of the hole in the present invention is preferably 10 to 100%, more preferably 30 to 100% of the thickness of the foamed sheet. If the depth of the hole is shallower than 10%, the incident sound wave cannot efficiently exhibit vibration using the open cell layer, and the sound absorption tends to be lowered.

Although the hole may have any shape, a circular shape is preferable in view of workability.
The opening diameter (equivalent circle diameter) of the hole is preferably 0.3 to 3 mmφ, and more preferably 0.5 to 1 mmφ. If the diameter of the opening (equivalent circle diameter) is larger than 3 mmφ, the bending rigidity of the sheet will be extremely lowered, and even if a rigid non-foamed layer is laminated, it will tend to fail to meet the practical characteristics as an interior material, and transparency will occur. There is a tendency for the designability to decrease. When the diameter is smaller than 0.3 mmφ, the incident sound wave cannot efficiently exhibit vibration using the open cell layer, and the sound absorbing property tends to be lowered, and the workability tends to be lowered.

  The aperture ratio of the holes is preferably 0.5 to 35.0%, more preferably 1.0 to 8.0%. When the aperture ratio is larger than 35.0%, the bending rigidity of the sheet is extremely lowered, and even if a rigid non-foamed layer is laminated, there is a tendency that the practical characteristics as the interior material are not satisfied. If it is less than 0.5%, the incident sound wave cannot efficiently exhibit vibration using the open cell layer, and the sound absorbing property tends to decrease and the workability tends to decrease.

  By the way, the aperture diameter and aperture ratio of the holes are values measured using the following method. The aperture ratio is an index of how many holes are present in the surface direction of the foamed sheet, and can be measured by determining the diameter (area) and the number of openings of the holes.

In general, the aperture ratio can be calculated as follows.
(A) The foamed sheet with holes formed in the thickness direction is photographed at an appropriate magnification using, for example, an optical microscope or a normal camera.
(B) An OHP sheet is placed on the photographed image, and the portion corresponding to the hole is painted with black ink and copied (primary processing).
(C) The primary processing image is taken into an image processing apparatus (for example, PIAS-II, manufactured by Pierce Co., Ltd.), and whether or not the dark color portion and the light color portion are painted with black ink is identified.
(D) Using “FRACTAREA (area ratio)” in the image analysis calculation function, the area ratio of the through holes in the entire image is obtained by the following equation.

  However, since all the non-through holes in this example were provided in a circular shape, the average value of the openings of the holes in the foam sheet (all used in the examples are circles) and the number of non-through holes were measured. The aperture ratio was obtained from the following equation.

  The formation state of the non-through holes may be uniform or non-uniform so long as structural rigidity is not non-uniform in the sheet surface direction and thickness direction.

  The open-cell foamed layer (11) made of the thermoplastic resin in the present invention is obtained by extrusion foam molding using a hydrocarbon-based foaming agent as a foaming agent. Therefore, it is preferable.

  The hydrocarbon-based foaming agent used when obtaining the open-cell foamed layer (11) of the present invention is preferably a volatile foaming agent, and specific examples include ethane, propane, butane, pentane and the like. . Among these, a hydrocarbon-based blowing agent having a Kauri butanol value (KB value) indicating the solubility of the blowing agent of 20 to 50 is preferable. In addition, it is also possible to use those having the above range by appropriately mixing two or more types having a KB value higher and lower than this range.

  In the present invention, when a thermoplastic resin is used as the base resin for the open-cell foam layer, among the specific examples of the foaming agent, moderate foaming agent dispersibility and foaming agent dispersibility are small. Butane is preferred in that the change in foamability with time of the layer is small. The butane may be isobutane, normal butane, or a mixture of isobutane and normal butane.

  In the present invention, the amount of the hydrocarbon-based foaming agent that is injected during extrusion foaming of the foamed layer (1) is preferably 3.0 to 6.0 parts by weight with respect to 100 parts by weight of the constituent resin of the foamed layer. More preferably, it is 0.0-4.5 weight part. When the amount of the foaming agent injected is less than 3.0 parts by weight, the foaming power to the resin tends to be too small, and a good open-cell foam cell tends to be not obtained. Tends to become unstable and the surface of the foam sheet tends to be rough.

  The thickness of the open-cell foamed layer (11) in the present invention is preferably 2.5 to 8.0 mm, more preferably 3.5 to 6.0 mm. When the thickness of the foamed layer (11) is less than 2.5 mm, there is a tendency that almost no sound absorption is exhibited. When the thickness is greater than 8.0 mm, breakage occurs during winding or the volume becomes large and transportation, etc. Productivity tends to decrease.

Basis weight open cell foam layer (11) in the present invention is preferably ^{100~300g / m 2, 200~250g / m} 2 is more preferable. When the basis weight of the foamed layer (11) is smaller than 100 g / m ² , the rigidity tends to be insufficient, and when it exceeds 300 g / m ² , the lightness tends to decrease.

  The expansion ratio of the open-cell foamed layer (11) of the present invention is preferably 5 to 25 times, and more preferably 15 to 20 times. When the foaming ratio of the foamed layer (11) is lower than 5 times, the flexibility is inferior, damage due to bending or the like tends to occur, and the effect of reducing the weight tends to be reduced. On the other hand, when the expansion ratio exceeds 25 times, the strength tends to decrease and the handling property tends to decrease.

  The laminated foam sheet for automobile interior materials according to the present invention includes a non-foamed layer (12) based on an amorphous thermoplastic resin and a non-foamed layer (11) on both sides of a foamed layer (11) based on a heat-resistant resin. A foam layer (13) is laminated. In the present invention, by laminating the non-foamed layer (12) and the non-foamed layer (13), it is possible to improve the bending rigidity of the molded body, control deformation during the heat test, and stabilize the molded body shape during molding.

  The reason why the amorphous thermoplastic resin is used as the base resin for the non-foamed layers (12) and (13) is that, when a crystalline thermoplastic resin is used, dimensional stability is improved due to crystal shrinkage or the like. It tends to be inferior, and when a thermosetting resin is used, it tends to be inferior in moldability.

  Examples of the amorphous thermoplastic resin used in the non-foamed layer (12) or (13) in the present invention include PS resins, heat-resistant PS resins, modified PPE resins, polycarbonate resins, and the like. May be used alone or in combination of two or more. However, when a modified PPE resin is used as the open-cell foamed layer (11), the thermoplastic resin used for the non-foamed layer (12) or the non-foamed layer (13) may be adhesive with the resin layer and From the viewpoint of dimensional stability, PS resins, heat resistant PS resins, and modified PPE resins are preferably used. In addition, when using polycarbonate-type resin, when using modified PPE-type resin as a foaming layer (10), it may be inferior to adhesiveness with respect to this resin.

  In the present invention, when a modified PPE resin is used as the thermoplastic resin used in the non-foamed layer (12) or the non-foamed layer (13), the modified PPE resin is used in the same manner as in the foamed layer (11). Is preferably modified by mixing a PPE resin and a PS resin, and refers to a mixed resin of a PPE resin and a PS resin. Modification by mixing a PPE resin and a PS resin is preferable from the viewpoint of easy production.

  Specific examples and preferred examples of PPE resins and PS resins in the modified PPE resin in the non-foamed layer, the reasons for using them, and the like are the same as those described for the foamed layer 11. However, as a preferred specific example of the PS resin, a styrene-butadiene copolymer represented by high impact polystyrene (HIPS) has a large impact resistance improving effect on the non-foamed layer (12) or (13). preferable.

  In the present invention, when a modified PPE resin is used as the thermoplastic resin used in the non-foamed layer (12) or (13), the ratio of the PPE resin and the PS resin in the mixed resin that is the modified PPE resin The PPE resin is preferably 5 to 70% by weight and the PS resin 30 to 95% by weight, more preferably 7 to 50% by weight PPE resin and 50 to 93% by weight PS resin. When the mixing ratio of the PPE resin is less than 5% by weight, the heat resistance tends to be inferior, and when it exceeds 70% by weight, the viscosity at the time of heat flow increases, and the extrusion molding of the non-foamed layer may be difficult. .

In the present invention, when a heat-resistant PS resin is used as the thermoplastic resin used in the non-foamed layer (12) or (13), the heat-resistant PS resin used is styrene or a derivative thereof, and heat resistance is improved. It is a copolymer with another monomer having an effect. Examples of monomers having an effect of improving heat resistance and copolymerizable with styrene or derivatives thereof include unsaturated carboxylic acids such as maleic acid, fumaric acid, acrylic acid, methacrylic acid, and itaconic acid or derivatives thereof. And acid anhydrides thereof; nitrile compounds such as acrylonitrile and methacrylonitrile or derivatives thereof. These may be used alone or in combination of two or more.
In addition, when polymerizing styrene or a styrene derivative, a polymer obtained by adding synthetic rubber or rubber latex, an unsaturated carboxylic acid such as maleic acid, fumaric acid, acrylic acid, methacrylic acid, itaconic acid or the like Derivatives and acid anhydrides thereof, and copolymers with nitrile compounds such as acrylonitrile and methacrylonitrile may also be used. Among these, styrene-maleic anhydride copolymer, styrene-acrylic acid copolymer, styrene-methacrylic acid copolymer, acrylonitrile-butadiene-styrene copolymer, its heat resistance improving effect, general purpose From the viewpoint of property and cost. The heat-resistant PS resin may be used alone or in combination of two or more.

  In the non-foamed layers (12) and (13) of the present invention, the non-foamed layer is cracked when punched when a heated laminated sheet is molded as an automobile interior material or when the laminated sheet or molded article is transported. From the viewpoint of preventing the above, it is preferable to contain a rubber component.

  The content of the rubber component in the non-foamed layers (12) and (13) of the present invention is preferably 0.3 to 15 parts by weight, and 0.4 to 13 parts by weight with respect to 100 parts by weight of the base resin. More preferred is 0.6 to 11 parts by weight.

  As the rubber component, rubbers such as natural rubber and synthetic rubber, and those obtained by graft polymerization of a monomer having an olefin double bond such as styrene or methyl methacrylate around rubber particles are preferably used. . Specific examples of the rubber include, for example, styrene-butadiene rubber, hydrogenated styrene-butadiene rubber, butadiene rubber, isoprene rubber, ethylene-propylene copolymer, ethylene-propylene-diene copolymer, acrylonitrile-butadiene copolymer, Examples include chloroprene rubber, butyl rubber, acrylic rubber, and ethylene-acrylic rubber. These may be used alone or in combination of two or more. Among these, styrene-butadiene rubber and hydrogenated styrene-butadiene rubber are preferable from the viewpoint of high compatibility with PS resin, heat-resistant PS resin, and modified PPE resin and versatility.

Basis weight of the non-foamed layer in the present invention (12) or non-foamed layer (13) is preferably ^{30~200g / m 2, 40~150g / m} 2 is more preferable. When the basis weight of the non-foamed layer is less than 30 g / m ² , the strength and rigidity tend to decrease. As a result, the effect of suppressing the movement of the foamed layer is not sufficient, and dimensional stability tends not to be obtained. There is. On the other hand, when the basis weight of the non-foamed layer is larger than 200 g / m ^2, it is disadvantageous for the weight reduction of the base material, and the effect of dimensional stabilization due to the lamination of the non-meltable organic fiber nonwoven fabric layer is hardly exhibited. Tend.

  In the amorphous thermoplastic resin forming the non-foamed layers (12 and 13) in the present invention, an impact resistance improver, a filler, a lubricant, an antioxidant, an antistatic agent, and a stabilizer are optionally added. An odor reducing agent or the like may be added alone or in combination of two or more.

  The amorphous thermoplastic resin that is the base resin of the non-foamed layer in the present invention preferably has a glass transition temperature (Tg) of 85 to 130 ° C, more preferably 100 to 130 ° C. When the glass transition temperature Tg of the thermoplastic resin is less than 85 ° C., there is a tendency that the intended dimensional stability at high temperature cannot be obtained even if it is combined with organic fibers. On the other hand, when the glass transition temperature Tg exceeds 130 ° C., there is a possibility that the film is subjected to stretch molding with strain left during the molding process, and as a result, the dimensional stability may be inferior.

  In addition, the glass transition temperature (Tg) in this invention is a measured value measured using differential scanning calorimetry (DSC) according to JISK7121.

  At least one [indoor side (12)] of the non-foamed layer in the present invention is formed by laminating an organic fiber nonwoven fabric layer and a crystalline resin film layer.

  In the present invention, by linearly laminating an organic fiber nonwoven fabric layer and a crystalline resin film layer on at least one [indoor side (12)] of the non-foamed layer, the linear expansion of the automobile interior material at 0 ° C. to 80 ° C. The rate can be reduced efficiently.

  Furthermore, the outdoor non-foamed layer (13) has a higher heat-retaining effect on the outdoor side without performing mold temperature control during heat molding, and contact cooling with the mold during pressing can be suppressed and the initial shape can be improved. From the viewpoint, it is preferable to laminate an organic fiber nonwoven fabric layer.

As an organic fiber which comprises the organic fiber nonwoven fabric layer used for this invention, a non-meltable organic fiber is used preferably.
Here, the “non-melting organic fiber” means its form without melting even at a temperature higher than the melting temperature of the foamed layer constituting the foamed laminated sheet and the base resin (non-crystalline resin) of the non-foamed layer. The fiber that can hold, bamboo, cotton, kapok cotton, flax, cannabis, kenaf, Manila hemp, sisal hemp, New Zealand hemp, mage hemp, wool, fir, tsutsuga, spruce, beech, etc. Examples thereof include fiber bodies such as rayon, which is a cellulosic regenerated fiber. In these organic fibers, rayon is most preferably used from the viewpoint of processability and cost.

  In the present invention, for the purpose of improving the impregnation state of the crystalline resin film layer and the non-meltable organic fiber layer used for lamination, heat fusion containing the same kind of crystalline resin or a resin having good compatibility It is preferable to use an auxiliary binder fiber as an auxiliary.

  The kind of the heat-fusible binder fiber used is selected according to the crystalline resin film layer, and specific examples thereof include olefin-based, polyamide-based, and polyester-based binder fibers such as polyethylene and polypropylene, polyethylene terephthalate, or polybutylene. A copolyester binder fiber obtained by copolymerizing terephthalate with isophthalic acid, diethylene glycol, 1,6-hexanediol or the like is preferable. A polyethylene binder fiber having a melting point of 130 ° C. or less, which is considered to be the lower limit of the molding temperature range as an automobile interior material, has a reduced distortion during molding, and a good organic fiber inclusion state. Is more preferable.

  The heat-fusible binder fiber is not only a fiber composed of a low-melting polymer, but also a composite having a core-sheath structure such as polyethylene terephthalate, polybutylene terephthalate or a main non-melting fiber in the core, and a low-melting polymer in the sheath. It can be used as a fiber.

  From the viewpoint of the effect of reducing the linear expansion coefficient, the heat-fusible binder fiber is usually preferably mixed in an amount of about 10 to 30% by weight when the total organic fiber is 100% by weight.

  In the non-melting organic fiber nonwoven fabric laminated on the non-foamed layer in the present invention, it is preferable that the fiber structure itself maintains a certain high-temperature rigidity by three-dimensionally interlacing the fibers.

  The three-dimensional entangled state of the fiber can be created by various methods. For example, the fibers can be entangled through a hot press or an adhesive, but the entangled state collapses due to heat and stress in the forming process, and is unstable, which is not preferable. The state in which the fibers are physically entangled is the most preferred form because it is not affected by the molding process.

  Since the entangled state of the fibers is affected by the fineness of the fibers used, the fineness of the non-meltable organic fiber in the present invention is appropriately selected, but 1 to 20 denier (1.1 to 22 dtex) is preferable. Furthermore, 1-7 denier (1.1-7.7 dtex) is more preferable from the ease of the entanglement of fibers. If the fineness of the organic fiber is less than 1 denier (1.1 dtex), a special process is required for entanglement between the fibers in addition to using special fine fibers, which tends to increase costs. When the fineness exceeds 20 denier (22 dtex), the fiber becomes bulky, the fiber crossing is incomplete, and the effect of dimensional stability tends not to be exhibited.

  20-100 mm is preferable and, as for the fiber length of the non-meltable organic fiber in this invention, 30-50 mm is more preferable. If the fiber length is less than 20 mm, it tends to be difficult to give sufficient strength to the nonwoven fabric. On the other hand, when the fiber length exceeds 100 mm, the entanglement between the fibers becomes insufficient, and it is difficult to obtain a high-strength nonwoven fabric. That is, entanglement between fibers by high-pressure columnar water flow processing or needling processing is promoted by the movement of the free ends of the constituent fibers. Therefore, if the fiber length is too long, the ratio of the free ends is reduced. May not be fully promoted.

  As the organic fiber nonwoven fabric layer (14, 15) in the present invention, by using a cross web manufactured by physically entangled fibers by high pressure columnar water flow processing or needling processing, Adjustment becomes possible, and the anisotropy of the linear expansion coefficient of the automobile interior material can be adjusted.

  Here, the cross web is a card web in which the direction of the fibers is aligned to some extent by carding of the card machine, and is folded by a machine called a cross wrapper in an oblique manner several times to several tens of layers (cross-wrapping). However, it is formed into a continuous cross web. This cross web is finally made into a non-woven fabric through several steps after being taken out from the cross wrapper, but it becomes an intermediate material, and the fiber orientation can be adjusted.

In the present invention, the fibers in the cross web are closely entangled with each other by applying a high-pressure columnar water flow to the cross web. In this way, the fibers are intertwined closely because the constituent fibers are in an unbonded state in the fiber web, and the free ends of the fibers move by the application of the high-pressure columnar water flow, and are intertwined with each other. Conceivable. Here, the high-pressure columnar water flow is obtained by jetting water at a high pressure through a nozzle hole having a fine diameter. Specifically, it is obtained by ejecting water at a pressure of 10 to 200 kg / cm ² using a nozzle having a diameter of about 0.01 to 0.3 mm. The nonwoven fabric produced in this manner is hereinafter referred to as “spunlace nonwoven fabric”.

In the present invention, as a method of causing the fibers in the cross web to be closely entangled with each other, a method using a needle punch may be employed instead of the method of applying the high-pressure columnar water flow described above. In the needle punch, a herb (a barbed needle or a fork needle) is passed through the fiber web many times to move the fibers in the fiber web so that the fibers are closely entangled with each other. Generally, the frequency (punch density) of penetrating the herb into the fiber web is about 80 to 300 / cm ² . When the punch density is less than 80 / cm ² , the entanglement of the constituent fibers is insufficient, and there is a tendency that a nonwoven fabric excellent in mechanical properties such as tensile strength cannot be obtained. On the other hand, when the punch density exceeds 300 / cm ² , the entanglement between the short fibers proceeds excessively, and distortion may occur during molding, which may have an adverse effect. The nonwoven fabric produced in this way is hereinafter referred to as “needle punched nonwoven fabric”.

20-100 g / m < ² > is preferable and the fabric weight of the organic fiber nonwoven fabric in this invention has more preferable 25-50 g / m < ² >. If the basis weight of the organic fiber nonwoven fabric is less than 20 g / m ² , the amount of fibers per unit area is small and the physical strength is small, so that a sufficient lamination effect on the non-foamed layer may not be obtained. Moreover, when the fabric weight of an organic fiber nonwoven fabric exceeds 100 g / m < ² >, while being included in a non-foamed layer, it tends to be disadvantageous in cost.

  In the present invention, the lamination of the crystalline resin film is introduced for the purpose of facilitating inclusion of the organic fiber non-woven fabric layer and suppressing increase in the internal strain after molding. For the purpose of reducing the internal strain after molding, the constituent resin of the crystalline resin film is preferably one whose melt viscosity is extremely lowered at 130 ° C. or lower, which is assumed to be the lower limit of the molding processing temperature. A crystalline resin having a melting point of 130 ° C. or lower is selected.

  In addition, as described above, the use of a crystalline resin film may result in inferior dimensional stability due to crystal shrinkage or the like, but the rigidity of the crystalline resin film having a low melting point (130 ° C. or lower) is Since it is overwhelmingly lower than the rigidity of the amorphous resin of the invention, it is possible to ignore the influence of crystal shrinkage of the crystalline resin film.

  In the present invention, by laminating the organic fiber nonwoven fabric and the crystalline resin film on the non-foamed layer, inclusion of the organic fiber in the resin is ensured, and the linear expansion coefficient of the non-foamed layer, the foamed laminated sheet and the automobile interior material is increased. Can be reduced.

  The base resin of the crystalline resin film (16, 17) laminated on the non-foamed layer in the present invention is preferably a polyolefin resin or polyacetal resin that is a crystalline resin. More preferably, polyolefin resin is preferable from the viewpoint of cost, versatility, and ease of film processing.

  Examples of the polyolefin-based resin used include homopolymers such as low-density polyethylene, high-density polyethylene, and linear low-density polyethylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene and methacrylate, Copolymers with monomers copolymerizable with olefins such as acrylate and butene, homopolymers with propylene, propylene vinyl acetate copolymers, and monomers capable of copolymerizing with olefins such as propylene and methacrylate, acrylate and butene A polypropylene resin made of a copolymer with a monomer or a mixture thereof is preferred. Among these, low-density polyethylene, linear low-density polyethylene or ethylene-propylene random copolymer having a melting point of 130 ° C. or lower, which is considered to be the lower limit of the molding processing temperature, can reduce distortion during molding processing, non-melting It is more preferable from the viewpoint of good inclusion of the organic organic fiber.

  Among these, linear low-density polyethylene is more preferable in terms of improving the inclusion state of the organic fiber because the reduction rate of the melt viscosity at the melting point or higher is large.

  The thickness of the crystalline resin film layers (16, 17) in the present invention is preferably 30 to 100 μm, and more preferably 40 to 70 μm. When the thickness of the crystalline resin film is less than 30 μm, the polyolefin film whose viscosity has been reduced by heating may be peeled off due to mold shear, particularly when it comes into contact with the bent portion of the mold. On the other hand, when the thickness is greater than 100 μm, the polyolefin film whose viscosity has been reduced by heating may permeate the organic fiber nonwoven fabric (15) in a large amount when the mold is closed, and lose the inclusion state capable of maintaining dimensional stability.

In some cases, the crystalline resin film layer (17) also plays a role as an anti-noise material layer.
In addition, the noise prevention material layer prevents abnormal noise generated when driving in a car, when the interior is rapidly cooled by a cooler, etc., or when traveling on uneven roads or traveling on a sharp curve. It is a layer that demonstrates the effect to do.

  In the laminated foam sheet of the present invention, after the non-foamed layer is laminated on the open-cell extruded foam sheet, a hole reaching the inside of the open-cell extruded foam layer (11) from the surface of the indoor laminate is further provided. Thus, sound absorption can be imparted.

  In that case, as a method of providing a hole reaching the inside of the open-cell foamed layer, the same hole-piercing method as described above can be mentioned, but as a practical characteristic of the automobile interior material, the interior material as a whole is non-breathable. There must be. In the present invention, when the interior material has air permeability as a whole, the design surface may be contaminated in such a manner that dust or dust is filtered when the air flow in the vehicle passes through the interior material. It is necessary to perform drilling so that it does not occur.

  The opening diameter (equivalent circle diameter) of the hole provided from the non-foamed layer side with respect to the open-cell foamed layer in the present invention is preferably 1.0 to 4.9 mmφ, and more preferably 2.0 to 4.9 mmφ. Preferably, 2.5 to 4.9 mmφ is more preferable. If the diameter of the opening is less than φ1.0 mm, the film acts as a reflector with respect to the sound wave, so that there is a tendency that desired sound absorption characteristics cannot be obtained. When the diameter of the opening exceeds 4.9 mmφ, the adhesion area with the skin material, which is the design surface, becomes small, causing the skin material to float, which causes problems with design properties and interfacial adhesion as practical characteristics. Tend to.

  The opening ratio of the non-through holes in the present invention is preferably 0.9 to 25%, more preferably 5 to 25%, and still more preferably 8 to 22%. When the aperture ratio is less than 0.9%, the film acts as a reflector for the sound wave, so that a desired sound absorption characteristic tends not to be obtained. When the aperture ratio exceeds 25%, the adhesion area with the skin material, which is the design surface, becomes small, so that the skin material floats, and there is a tendency for the problem of design property and the problem of interfacial adhesion as a practical characteristic to occur. There is.

  The extruded laminated foam sheet of the present invention can be used as automobile interior materials such as automobile ceilings, doors, luggage boxes and the like because it can achieve both VOC content reduction (particularly toluene content) and sound absorption.

  The crystalline resin film (16) laminated | stacked on the indoor side non-foaming layer in this invention also plays the role of the adhesive bond layer which adhere | attaches a foaming lamination sheet (27) and a skin material layer (26) depending on the case.

  In order to obtain good adhesion to the skin material layer (26), it is preferable to use a polyolefin-based film as the crystalline resin film (17), more preferably 130 ° C. or less, which is considered to be the lower limit of the molding processing temperature. A polyethylene film made of a linear low density polyethylene resin having a melting point is preferably used. The linear low density polyethylene resin has crystallinity and can stably maintain a low viscosity state by heating. Therefore, the anchor effect is obtained by the good penetration of the melted linear low density polyethylene resin into the skin material. It can be exhibited effectively and can exhibit strong adhesiveness with the skin material layer (26).

  When used as an adhesive layer, the thickness of the crystalline resin film is preferably 30 to 100 μm, and more preferably 40 to 70 μm. When the thickness of the crystalline resin film is less than 30 μm, the polyolefin film whose viscosity has been reduced by heating soaks into the non-meltable organic fiber nonwoven fabric layer (14), so that it does not penetrate into the skin material layer (26) and is moderate. The anchor effect cannot be exhibited, and there is a tendency that good adhesion with the skin material is not exhibited. On the other hand, when the thickness is greater than 100 μm, a large amount of the polyolefin-based film whose viscosity has been reduced by heating may permeate the skin material layer (26), which may worsen the feel of the skin material.

  Examples of the non-foamed layer (12 or 13) made of an amorphous resin in which the organic fiber nonwoven fabric layer (14, 15) and the crystalline resin film layer (16, 17) are laminated in the present invention include, for example, an organic fiber in advance. A sheet in which a nonwoven fabric layer, a crystalline resin film layer (if necessary), and an amorphous resin film layer are combined can be used. As an example of the compounding method, for example, an amorphous resin is melt-kneaded from one side with an extruder and then extruded into a film shape using a T-die, and the organic fiber nonwoven fabric layer and the crystalline resin film fed out from the other side are used. A method of laminating the layers and press-bonding them between the rolls [extruded binder method (extruded laminating method)] can be mentioned. At this time, the degree of inclusion of the resin in the organic fiber can be adjusted by adjusting the gap between the crimping rolls or by adjusting the temperature of the crimping rolls. In addition, for example, there is a method in which an organic fiber nonwoven fabric layer is sandwiched between an amorphous resin and a crystalline resin film that are in a molten state and pressure-bonded using a press.

  In the present invention, the state in which the resin (mainly crystalline thermoplastic resin) is included between the organic fibers of the nonwoven fabric is a state in which the gap between the organic fibers is filled with the thermoplastic resin. However, the resin component (mainly crystalline thermoplastic resin) may be in a state in which the fiber component partially enters, but if only the surface layer portion of the fiber component is present, the effect of improving the dimensional stability and bending rigidity is obtained. There is no tendency.

  In the automobile interior material of the present invention, as shown in FIG. 3, the foam layer (12) of the indoor side non-foam layer (12) in which the non-meltable organic fiber nonwoven fabric layer (14) and the crystalline resin film (16) are laminated. A skin material layer (26) is laminated on the surface not laminated with 11).

  As the skin material layer (26), a nonwoven fabric is used as a skin material for automobile interior materials, such as a nonwoven fabric, a knit / nonwoven fabric, a knit / urethane / nonwoven fabric, etc. Any of these can be used.

  The nonwoven fabric layer functioning as the main component of the skin material layer (26) may be any cloth-like material or sheet-like material in which raw fibers are joined or entangled by an adhesive, a molten fiber, or a mechanical method. Any type can be used.

  In the present invention, the raw fiber constituting the non-woven fabric as the skin material layer (26) is a non-woven fabric obtained by mixing synthetic fibers and regenerated fibers (sometimes referred to simply as “mixed spinning” in the present invention). Is preferably used.

  The synthetic fiber referred to in the present invention is used in a concept including synthetic fiber and semi-synthetic fiber. Specifically, examples of the synthetic fiber include polyester, polypropylene, polyamide (nylon), polyacrylonitrile, polyvinyl chloride, and polyvinylidene chloride. Semi-synthetic fibers include cellulosic and protein-based fibers, and one or a mixture of two or more of these fibers can be used. As the recycled fiber, one or a mixture of two or more of rayon, special rayon, cupra and the like can be used.

  Among the raw material fibers constituting these nonwoven fabrics, from the viewpoint of strength, heat resistance, light resistance and flammability, it is preferable to use a polyester fiber as a synthetic fiber from the viewpoint of recyclability, etc. High polyethylene terephthalate fibers are most preferred. Further, rayon fibers are most preferable from the viewpoint of economy as recycled fibers blended with the synthetic fibers.

  Examples of the type of nonwoven fabric in the present invention include a bonded binder-bonded fabric, a needle punched fabric, a spunbonded fabric, a spray fiber fabric, a waterpunched fabric, or a stitchbonded fabric, and any nonwoven fabric can be used depending on the manufacturing method. Can do. Among these, the needle punch cloth and the water punch cloth are preferable from the viewpoint that the filament is crimpable, has high strength, and has a soft texture.

  In the present invention, the non-woven fabric used as the skin material layer (26), as a preferred embodiment, is a mixture of polyester fibers and regenerated fibers. In this case, the mixing ratio of the regenerated fibers is 2 to 15% by weight of the total weight of the skin material. It is preferable to mix the recycled fibers in proportions. When the mixing ratio is less than 2% by weight, it tends to be difficult to ensure the flame resistance of the skin material layer (26). When the mixing ratio exceeds 15% by weight, the flame resistance is excellent, but the light resistance deteriorates. It may be easy.

  As the knit that may be used as an element constituting the skin material layer (26), any of those used for automobile interior materials such as tricot, double russell, and velvet can be used.

  The knit is made by knitting a loop continuously using a single thread, and has a structure in which the loops are gathered, so it is rich in elasticity and flexible, Wrinkles and creases are not easily formed, and since it is porous, it has excellent heat retaining properties, and has a low specific gravity and a light finish for volume. The knit is finished in various textures depending on how it is knitted, and in particular, the tricot is a loop that is continuously connected in the thickness direction of the fabric. Therefore, it is particularly preferably used for automobile interiors.

  Synthetic fibers, semi-synthetic fibers, natural fibers, regenerated fibers, and the like similar to the above-described nonwoven fabric are used as the raw fibers constituting the knit.

Nonwoven fabric used as the skin material layer (26) in the present invention, considering the quality and cost, preferably has a basis weight of 100 to 300 g / ^{m 2,} even basis weight of 140~200g / ^{m 2} It is preferable to have. When the basis weight of the nonwoven fabric for skin material is less than 100 g / m ² , it may be impossible to obtain a sufficient feel as an interior material. On the other hand, if the basis weight exceeds 300 g / m ² , the molding distortion of the skin material may affect the thermal deformation.

  The non-woven fabric fibers used as the skin material layer (26) are bonded to each other, and in order to ensure the wear resistance of the skin material, a binder resin is applied and coated as an adhesive from the front or back surface of the skin material. In general, a method of impregnation is performed. In this case, in general, in order to ensure flame retardancy, a method of using a flame retardant mixed with the binder resin or using a halogen-containing binder resin is employed. However, in these methods, if an attempt is made to impregnate a binder resin containing a flame retardant or a halogen-containing binder resin from the design surface (surface) of the skin material, the toning of the skin material is extremely difficult due to the influence of the flame retardant or the resin. It becomes difficult. Therefore, in the case of impregnating a binder resin containing a flame retardant or a halogen-containing binder resin, it must be impregnated from the design opposite surface (back surface) of the skin material. Moreover, in order to ensure the abrasion resistance of the skin, the amount of the binder resin containing a flame retardant or the halogen-containing binder resin must be increased.

  In contrast to this fact, in the present invention, flame retardancy is achieved by using a foamed laminated sheet having a modified polyphenylene ether resin as a base resin, and using a nonwoven fabric in which recycled fibers are blended in a synthetic fiber as a skin material. improves. For this reason, it is possible to use a flame retardant-free binder resin or a halogen-free binder resin without using a binder resin containing a flame retardant, or a halogen-containing binder resin, as a binder resin for bonding the raw material fibers of the nonwoven fabric. It becomes possible.

  These binder resins are excellent in toning due to their good transparency, can be impregnated from the design surface (surface) of the nonwoven fabric, and ensure the abrasion resistance of the nonwoven fabric as a skin material only by impregnation with a small amount of binder resin. become able to. In the present invention, such a structure can ensure good flame retardancy, and can use a good skin material that is light in weight, excellent in design properties, and excellent in environmental compatibility.

  Examples of the binder resin include water-soluble, solvent-soluble, viscose liquid, emulsion, and synthetic resin powder. From the viewpoint of water resistance, flexibility, and workability, an emulsion is preferable. As the emulsion type, acrylo / nitrile / butadiene latex, styrene / butadiene latex, acrylate / latex, vinyl acetate latex and the like can be used, and these can be used as one kind or a mixture of two or more kinds.

Density of the skin material (26) in the present invention is preferably ^{0.01~0.50g / cm 3, 0.05~0.25g / cm} 3 is more preferable. If the density of the skin material (26) is less than 0.01 g / cm ³ , the designability or wear resistance tends to be inferior. If it exceeds 0.50 g / cm ³ , the lightness, workability, moldability, etc. There is a tendency to be inferior.

  As thickness of the skin material (26) in this invention, 0.5-3 mm is preferable, 1-3 mm is more preferable, 1.2-2.4 mm is further more preferable. When the thickness of the woven fabric or the non-woven fabric skin material (1) is less than 0.5 mm, problems such as see-through occur and the design properties tend to deteriorate. When it exceeds 3 mm, a problem may arise in lightness, a moldability, or cost.

Nonwoven fabric used as the skin material (26) in the present invention, considering the quality and cost, preferably has a basis weight of 100 to 300 g / ^{m 2,} it has a basis weight of 120~200g / ^{m 2} More preferably. When the basis weight of the nonwoven fabric for skin material is less than 100 g / m ² , it may be impossible to obtain a sufficient feel as an interior material. On the other hand, if the basis weight exceeds 300 g / m ² , the molding distortion of the skin material may affect the thermal deformation.

  Next, the manufacturing method of the automotive interior material of the present invention will be described.

The open cell foam layer (11) used in the present invention is produced as described above.
Specifically, for example, a thermoplastic resin to which various additives are added is melt-kneaded at a resin temperature of 150 ° C. to 300 ° C. using an extruder. Subsequently, under a high temperature and high pressure of 150 to 300 ° C. and 10 to 30 MPa, 1 to 15 parts by weight of a foaming agent was press-fitted into the extruder with respect to 100 parts by weight of the resin, and the foaming optimum temperature (150 to 300 ° C.) was adjusted. Then, using a circular die or the like, after extruding to a low pressure zone (usually in the atmosphere), contact with a mandrel (cooling cylinder), etc., for example, forming into a sheet while taking up at a speed of 3 to 30 m / min. It can be produced by a method such as winding after cutting.

  Examples of the non-foamed layer (12 or 13) made of an amorphous resin in which the organic fiber nonwoven fabric layer (14, 15) and the crystalline resin film layer (16, 17) are laminated in the present invention include, for example, an organic fiber in advance. A sheet in which a nonwoven fabric layer, a crystalline resin film layer (if necessary), and an amorphous resin film layer are combined can be used. As an example of the compounding method, for example, an amorphous resin is melt-kneaded from one side with an extruder and then extruded into a film shape using a T-die, and the organic fiber nonwoven fabric layer and the crystalline resin film fed out from the other side are used. A method of laminating the layers and press-bonding them between the rolls [extruded binder method (extruded laminating method)] can be mentioned. Under the present circumstances, the inclusion degree of resin in an organic fiber can be adjusted by adjusting the clearance gap between crimping | compression-bonding rolls or adjusting the temperature of a crimping | compression-bonding roll. In addition, for example, there is a method in which an organic fiber nonwoven fabric layer is sandwiched between an amorphous resin and a crystalline resin film that are in a molten state and pressure-bonded using a press.

  As a method of laminating a non-foamed layer in which an organic fiber nonwoven fabric or the like is combined on the open-cell foamed layer (11) in the present invention, an organic material prepared in advance on the surface of the foamed layer (11) using a hot roll. A non-foamed layer in which an organic fiber nonwoven fabric and a molten amorphous resin are combined is fed out by a heat laminating method in which a non-foamed layer on which fibers, etc. are laminated is heat-sealed, or by the above-mentioned extrusion binder method (extrusion laminating method). Then, after laminating with the foam layer (11), a method of thermally fusing the crystalline film layer to the surface of the organic fiber nonwoven fabric, and the like can be mentioned.

  In the present invention, the non-foamed layer (12 or 13) formed by laminating the organic fiber nonwoven fabric layer (14 or 15) and the crystalline resin film layer (16, 17) and the foamed layer (11) Lamination may be performed simultaneously.

  Examples of the method of laminating the skin material (26) in the present invention include a method of laminating the foam laminated sheet (27) for interior materials, a laminating method during interior material molding processing, and the like.

  First, a method of laminating the foam laminate sheet for interior material (27) will be described. A method in which a crystalline thermoplastic resin film layer (16) having holes is softened by an electric heater or a heat roll, and the outer skin material (26) fed out from the other is pressed and laminated simultaneously, or a crystalline thermoplastic having pores Examples thereof include a method in which the resin film layer (16) is laminated and integrated through a urethane-based, silicone-based, or epoxy-based adhesive or a thermoplastic resin adhesive.

  Next, as a lamination method at the time of interior material molding processing, an interior material in which a skin material is laminated is obtained through product molding to obtain an automotive interior material. Specifically, only the foamed laminated sheet for interior use is heated to the heating zone of the molding machine, the skin material (26) is sent immediately before the die press, and the interior material is heated first at the same time as the design opposite surface (back surface) of the skin material. It is obtained by performing press working simultaneously with the foam laminated sheet (27).

  As a method for obtaining an automobile interior material by molding the foamed laminated sheet of the present invention, for example, a laminated foamed sheet is clamped and led to a heating furnace having heaters at the top and bottom, and a temperature suitable for molding (for example, foaming) It is obtained by heating and softening so that the surface temperature of the laminated sheet becomes 120 to 200 ° C., and then press molding with a temperature-controlled mold.

  Examples of molding methods include, for example, plug molding, free drawing molding, plug and ridge molding, ridge molding, matched molding, straight molding, drape molding, reverse draw molding, air slip molding, plug assist molding, plug Examples include assist reverse draw molding.

The linear expansion coefficient calculated from the dimensional change amount of 0 to 80 ° C. of the automobile interior material in the present invention is preferably less than 4 × 10 ⁻⁵ / ° C. in both the length direction and the width direction, and is preferably 3 × 10 ⁻⁵ / It is more preferable that the temperature is less than ° C. When the linear expansion coefficient in either the length direction or the width direction is 4 × 10 ⁻⁵ / ° C. or more, a dimensional change of 5 mm or more occurs due to a change in the in-vehicle temperature, and the fastener is detached or the base material is deformed. It tends to be easier.

In addition, the linear expansion coefficient calculated from the dimensional change amount of 0 ° C. to 80 ° C. of the automobile interior material in the present invention is a value calculated as follows for the molded body. That is, three 300 mm × 30 mm test pieces are sampled and left for 24 hours in an 85 ° C. constant temperature bath, then allowed to cool in an atmosphere of 23 ° C. and 50% RH and left for 24 hours. Then, annealing and normal adjustment were performed, and a test line was marked with a 280 mm mark in an atmosphere of 23 ° C. and 50% RH, and the dimensions were measured.
Next, after leaving the test piece with the marked line in an 80 ° C. constant temperature bath for 6 hours, the dimension between the marked lines was measured in the 80 ° C. constant temperature bath. Furthermore, after leaving this test piece in a 0 degreeC thermostat for 6 hours, the dimension between marked lines was measured in the 0 degreeC thermostat. About the dimension between the marked lines of the test piece in each temperature, the linear expansion coefficient in 0 degreeC-80 degreeC was computed using the following formula, and the arithmetic mean value was employ | adopted.

Further, the length direction and the width direction of the molded body in the present invention mean a flow direction (MD direction) and a direction perpendicular to the flow direction (TD direction), respectively, during sheet production.

  The heat shrinkage ratio of the automobile interior material in the present invention is preferably less than 0.7%, more preferably less than 0.5%, and still more preferably less than 0.3%. When the heat shrinkage rate in either the length direction or the width direction is 0.7% or more, there is a possibility that the automobile interior material may be distorted and deformed due to an increase or decrease in the vehicle interior temperature.

  In addition, the heat shrinkage rate of the automobile interior material in the present invention is a value calculated as follows for the molded body. That is, after three 150 mm × 30 mm test pieces were collected and the test pieces were stretched 10% at 130 ° C. in the longitudinal direction of the sample at a stretching rate of 200 mm / min and then rapidly cooled. The normal state is adjusted by leaving it in an atmosphere of 23 ° C. and 50% RH for 24 hours. A marked line of 140 mm was attached under a 23 ° C., 50% RH atmosphere, and the dimensions were measured.

  Next, the test piece with the marked line was allowed to stand in an 85 ° C. constant temperature bath for 24 hours, then taken out in an atmosphere of 23 ° C. and 50% RH for 24 hours, and the dimension between marked lines was measured. Using the dimension between the marked lines of the test piece before and after heating, the heat shrinkage rate was calculated using the following formula.

  Further, the length direction and the width direction of the molded body in the present invention mean a flow direction (MD direction) and a direction perpendicular to the flow direction (TD direction), respectively, during sheet production.

  The bending elastic gradient of the automobile interior material in the present invention is preferably 30 N / 50 mm / cm or more, more preferably 40 N / 50 mm / cm or more in both the flow direction (MD direction) and the width direction (TD direction) in producing the laminated foam sheet. Preferably, 50 N / 50 mm / cm is more preferable. If the bending elastic gradient in either the flow direction (MD direction) or the width direction (TD direction) is less than 30 N / 50 mm / cm, bending occurs during transfer or assembly to the vehicle body, and the defect rate tends to increase. .

  Although various embodiments of the laminated foam sheet for automobile interior materials according to the present invention have been described above, the present invention is not limited to the above-described embodiments. For example, the foamed laminated sheet for automobile interior materials can be used as a foamed laminated sheet for interior materials such as trains as applications, and should be interpreted broadly.

  Hereinafter, the present invention will be described in more detail based on examples, but the present invention is not limited thereto. Table 1 shows the resins, nonwoven fabrics, and film layers used in the examples.

In addition, each abbreviation regarding the resin shown in Table 1 is as follows.
PPE: Polyphenylene ether resin PS: Polystyrene resin HIPS: High impact polystyrene resin Heat resistant PS: Heat resistant polystyrene resin LLDPE: Linear low density polyethylene resin PET: Polyethylene terephthalate resin.

  The evaluation methods performed in the examples are shown below.

(Thickness of foam layer and molded body)
Using the magnifying loupe (manufactured by PEAK, zoom scale magnifying glass, magnification 15 times), the thickness of the obtained laminated foam sheet and molded product was measured at any 20 locations in the width direction, and the measured value The average value was calculated.

(Foaming ratio)
The density df of the obtained laminated foamed sheet was measured according to JIS K7222, the density dp of the modified PPE resin was measured according to JIS K7112, and determined from the following.

(Open cell ratio)
The obtained primary foamed sheet was measured according to ASTM D-2859 using a multi-pycnometer (manufactured by Beckman).
The open cell ratio was determined from the obtained closed cell ratio by the following formula.

(Weight)
A test piece having a size of 100 mm × 100 mm was cut out from five locations in the extrusion direction of the obtained laminated foamed sheet, and after measuring the weight thereof, an average value was calculated and converted per m ² .

(Sound absorption)
In accordance with JIS A1409 “Measurement method of sound absorption coefficient of reverberation chamber method”, a test sheet having a size of 0.7 m × 0.7 m is placed on the floor surface with a 0 mm back air layer in a 9 m ³ reverberation chamber manufactured by Nittobo Acoustic Engineering Co., Ltd. The reverberation time was measured 3 times by repeating the measurement at 5 points on the measurement microphone and repeating each point. The sound absorption rate was obtained from the average value of the obtained reverberation time by the following sabine reverberation equation, and was defined as the reverberation chamber method sound absorption rate α.
From the average value of α at a frequency of 1000 to 6300 Hz in the 1/3 octave band, sound absorption was determined according to the following criteria.
○: The average value of α is larger than 0.2.
X: The average value of α is 0.2 or less.

V: reverberation chamber volume = 9 m ³
S: Sample surface area = 0.49 m ²
T _m : Reverberation time at the time of sample insertion (second)
T ₀ : reverberation time when no sample is inserted (seconds)
c: speed of sound [= 331.5 + 0.61 × measured temperature (° C.)].

(Dimensional stability evaluation: linear expansion coefficient)
Tests of 300 mm × 30 mm in the length direction [flow direction (MD direction)] and width direction [vertical direction of flow direction (TD direction)] from the molded bodies obtained in Examples and Comparative Examples Three pieces were collected.
After leaving the test piece in a constant temperature bath at 85 ° C. for 24 hours, it was allowed to cool in an atmosphere of 23 ° C. and 50% RH and left for 24 hours to perform annealing and normal adjustment. The test piece was marked with a 280 mm mark in a 23 ° C., 50% RH atmosphere, and the dimensions were measured.
Next, after leaving the test piece with the marked line in an 80 ° C. constant temperature bath for 6 hours, the dimension between the marked lines was measured in the 80 ° C. constant temperature bath. Furthermore, after leaving this test piece in a 0 degreeC thermostat for 6 hours, the dimension between marked lines was measured in the 0 degreeC thermostat. About the dimension between the marked lines of the test piece in each temperature, the linear expansion coefficient in 0 to 80 degreeC was computed using the following formula, and the average value was calculated | required.

(Dimensional stability evaluation: Heat shrinkage)
Three test pieces of 150 mm × 30 mm in each of the length direction (flow direction (MD direction)) and the width direction (vertical direction of the flow direction (TD direction)) from the molded bodies obtained in Examples and Comparative Examples Collected one by one.
Using the uniaxial stretching machine, the test piece was stretched 10% at 130 ° C. in the lengthwise direction of the sample at a stretching speed of 200 mm / min, quenched, and then allowed to stand in an atmosphere of 23 ° C. and 50% RH for 24 hours. Thus, normal adjustment was performed, and a 140 mm mark was attached under a 23 ° C., 50% RH atmosphere, and the dimensions were measured.
Next, the test piece with the marked line was left in an 85 ° C. constant temperature bath for 24 hours, then taken out and left in a 23 ° C., 50% RH atmosphere for 24 hours, and the dimension between the marked lines was measured. Using the dimension between the marked lines of the test piece before and after heating, the heat shrinkage rate was calculated using the following formula. In addition, the heat shrinkage rate described in the examples and comparative examples described in Table 2 is a calculated value of an arithmetic average in each of the length direction (MD) and the width direction (TD).

(Bending elastic gradient)
Three test pieces each having a size of 150 mm × 50 mm were collected from the molded body obtained in Examples and Comparative Examples from the length direction (MD direction) and the width direction (TD direction), and then at 23 ° C. and 50% RH. Normal state adjustment was performed by leaving it to stand in an atmosphere for 24 hours. Using this test piece, set in a three-point bending test jig (distance between fulcrums of 100 mm, wedge R3.2 mm) so that the interior side becomes the upper surface, and a load was applied from the center at a speed of 50 mm / min. JIS K7203 The bending elastic gradient was measured according to the above.

Example 1
[Method for producing foamed layer]
Mixed resin [modified PPE resin] in which 57.1 parts by weight of PPE resin (M) and 42.9 parts by weight of PS resin (B) are mixed so that the PPE resin component is 40% by weight and the PS resin component is 60% by weight. 100 parts and 0.34 parts by weight of talc are fed to a 115-152 mmφ tandem extruder, melted in a first stage extruder (115 mmφ) so that the resin temperature is about 280 ° C., and then 100 weights of resin mixture As a blowing agent, 3.4 parts by weight of a hydrocarbon-based blowing agent (iso-butane / n-butane = 85/15% by weight) was press-mixed with respect to parts. Then, after the cylinder temperature of the second stage extruder (152 mmφ) was cooled to 200 ° C., it was extruded from a circular die at 150 kg / hour under atmospheric pressure, and the mandrel (outer diameter was 445 mmφ, and the temperature was adjusted to 40 ° C. ) And taking it up at 8.0 m / min, and cutting it with a cutter to make it into a sheet and winding it into a roll.
The extruded foam sheet (α-1) obtained as a whole had an expansion ratio of 18 times, an open cell ratio of 85%, a basis weight of 230 g / m ² , a sheet width of 1400 mm, and a sheet thickness of 5.0 mm.
[Formation of pores in the foam layer]
While feeding out the obtained extruded foam sheet (α-1), the needles having a needle diameter of 2 mmφ are passed through a roll having a grid shape at a pitch of 5 mm, thereby having needles having a diameter of 1.4 mmφ in a grid shape at a pitch of 5.7 mm. The plate material was pressed to obtain a breathable foam layer (β-1) having a through hole (opening ratio = 4.7%).
[Formation of outdoor non-foamed layer]
PPE resin (A) 28.6 parts by weight, PS resin (B) 66.4 parts by weight so that the PPE resin component is 20% by weight, the PS resin component 89.4% by weight and the rubber component 0.6% by weight. Part and HIPS resin (C) 5.0 parts by weight mixed resin [modified PPE resin] (PPE-1) was melted and kneaded in an extruder, and at a resin temperature of 265 ° C. using a T-die, The film was extruded at a line speed of 4 m / min (weight per unit area: 60 g / m ² ).
Between a pair of pinching rolls, a modified PPE resin in a molten state (PPE-1) and a rayon cross-web non-woven fabric (E-1) drawn out from the other are introduced, pressure-bonded, and fibers are included. The breathable foam layer (β-1) was drawn between the next rolls so as to be on the PPE resin layer surface side and laminated to obtain a foam laminate sheet (γ-1a).
[Formation of indoor non-foamed layer]
A mixed resin (heat-resistant PS resin) (PS-1) in which 50 parts by weight of a methacrylic acid-modified polystyrene resin (D) and 50 parts by weight of an HIPS resin (C) are mixed is melted and kneaded with an extruder, and a T-die. Was extruded into a film (weight per unit area: 60 g / m ² ) at a resin temperature of 265 ° C. and a line speed of 4 m / min.
Between a pair of pinching rolls, a heat-resistant PS resin (PS-1) in a molten state and a cross-web nonwoven fabric made of rayon (E-1) drawn from the other are introduced, pressure-bonded, fibers are included, and subsequently Then, the extruded foam sheet (γ-1a) is drawn out and laminated so as to be in contact with the heat-resistant PS-based resin between the next nipping rolls, and then the LLDPE film (F) is thermally fused to the nonwoven fabric side to produce a foam laminate. A sheet (γ-1b) was obtained.
[Method of manufacturing perforated foamed sheet]
While feeding out the obtained foamed laminated sheet (γ-1b), by passing the needles having a needle diameter of 1.5 mmφ from the LLDPE film (F) surface through a roll having a lattice shape at a pitch of 10 mm, from the indoor non-foamed layer, A non-through hole (depth 3.5 to 4.0 mm) having an aperture ratio of 1.8% was provided to obtain an extruded foam laminated sheet (δ-1) for automobile interior materials.
[Method for producing molded article]
Using a compression molding machine (manufactured by Asano Laboratory Co., Ltd.), the four sides of the foamed laminated sheet (δ-1) were clamped, placed in a heating furnace, and heated for 60 seconds so that the surface temperature was 150 ° C. Then, plug molding was performed using a flat plate mold having a length of 300 mm and a width of 300 mm with a mold clearance of 5.0 mm.
Table 2 shows the results of measuring the physical properties of the foamed laminated sheet and the molded product.

(Example 2)
[Method for producing foamed layer]
In the same manner as in Example 1, an extruded foam sheet (α-1) was obtained.
[Formation of pores in the foam layer]
In the same manner as in Example 1, an extruded foam sheet (β-1) was obtained.
[Method for forming outdoor non-foamed layer]
The same mixed resin (modified PPE resin) (PPE-1) as in Example 1 was melted and kneaded with an extruder, and was formed into a film (weight per unit area) using a T-die at a resin temperature of 265 ° C. and a line speed of 4 m / min. 60 g / m ² ).
A molten modified PPE resin (PPE-1) and a cross-web nonwoven fabric (E-2) fed from the other are introduced between a pair of sandwiching rolls, and are crimped to include the fibers. Then, the extruded foam sheet (γ-1a) is drawn out and laminated so as to be in contact with the modified PPE resin, and then the LLDPE film (F) is thermally fused to the nonwoven fabric side to obtain a foam laminated sheet ( γ-2a) was obtained.
[Method for forming indoor non-foamed layer]
A foamed laminated sheet (γ-2b) was obtained in the same manner as in Example 1 except that the cross web nonwoven fabric (E-2) was used.
[Perforation processing to foam laminated sheet]
In the same manner as in Example 1, a foamed laminated sheet (δ-2) having a hole in the indoor side surface was obtained.
[Method for producing molded article]
Using a compression molding machine (manufactured by Asano Laboratory Co., Ltd.), the four sides of the foamed laminated sheet (δ-2) were clamped, placed in a heating furnace, and heated for 60 seconds so that the surface temperature was 150 ° C. Then, plug molding was performed using a flat plate mold having a length of 300 mm and a width of 300 mm with a mold clearance of 5.0 mm.
The results of measuring the physical properties of the molded product are shown in Table 2. In addition, when the obtained molded object was burned, the residue was not recognized.

(Example 3)
[Method for producing foamed layer]
In the same manner as in Example 1, an extruded foam sheet (α-1) was obtained.
[Formation of pores in the foam layer]
In the same manner as in Example 1, an extruded foam sheet (β-1) was obtained.
[Method for forming outdoor non-foamed layer]
The same mixed resin (modified PPE resin) (PPE-1) as in Example 1 was melted and kneaded with an extruder, and was formed into a film (weight per unit area) using a T-die at a resin temperature of 265 ° C. and a line speed of 4 m / min. 60 g / m ² ).
Between the pair of pinching rolls, the molten modified PPE resin (PPE-1) and the rayon cross-web nonwoven fabric (E-1) fed from the other are introduced, pressure-bonded, and fibers are included. Then, the extruded foam sheet (γ-1a) is drawn out and laminated so as to be in contact with the modified PPE resin between the next nipping rolls, and then the LLDPE film (F) is heat-sealed to the nonwoven fabric side to produce a foam laminate. A sheet (γ-3a) was obtained.
[Method for forming indoor non-foamed layer]
A foamed laminated sheet (γ-3b) was obtained in the same manner as in Example 2 except that the resin was modified PPE resin (PPE-1) and the nonwoven fabric was changed to a rayon crossweb nonwoven fabric (E-1). .
[Perforation processing to foam laminated sheet]
In the same manner as in Example 1, a foamed laminated sheet (δ-3) having a hole in the indoor side surface was obtained.
[Method for producing molded article]
Using a compression molding machine (manufactured by Asano Laboratory Co., Ltd.), the four sides of the foamed laminated sheet (δ-3) were clamped, placed in a heating furnace, and heated for 60 seconds so that the surface temperature was 150 ° C. Then, plug molding was performed using a flat plate mold having a length of 300 mm and a width of 300 mm with a mold clearance of 5.0 mm.
The results of measuring the physical properties of the molded product are shown in Table 2.

(Comparative Example 1)
[Method for producing foamed layer]
In the same manner as in Example 1, an extruded foam layer (α-1) was obtained.
[Formation of pores in the foam layer]
In the same manner as in Example 1, an extruded foam sheet (β-1) was obtained.
[Lamination of organic fiber nonwoven fabric on foam layer]
On both sides of the extruded foam sheet (β-1), via a hot melt film (L) (Kurabo Co., Ltd., Grand Vedder X-2200, basis weight 24 g / m ² ), a rayon cross-web nonwoven fabric (E-2) ), And sandwiched between hot rolls at 150 ° C. to obtain a foamed laminated sheet (γ-4).
[Method of manufacturing perforated foamed sheet]
While feeding out the obtained foamed laminated sheet (γ-4), the aperture ratio = 1 from the indoor non-foamed layer by passing the needles having a needle diameter of 1.5 mmφ from the indoor side through a roll having a 10 mm pitch in a lattice shape. An 8% non-through hole (depth 4.5 to 5.0 mm) was provided to obtain an extruded foam sheet (δ-4) for automobile interior materials.
[Method for producing molded article]
Using a compression molding machine (manufactured by Asano Laboratory Co., Ltd.), the four sides of the foamed laminated sheet (δ-4) were clamped, placed in a heating furnace, and heated for 60 seconds so that the surface temperature was 150 ° C. Then, plug molding was performed using a flat plate mold having a length of 300 mm and a width of 300 mm with a mold clearance of 5.0 mm.
The results of measuring the physical properties of the molded product are shown in Table 2.

FIG. 1 is an enlarged sectional explanatory view of a main part of a foamed laminated sheet for automobile interior material according to the present invention. FIG. 2 is an enlarged sectional explanatory view of a main part of the foamed laminated sheet for automobile interior material according to the present invention. FIG. 3 is an enlarged cross-sectional explanatory view of a main part of the automobile interior material according to the present invention.

Explanation of symbols

11 Open cell foam layer
DESCRIPTION OF SYMBOLS 12 (Indoor side) Non-foamed layer 13 (Outdoor side) Non-foamed layer 14 Organic fiber nonwoven fabric layer 15 Organic fiber nonwoven fabric layer 16 Crystalline resin film layer 17 Crystalline resin film layer 24 Adhesive layer 27 Foam laminated sheet for automobile interior materials

Claims (14)

A foam laminated sheet in which a non-foamed layer using an amorphous thermoplastic resin as a base resin is laminated on both sides of an open-cell foamed layer in which holes are formed in the thickness direction,
At least on the indoor side specific foam layer, a film comprising an organic fiber nonwoven fabric and a crystalline thermoplastic resin as a base resin is laminated, and
A foam laminate sheet for automobile interior materials, having holes reaching the interior of the foam layer from the surface of the indoor laminate.   The automobile interior material according to claim 1, wherein the foam layer is made of a thermoplastic resin foam sheet having an open cell ratio of 60 to 98% before the pores are formed in the thickness direction. Foam laminated sheet.   3. The foam laminate for an automobile interior material according to claim 1, wherein the heat-resistant resin constituting the foam layer is a modified polyphenylene ether resin comprising a mixed resin of a polystyrene resin and a polyphenylene ether resin. Sheet.   The thermoplastic resin constituting the foamed layer is 25 to 70 parts by weight of a polyphenylene ether resin and 75 to 30 parts by weight of a polystyrene resin (the total of the polyphenylene ether resin and the polystyrene resin is 100 parts by weight) The foamed laminated sheet for automobile interior materials according to any one of claims 1 to 3, which is a polyphenylene ether resin.   The amorphous thermoplastic resin constituting the non-foamed layer is at least one selected from the group consisting of a polystyrene-based resin, a heat-resistant polystyrene-based resin and a polyphenylene ether-based resin. The foaming laminated sheet for automotive interior materials in any one.   The foamed laminated sheet for automobile interior materials according to any one of claims 1 to 5, wherein a glass transition temperature of an amorphous thermoplastic resin constituting the non-foamed layer is 85 ° C or higher and 130 ° C or lower.   The foamed laminated sheet for automobile interior materials according to any one of claims 1 to 6, wherein the organic fiber nonwoven fabric is a nonwoven fabric obtained by subjecting a cross web to high-pressure columnar water flow processing or needling processing.   The foamed laminated sheet for automobile interior materials according to any one of claims 1 to 7, wherein the organic fibers constituting the nonwoven fabric are non-meltable organic fibers.   The foamed laminated sheet for automobile interior materials according to any one of claims 1 to 8, wherein the organic fibers constituting the nonwoven fabric are rayon fibers.   The organic fiber constituting the nonwoven fabric is formed by mixing 10 to 30% by weight of a heat-fusible binder fiber when the entire organic fiber is 100% by weight. The foaming laminated sheet for automotive interior materials as described. The foaming laminated sheet for automobile interior materials according to any one of claims 1 to 10, wherein the basis weight of the organic fiber nonwoven fabric is 50 g / m ² or less.   12. The foamed laminated sheet for automobile interior materials according to claim 1, wherein the melting point of the crystalline thermoplastic resin is 130 ° C. or less.   The foamed laminated sheet for automobile interior materials according to any one of claims 1 to 12, wherein the crystalline thermoplastic resin is a linear low density polyethylene resin. The automotive interior material obtained by shape | molding the foaming lamination sheet for automotive interior materials in any one of Claims 1-13.

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