JP2009214589A - Vehicular seat interior trim material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a lightweight vehicle interior trim skin material having excellent design and cushion performance, and capable of enhancing recyclability by eliminating a urethane layer without causing a problem such as the oozing-out of an adhesive, though a skin material is directly adhered to a base material layer without using soft polyurethane foam. <P>SOLUTION: This vehicle interior trim skin material has the design for enabling weight reduction by improving the recyclability by eliminating an adhesive process of urethane by being directly adhered to the base material layer without interposing the urethane layer by applying raising 4 to the reverse side of the skin material as a vehicle interior trim material of an automobile. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

TECHNICAL FIELD The present invention relates to a vehicle seat interior material for automobiles, railway vehicles, and the like, which relates to a vehicle seat interior material having cushioning properties, light weight, excellent recyclability, good feel and design. .

Conventionally, in vehicle seat interior materials such as automobiles, railway vehicles, etc., a soft skin material having a good touch feeling is used as a surface side layer, and a cushion material such as polyurethane foam is used as a back side layer. For the purpose of imparting cushioning properties, suppressing wrinkles and scars on the skin material, and preventing the adhesive from seeping out onto the surface of the skin material, a structure in which the joints are integrated is used. For example, in Patent Document 1, a knitted fabric, a nonwoven fabric, a suede-like synthetic leather, etc. is used as a skin material, and a polyurethane foam is laminated on the back surface of the skin material to create a vehicle seat interior material. A vehicle seat interior material is disclosed in which a base layer made of a resin plate or foam is bonded and laminated via an adhesive layer and molded into a predetermined shape.

However, the vehicle seat interior materials according to these inventions have a problem in that it takes a very complicated work to laminate polyurethane foam on one side of the skin material, and the manufacturing cost is high. In addition, since polyurethane foam is very flammable, in order to use it as a vehicle seat interior material, a large amount of an expensive flame retardant must be blended in the polyurethane foam, which increases the material cost. Furthermore, there is a problem that recycling becomes very difficult because of a composite material in which a polyurethane foam is laminated with a skin material in which polyester or the like is used.

Patent Document 2 also proposes a vehicle seat interior material in which a nonwoven fabric containing a low-melting point polyester or the like is laminated on the back surface of the skin material without using polyurethane foam.

However, in the vehicle seat interior material according to these inventions, although the problem derived from the polyurethane foam can be solved, there is a problem that the cushioning property of the nonwoven fabric is insufficient and a good touch cannot be obtained. In addition, the adhesive used for laminating and integrating the non-woven fabric and the skin material has a problem that it exudes during molding, creating irregularities on the surface of the skin material, resulting in poor appearance.

Moreover, in patent document 3, raising is given to the back side of the skin material as the skin material for the ceiling of vehicles such as automobiles and railway vehicles previously invented by the present inventors, and the ceiling base material layer is directly applied without using polyurethane foam. A technique is disclosed that eliminates the step of adhering to polyurethane foam by adhering. However, the ceiling skin material has poor design and can be used as a ceiling skin material, but cannot be used as a vehicle seat interior material.
JP 2003-245969 A JP 2000-095036 A Japanese Patent Laying-Open No. 2005-068577

In seat interior materials for vehicles such as automobiles and railway vehicles that have been widely used in the past, the skin material is prevented from wrinkling, prevents the adhesive from seeping between the stitches of the skin material, and provides cushioning properties. Therefore, when the skin material is attached to each part inside the vehicle, it is necessary to intervene the polyurethane foam. However, the problem to be solved by the present invention is to directly use the polyurethane foam without using the polyurethane foam. In spite of being mounted on each part inside the vehicle, there are no problems such as bleeding of adhesive, light weight, good design and cushioning, and polyurethane foam is omitted By this, it is providing the outstanding vehicle seat interior material which can improve recyclability.

In particular, the skin material used for vehicle seat interior materials has no thickness, and the unevenness of each part inside the vehicle tends to appear as scratches on the surface of the skin material, and it was difficult to omit polyurethane foam, but the tricot skin material The present invention has been found by raising the back surface of the resin and making it have a specific thickness, thereby providing cushioning properties and omitting the polyurethane foam.

The present invention provides brushing on the back side of a skin material as a vehicle seat interior material for automobiles, railway vehicles, etc., and enables direct adhesion to each part inside the vehicle without using polyurethane foam. The present invention provides a vehicle seat interior material having a design property that eliminates processes, improves recyclability, and realizes weight reduction. That is, the present invention provides the following means.

[1] The vehicle seat interior material to be mounted on each part inside the vehicle by molding or sewing is a single body made of a tricot knitted fabric, and a mesh pattern is expressed on the surface of the tricot knitted fabric, the tricot knitted fabric The interior of the vehicle seat interior material is characterized in that a raised surface is formed by raising the back surface of the vehicle and is directly attached to each part inside the vehicle.

[2] The fiber constituting the tricot knitted fabric is at least one fiber selected from synthetic fibers or natural fibers, and the thickness of the fiber used in the raised portion is 0.4 to 4.0 dtex. The skin material for vehicle interior according to [1], wherein the tricot knitted fabric has a thickness of 1.0 mm to 8.0 mm.

In the invention of [1], since the vehicle seat interior material is composed of a single piece made of a tricot knitted fabric without attaching a cushion material such as polyurethane foam, a complicated polyurethane foam lamination process can be omitted and recycled. It becomes a vehicle seat interior material with improved performance. Further, since the mesh pattern is expressed on the surface of the tricot knitted fabric, the tricot knitted fabric can be used as a vehicle seat interior material in various parts of the vehicle interior such as the back and the back where the design is required. Furthermore, since the back surface of the tricot knitted fabric is raised to form a raised portion, a vehicle seat interior material that can be directly bonded to each part inside the vehicle can be provided.

In the invention of [2], at least one kind of fiber selected from synthetic fiber or natural fiber is used as the fiber constituting the vehicle interior skin material, and the thickness of the fiber used in the raised portion is 0.4. Since it is composed of a fiber having a thickness of ˜4.0 dtex, it is a lightweight vehicle seat interior material. Further, since the tricot knitted fabric has a thickness of 1.0 mm to 8.0 mm, it has cushioning properties, and the adhesive does not ooze out when adhering to each part of the vehicle interior. The skin material for both interior materials is obtained in which the unevenness of each part of the interior material does not appear as scratches on the surface of the skin material as it is.

The vehicle interior skin material of the present invention will be described in detail with reference to the drawings. FIG. 1 is a cross-sectional view showing an embodiment of the skin material (1) for both interior materials of the present invention, and a partially enlarged view is also shown. That is, the vehicle interior skin material is made of a tricot knitted fabric, the surface has a mesh-pattern skin portion, and the back surface has a raised portion (4) raised. When used as a vehicle interior material, the raised portion (4) serves as an adhesive surface with each part (2) of the vehicle interior via an adhesive layer.

The fibers constituting the tricot knitted fabric may be natural fibers or synthetic fibers, but synthetic fibers such as polyester and polypropylene are preferred in terms of raising properties and recyclability.

The vehicle interior skin material (1) of the present invention is knitted by a tricot knitting machine having three or more ridges, and the surface skin portion is expressed by a back yarn and a mesh pattern is expressed by up to three guide bars. The skin becomes invisible. The middle yarn connects the back yarn and the front yarn, and the front yarn knits the raised portion (4) on the back surface. Furthermore, if the number of front heels is two, the amount of the front yarn is doubled, and the raised portion (4) that can provide good adhesion and cushioning properties can be knitted. When a tricot knitted fabric manufactured by a tricot knitting machine having two or less wrinkles is used, the raised front yarn is hardened, and graininess tends to appear, resulting in poor surface quality.

Although there is no restriction | limiting in particular about the gauge of the tricot knitting machine to be used, It is preferable to use a 28-36 gauge knitting machine. If it is less than 28 gauge, the surface material becomes coarse, and a fine mesh-like surface appearance cannot be obtained. If it exceeds 36 gauge, the thread to be used becomes thin, so that the friction strength suitable for the vehicle application cannot be obtained.

Further, the course on the knitting machine during tricot knitting is preferably 55 to 70 courses / inch. If it is less than 55 courses / inch, the density of raised hair is low and a fine appearance of the mesh pattern cannot be obtained. If it exceeds 70 courses / inch, the surface skin portion on which the obtained mesh pattern is expressed is used for a vehicle interior. It becomes a skin material (1).

Since the back surface is raised, it is raised as a 3 to 12 needle swinging tissue as shown in FIG. 2 which is easy to raise.

By forming the fibers constituting the raised portion with a fiber group of 0.4 to 4.0 dtex, the vehicle interior skin material (1) is lightweight and has good cushioning properties. Furthermore, if the crimped yarn is used for the fiber group constituting the raised portion, the cushioning property can be improved.

The thickness of the tricot knitted fabric is preferably 1.0 mm to 8.0 mm, and more preferably 2.0 to 6.0 mm. This thickness provides good cushioning properties, and the adhesive does not ooze out when adhering to each part (2) of the vehicle interior, and the unevenness of each part (2) inside the vehicle is directly on the surface of the skin material. The vehicle interior skin material (1) does not appear as a scar. The thickness is adjusted according to the number of needle swings on the back surface, the number of yarns, raising conditions, and the like.

The method of raising is not particularly limited, but a method using a needle cloth is generally used, and fibers are trimmed by shearing to prepare the surface after raising.

The method of laminating the vehicle interior skin material to each part (2) inside the vehicle according to the present invention is called molding sheet, and the vehicle interior skin material is used for each part (2) inside the vehicle such as the back, gusset and the like. Depending on the shape, a method of laminating with a press using an adhesive at the same time as molding or after molding, or a vehicle interior skin material (1) called a sewing sheet, such as the back, gusset, etc. After sewing according to the shape of a part, the method can be used in which the vehicle interior covering material (1) is placed on each part and laminated with a press using an adhesive.

The adhesive used at the time of lamination is a hot melt adhesive, for example, polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer polyolefin resin, or a modified product of the polyolefin resin alone. Or it is a mixture of 2 or more types, and it is preferable to use a sheet-like or powdery resin.

As shown in the enlarged view of FIG. 1, the depth of the adhesive in the raised portion (4) is preferably 1/3 to 2/3 of the raised portion. If it is less than 1/3, the adhesive strength is weak and may be peeled off during use. If it is more than 2/3, the cushioning property is impaired, which is not preferable.

Examples of the present invention will be described below, but the present invention is not limited to the following examples. In addition, the measurement of the characteristic value in an Example was performed as follows. (1) Thickness Measured with a dial gauge with a constant load of 0.78N. (2) Cushioning sensory evaluation, manufactured test sample is press-bonded to a plastic plate with a thickness of 5 mm, the surface of the test sample is touched, and the most preferred cushioning material is grade 5, and the vehicle interior skin material A five-level evaluation was made with the first class of plastic plates that were not bonded. Grade 4 or higher was accepted. (3) Appearance The manufactured test sample was press bonded to a 5 mm thick plastic plate, and the appearance of the test sample was visually evaluated. A five-point evaluation was performed, with the most preferable one having no oozing out of the adhesive and no wrinkling being classified as grade 5, and the most unfavorable one having wrinkles and marked unevenness being classified as first grade. Grade 4 or higher was accepted.

Example 1 A 28-gauge tricot knitting machine is used, 56 dtex / 24f of polyester is used for the back yarn, and 84 dtex / 36f of polyester is used for the middle yarn. The mesh pattern was knitted on the surface by alternately inserting open and closed loops. Polyester 84dtex / 36f was passed through the front yarn and polyester 84dtex / 36f was passed through the other front yarn 1 in 1 out, and the raised surface was knitted in a closed loop with 5 stitches. Knitted at a density of 46 courses / 2.54 cm, dyed with a gray disperse dye with a liquid dyeing machine at 130 ° C. for 60 minutes, dried and then treated with a raised oil agent, then backed with a needle cloth raising machine Brushed, surfaced by shirring, and processed for width to obtain a vehicle seat interior material. The basis weight was 240 g / m ² and the thickness was 3.8 mm.

<Example 2> A vehicular seat interior material was obtained in the same manner as in Example 1 except that a three-piece tricot knitting machine comprising 28 gauges was used and only the polyester 84 dtex / 36f was used as the front yarn. The basis weight was 225 g / m ² and the thickness was 3.3 mm.

Example 3 A vehicle seat interior material was obtained in the same manner as in Example 1 except that polyester 84dtex / 72f was used for the front yarn and polyester 84dtex / 72f was used for the other front yarn. The basis weight was 234 g / m ² and the thickness was 3.6 mm.

Example 4 A vehicle seat interior material was obtained in the same manner as in Example 1 except that polyester 84 dtex / 24f was used for the front yarn and polyester 84 dtex / 24f was used for the other front yarn. The basis weight was 245 g / m ² and the thickness was 3.9 mm.

<Example 5> A vehicle seat interior material was obtained in the same manner as in Example 1 except that 5-swing was changed to 4-swing. The basis weight was 186 g / m ² and the thickness was 2.8 mm.

<Example 6> A vehicle seat interior material was obtained in the same manner as in Example 1 except that the 5-hand swing was changed to the 10-hand swing. The basis weight was 423 g / m ² and the thickness was 4.2 mm.

<Comparative Example 1> A vehicle seat interior material was obtained in the same manner as in Example 1 except that back surface raising was not performed. The basis weight was 243 g / m ² and the thickness was 1.2 mm. The cushioning and appearance were both unsatisfactory and not satisfactory.

<Comparative Example 2> A vehicle seat interior material was obtained in the same manner as in Example 1 except that polyester 108 dtex / 24f was used for the front yarn and polyester 108 dtex / 24 was used for the other front yarn. The basis weight was 455 g / m ² and the thickness was 4.7 mm.

<Comparative Example 3> A vehicle seat interior material was obtained in the same manner as in Example 1 except that the 5-hand swing was changed to the 2-hand swing. The basis weight was 103 g / m ² and the thickness was 1.8 mm.

Table 1 shows the results of examining the cushioning properties and the appearance of each vehicle seat interior material obtained as described above based on the evaluation method.

As is clear from Table 1, the vehicle seat interior materials of Examples 1 to 6 all obtained vehicle seat interior materials excellent in cushioning properties and appearance.

On the other hand, Comparative Examples 1 and 3 did not give good cushioning properties and appearance, and Comparative Example 2 had cushioning properties, but adhesive exudation occurred and good appearance was not obtained.

It is the schematic of the vehicle seat interior material concerning one Embodiment of this invention. It is a knitting | organization organization chart of the vehicle seat interior material concerning one Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ......... Vehicle seat interior material 2 ......... Each part 3 in the vehicle ......... Composite part 4 to each part in the vehicle ......... Raised part

Claims (2)

In the vehicle seat interior material to be mounted by molding or sewing to each part inside the vehicle, it is composed of a single piece made of tricot knitted fabric, the mesh pattern is expressed on the surface of the tricot knitted fabric, and the back surface of the tricot knitted fabric is A vehicle seat interior material, wherein a raised portion is formed by raising, and is directly attached to each part inside the vehicle. At least one fiber selected from synthetic fibers or natural fibers is used as the fiber constituting the tricot knitted fabric, and the thickness of the fiber used for the raised portion is 0.4 to 4.0 dtex. The vehicle seat interior material according to claim 1, wherein the tricot knitted fabric has a thickness of 1.0 mm to 8.0 mm.