JP2012240380A - Laminated sheet for automotive interior material, molding method, and automotive interior material molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a laminated sheet whose both ends in a width direction are securely held when thermoforming and which has material transport stability in the thermoforming.SOLUTION: In an outer skin laminated sheet in which a modified PPE resin non-foamed sheet is laminated and integrated on both sides of a modified PPE resin foamed sheet, and an outer skin material is laminated on one face of the modified PPE resin non-foamed sheet in a width direction via a hot-melt adhesive layer, the hot-melt adhesive layer is not laminated within 30 to 100 mm from both ends in the width direction of the outer skin laminated sheet.

Description

  The present invention relates to a skin laminate sheet (a laminate sheet for automobile interior materials), a molding method of the sheet, and a molded body (automobile interior material molded body).

  Conventionally, a laminated sheet in which a modified polyphenylene ether resin (hereinafter sometimes referred to as a “modified PPE resin”) foamed sheet is integrally laminated with a modified polyphenylene ether resin non-foamed sheet is heat resistant and lightweight. In addition, since it is excellent in moldability and the like, it is suitably used for automobile interior materials.

  As such a laminated sheet, Patent Document 1 discloses a non-foamed foamed laminated sheet obtained by laminating a modified polyphenylene ether-based resin non-foamed layer on both sides or one side of a foamed sheet using a modified polyphenylene ether-based resin as a base resin. A laminated sheet for automobile interior materials is disclosed in which a hot-melt adhesive layer is provided on one side of the layer.

  The laminated sheet is a laminated sheet in which the skin material is laminated and integrated on the entire surface in the width direction on the upper side of the laminated sheet, then continuously conveyed, the laminated sheet is supplied to the heating furnace, and the skin is laminated and integrated. After being heated to a predetermined temperature, it is conveyed to a mold and molded into a desired shape.

  In order to transport the laminated sheet, the endless belt or the endless belt or the endless chain is pierced sequentially at both ends in the width direction of the laminated sheet, and the endless belt or The laminated sheet is conveyed by operating the endless chain, and the laminated sheet is heated and softened in a heating furnace, and then shaped by a molding die.

  However, when pins are pierced at both ends in the width direction of the laminated sheet, the laminated sheet is relatively hard, so the pins pierce steadily, whereas the skin material laminated and integrated on the laminated sheet is relatively Because it is made of a soft material, not only the pins do not pierce steadily, but also the skin material becomes a resistance and the grip by the pin piercing to the laminated sheet becomes insufficient, or the pin once stuck in the laminated sheet comes off When transporting, the laminate sheet with the outer skin laminated from the endless belt or endless chain will come off and fall into the heating furnace, causing problems during molding, resulting in problems that prevent good molding. doing.

  Therefore, there is a demand for the emergence of a laminated sheet that does not cause a problem in the molding process by sequentially piercing pins fixedly laid on the outer peripheral portion of the endless belt or the endless chain and transporting the laminated sheet.

Utility Kaihei 9-29875

  The object of the present invention is to reliably hold both ends of the material in the width direction during material conveyance in thermoforming, and not only can prevent the material from dropping in the heating furnace, but also can perform shaping accurately. It is providing the laminated sheet, the shaping | molding method using this laminated sheet, and the molded object using this laminated sheet.

  The inventor is a modified PPE resin foam laminated sheet obtained by laminating a non-foamed layer made of a modified PPE resin on both sides of a modified PPE resin foam sheet obtained by extrusion foam molding of a modified PPE resin. It is a skin laminate sheet obtained by laminating a hot-melt adhesive on one of the non-foamed layer surfaces (specifically, the indoor non-foamed layer surface) and laminating a skin material layer via the adhesive layer. Then, by laminating the skin material in a state where the hot melt adhesive layer is not laminated inside each specific distance from both ends in the width direction of the skin laminated sheet, the skin laminated sheet is placed on the conveyance clamp pin. The present inventors have found that the laminated sheet excluding the skin material can be securely gripped, and have reached the present invention.

That is, the present invention
[1] A modified polyphenylene ether-based resin non-foamed sheet is laminated and integrated on both surfaces of a modified polyphenylene ether-based resin foamed sheet, and either one of the modified polyphenylene ether-based resin non-foamed sheets is interposed via a hot melt adhesive layer. A skin laminated sheet in which skin materials are laminated,
A skin laminate sheet, characterized in that a hot melt adhesive layer is not laminated on the inner side of both ends from 30 to 100 mm in the width direction of the skin laminate sheet.
[2] A modified polyphenylene ether resin non-foamed sheet is laminated and integrated on both sides of a modified polyphenylene ether resin foam sheet, and either one of the modified polyphenylene ether resin non-foamed sheets is interposed via a hot melt adhesive layer. A skin laminated sheet made by laminating a skin material is conveyed in a state of being gripped by using a pair of endless chains or belts having pins fixed to the outer peripheral surface at predetermined intervals, and subjected to heating and thermoforming. A method of forming a laminated sheet,
Place the skin laminate sheet so that the skin material is on the upper side, and in the width direction of the skin laminate sheet, pierce the pin into the portion where the hot melt adhesive layer is not laminated on the inner side of both ends from 30 to 100 mm. A method for forming a skin laminate sheet, characterized by
[3] A molded article obtained by thermoforming the laminated sheet according to [1], and a molded article obtained by the method for molding a skin laminated sheet according to [4] [2] body,
About.

  The skin laminated sheet of the present invention is formed by laminating and integrating a modified PPE resin non-foamed sheet on both sides of a modified PPE resin foam sheet, and a hot melt adhesive layer is provided on one of the modified PPE resin non-foamed sheets. A skin laminate sheet in which a skin material is laminated, and a hot melt adhesive layer is not laminated in a region (part) of 30 to 100 mm from both ends in the width direction of the skin laminate sheet. In order to transport the skin laminated sheet, both ends of only the laminated sheet excluding the skin material are inserted into the both ends in the width direction of the skin laminated sheet in order to pierce the pins that are fixedly laid on the outer periphery of the endless belt or endless chain. Can be securely gripped, and the laminated sheet can be held in a stable state without detaching the skin laminated sheet from the gripping tool when transported to the heating furnace. It can be conveyed as well as thermoforming.

FIG. 1 shows a cross-sectional configuration of a skin laminate sheet according to an embodiment of the present invention. FIG. 2 is a schematic diagram showing the relationship between the width of each constituent material of the skin laminated sheet and the width of the foamed layer 10 in the example of the present invention. The distance from the end in the width direction of each constituent material is shown with the end in the width direction of the foam layer 10 as the reference position, and the measured value is that the end of each constituent is more than the end of the foam layer 10. When it exists inside, it was set as a plus display, and when it existed outside, it was set as a minus display. In addition, the number accompanying a code | symbol 1 is the left side (L) of the width direction of a skin lamination sheet, 2 means the right side (R).

  The skin laminated sheet of the present invention is formed by laminating and integrating a modified PPE resin non-foamed sheet on both sides of a modified PPE resin foam sheet, and either one of the modified PPE resin non-foamed sheets is a hot melt adhesive layer. A skin laminate sheet in which a skin material is disposed and laminated via a hot melt adhesive layer is not laminated in a region of 30 to 100 mm from both ends in the width direction of the skin laminate sheet. The present invention relates to a skin laminated sheet.

  The thermoforming method of the present invention ensures that only the laminated sheet excluding the skin material is pierced with a pin at a portion where no hot melt adhesive layer of 30 to 100 mm is laminated from both ends in the width direction of the skin laminated sheet. The outer skin layered sheet is placed on the upper side and thermoformed and thermoformed, so that the endless belt or endless chain is pierced into the pin fixedly placed on the outer periphery of the endless belt. The present invention relates to a method for forming a skin laminate sheet, which can be gripped and can be transported and thermoformed in a stable state without the laminate sheet being detached from the gripping tool when transported to a heating furnace. .

  The skin laminated sheet of the present invention (sometimes referred to as “laminated sheet for automobile interior materials”), a molding method thereof and a molded body (sometimes referred to as “automobile interior material molded body”) are based on the drawings. Although explained, it is not limited to these.

  FIG. 1 shows a cross-sectional configuration of a skin laminated sheet according to an embodiment of the present invention. The skin laminated sheet 30 of FIG. 1 has non-foamed layers 11 and 13 (inside the indoor side) having a modified PPE-based resin as a base resin on both surfaces of a foamed layer 10 which is an extruded foam sheet having a modified PPE-based resin as a base resin. A non-foamed layer 11 and an outdoor non-foamed layer 13) are formed, and an abnormal sound preventing layer 20 is laminated on the surface of the outdoor non-foamed layer 13 via an adhesive layer 16, thereby causing a non-foamed indoor side. A hot melt adhesive layer 18 is laminated on the surface of the layer 11. Further, a skin material 22 serving as a design layer is laminated via a hot melt adhesive layer 18.

  The thermoplastic resin used as the base resin of the foamed layer 10 which is an extruded foam sheet in the present invention is a resin mixture of PPE resin and polystyrene resin (hereinafter referred to as “PS resin”), PPE. Examples thereof include modified PPE resins such as styrene / phenylene ether copolymers such as styrene graft polymers. The modified PPE resin is preferable in that it has excellent quality such as heat resistance and rigidity, and is easy to process and manufacture.

  The modified PPE resin used in the present invention is 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 of the PPE resin in the modified PPE resin include, for example, poly (2,6-dimethylphenylene-1,4-ether), poly (2-methyl-6-ethylphenylene-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). These may be used alone or in combination of two or more.

  Of these, poly (2,6-dimethylphenylene-1,4-ether) is preferable from the viewpoint of versatility and cost of raw materials. In addition, when it is desired to impart flame retardancy, poly (2-methyl-6-chlorophenylene-1,4-ether) or poly (2-methyl-6-bromophenylene-1,4) containing a halogen element. -Ether) and poly (2-ethyl-6-chlorophenylene-1,4-ether) are preferred.

  Specific examples of the PS resin in the modified PPE resin include polystyrene, a styrene-α-methylstyrene copolymer, and a styrene-butadiene copolymer represented by high impact polystyrene. Among these, polystyrene is preferable from the viewpoints of versatility and cost.

  In the present invention, the proportion of the PPE resin and the PS resin in the mixed resin constituting the modified PPE resin that is the base resin of the extruded foam sheet (the total amount of both) is PPE resin 25-70. It is preferably 30% by weight and 30 to 75% by weight of PS resin, and more preferably 30 to 60% by weight of PPE resin and 40 to 70% by weight of PS resin. When the mixing ratio of the PPE resin is less than 25% by weight, the heat resistance tends to be inferior, and when it exceeds 70% by weight, the viscosity at the time of heating flow increases, and foam molding may be difficult.

  The foam layer 10 which is a foam sheet in the present invention is preferably obtained by extrusion foam molding using a hydrocarbon-based foaming agent as a foaming agent.

  The hydrocarbon-based foaming agent used when obtaining the foamed layer 10 which is a foamed sheet is preferably a volatile foaming agent, and specific examples include ethane, propane, butane, pentane and the like. Especially, the hydrocarbon type foaming agent whose Kauri butanol value (KB value) which shows the solubility of a foaming agent is 20-50 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, among the specific examples of the foaming agent, the moderate solubility of the foaming agent and the dissipative property of the foaming agent are small, and the change in foamability with the aging of the foamed layer is small. Alternatively, a mixture of isobutane and normal butane having a high ratio of isobutane is preferable. When the blowing agent is a mixture of isobutane and normal butane, the isobutane content in the mixture is preferably 50% by weight or more. When the isobutane content is less than 50% by weight, the dissipating property of the foaming agent is large, and the change in foaming property with the aging of the foamed layer tends to be large.

  The addition amount of the hydrocarbon-based foaming agent at the time of extrusion foaming in the present invention is preferably 2.0 to 5.0 parts by weight, and 3.0 to 5.0 parts by weight with respect to 100 parts by weight of the thermoplastic resin. More preferably, it is a part. If the amount of the hydrocarbon-based foaming agent added is less than 3.0 parts by weight, the secondary foaming ratio at the time of molding heating may be too low, which tends to have an adverse effect on obtaining good moldability. If it exceeds 0.0 part by weight, extrusion foaming becomes unstable, and the surface of the foamed sheet tends to be rough.

  In the present invention, the thickness of the foamed layer 10 (primary foamed layer), which is a foamed sheet using a modified PPE resin as a base resin, is preferably 1.0 to 5.0 mm, and 2.3 to 3. 5 mm is more preferable. If the thickness of the foamed layer 10 (primary foamed layer), which is a foamed sheet, is less than 1.0 mm, the strength and heat insulating properties are inferior and may not be suitable as a foamed laminated sheet for automobile interior materials. On the other hand, when the thickness exceeds 5.0 mm, the foamed layer 10 (primary foamed layer) is further foamed (secondary foamed) during heating during molding, but it is difficult to transmit to the center of the foamed layer 10 in the thickness direction. Sufficient heating cannot be performed, and moldability tends to decrease. In addition, if the heating time is increased to perform sufficient heating, bubbles on the surface of the foamed layer are generated, which tends to make it difficult to obtain an acceptable product.

  In the present invention, the expansion ratio of the foam layer 10 (primary foam layer) which is a foam sheet is preferably 16 to 25 times, and more preferably 18 to 23 times. If the expansion ratio of the foam layer 10 (primary foam layer) is lower than 16 times, the effect of reducing the weight tends to be small. When the foaming ratio of the foamed layer 10 (primary foamed layer) exceeds 25 times, the strength is lowered and the moldability tends to be lowered due to difficulty in heating to the center.

  In the present invention, the closed cell ratio of the primary foam layer forming the foam layer 10 which is a foam sheet is preferably 80% or more, and more preferably 85% or more. When the closed cell ratio is less than 80%, the heat insulation and rigidity are inferior, and it is difficult to obtain the desired secondary foaming ratio by molding heating, and the moldability tends to be inferior.

  In the present invention, the cell diameter of the foamed layer 10 (primary foamed layer) which is a foamed sheet is preferably 0.05 to 0.9 mm, and more preferably 0.1 to 0.7 mm. If the cell diameter of the foam layer 10 is smaller than 0.05 mm, sufficient strength tends to be difficult to obtain, and if it exceeds 0.9 mm, the heat insulation tends to be poor.

In the present invention, the basis weight of a foam sheet foamed layer 10 (primary foamed layer) is preferably ^{80~180g / m 2, 100~150g / m} 2 is more preferable. When the basis weight of the foamed layer 10 is lower than 80 g / m ² , the required rigidity as the laminated sheet 40 for automobile interior materials tends to be insufficient, and when the basis weight exceeds 180 g / m ² , the effect of lightness tends to decrease. There is.

In the present invention, the amount of residual volatile components in the foamed layer 10 (primary foamed layer), which is a foamed sheet, is preferably 1.0 to 5.0% by weight with respect to the total weight of the foamed layer 10, and 2.0 to More preferred is 4.5% by weight. If the amount of residual volatile components in the foamed layer 10 is less than 1.0% by weight, the secondary foaming ratio may be too low, and this tends to affect obtaining good moldability. On the other hand, if the amount of residual volatile components in the foamed layer 10 exceeds 5.0% by weight, air retention may occur between the adhesive layer and the dimensional stability over time tends to decrease.
The amount of residual volatile components in the foamed layer 10 may be measured by gas chromatography, but usually the temperature range above the temperature at which the heat-resistant resin begins to soften the test piece of the foamed layer 10 and below the decomposition temperature. It can be measured by the difference in weight before and after heating to sufficiently volatilize volatile components by heating.

  In general, in the foamed layer 10 (primary foamed layer) which is a foamed sheet, a cell that has been flattened during extrusion foam molding changes its shape in a direction to eliminate the flatness ratio during molding heating. Heat shrinkage is developed. The heat shrinkage results in heat-resistant deformation of the automobile interior material molded body 40.

  In the present invention, “heat-resistant deformation” means that, when the automotive interior material molded body 40 is subjected to a heating test, a change in the size of the automotive interior material molded body 40 occurs due to shape deformation caused by heat shrinkage of the foamed cell before and after heating. Means.

  In the present invention, in order to suppress changes in shape such as heat-resistant deformation, the cell shape of the foamed layer 10 (primary foamed layer) can be increased by increasing the cell density of the double-sided surface layer portion of the foamed layer at the time of forming the extruded foamed sheet. By forming both surfaces as a hard skin layer by cooling uniformly, the amount of heat shrinkage can be suppressed by stiffening the surface layer portion of the foam layer.

  Furthermore, the amount of heat shrinkage can be reduced by making the change in the cell internal pressure of the foamed layer 10 as small as possible. For example, the change in the cell internal pressure can be made as small as possible by securing a curing time of 30 days or more after the foaming layer 10 is extruded and foamed until the non-foamed layers 11 and 13 are laminated.

  Furthermore, the amount of heat-resistant deformation due to heat shrinkage is controlled by controlling the heating temperature at the time of secondary thermoforming to a range of 120 to 150 ° C., and molding the cells under the conditions that do not give distortion at the time of thermoforming to the cells of the foam layer 10. Even if the non-foamed layer 11 or 13 is not laminated, it can be reduced.

  The base resin of the foamed layer 10 which is a foamed sheet used in the present invention includes, as necessary, a bubble regulator, impact resistance improver, lubricant, antioxidant, antistatic agent, pigment, stabilizer, odor A reducing agent, talc or the like may be added.

  In the present invention, as the thermoplastic resin used for the non-foamed layer 11 or 13, a modified PPE resin or a heat-resistant PS resin is preferably used from the viewpoint of adhesion to the foamed layer 10. A modified PPE resin is more preferred from the viewpoints of excellent quality such as heat resistance and rigidity as well as the foamed layer 10 and easy workability and production.

  In the present invention, the modified PPE resin used for the non-foamed layer 11 or 13 is modified by mixing a PPE resin and a PS resin in the same manner as the foamed layer 10 described above. , Refers to a mixed resin of PPE resin and 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 non-foamed layer, the reasons for using them, and the like are the same as those described for the foamed layer 10. However, as a preferable specific example of the PS resin, a styrene-butadiene copolymer represented by high impact polystyrene (HIPS) is preferable because the impact resistance improving effect of the non-foamed layer 11 or 13 is large.

In the present invention, the ratio of the PPE resin and the PS resin in the mixed resin constituting the modified PPE resin used for the non-foamed layer 11 or 13 is 5 to 70% by weight of the PPE resin and 30 to 95% by weight of the PS resin. %, More preferably 7 to 50% by weight of PPE resin and 50 to 93% by weight of 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. .

60-200 g / m < ² > is preferable and the fabric weight of each layer of the non-foamed layers 11 and 13 in this invention has more preferable 75-180 g / m < ² >. When the surface area of the non-foamed layer is lower than 60 g / m ² , the strength, heat resistance and the like tend to decrease, and when it is higher than 200 g / m ² , the light weight effect tends to decrease.

  In the present invention, the widths of the modified PPE resin non-foamed layers 11 and 13 laminated on both surfaces of the modified PPE resin foam layer 10 are preferably shorter than the width of the foam layer 10 by 0 to 15 mm from the both ends. That is, it is preferable that the non-foamed layers 11 and 13 are laminated from 0 to 15 mm inside from both ends in the width direction of the foamed layer.

  When the width of the non-foamed layer protrudes outside the width of the foamed layer and is laminated, the non-foamed layer protruding from the foamed layer comes into contact with the side surface of the jig when the skin laminated sheet is set on the conveying jig (pin). This is not preferable because cracks and chipping due to this may cause a fragmented foreign material to be mixed into the automobile interior material molded body 40. In addition, if the width of the non-foamed layer is laminated only to the inner side exceeding 15 mm from both ends in the width direction of the foamed layer, foaming of the laminated sheet is performed when sequentially piercing pins fixedly laid on the outer periphery of the endless belt or endless chain. Since only the layers are gripped, it is not preferable because the gripping of the laminated sheet is not sufficient, and a drop-out trouble occurs due to the pin coming off during transport.

  In the present invention, when a non-foamed layer is formed, an impact resistance improver, a filler, a lubricant, an antioxidant, an antistatic agent, a pigment, a stabilizer, an odor reducing agent, etc. are used alone as necessary. Or you may add in combination of 2 or more types.

  The impact resistance improver is a punching process when the non-foamed layers 11 and 13 are laminated on the foamed layer 10 and the skin laminated sheet 30 that is secondarily foamed at the time of heat molding is molded as an automobile interior material molded body 40, or the skin. This is effective for preventing cracking of the non-foamed layers 11 and 13 when the laminated sheet 30 and the automobile interior material molded body 40 are transported. The impact resistance improver in the present invention can be used without particular limitation as long as the effect is improved by mixing with the base resin. The impact resistance improver may be a component capable of exhibiting the impact resistance improving effect introduced into the thermoplastic resin by modification by polymerization. For example, a mixture containing an impact resistance improving component such as HIPS is mixed. Even when used for a non-foamed layer, impact resistance can be imparted to the non-foamed layer 11 or 13.

  The skin laminate sheet 30 of the present invention has an indoor non-foamed layer 11 and an outdoor non-foamed layer 13 laminated on both surfaces of the foamed layer 10, and an abnormal sound prevention layer 20 is laminated on the outdoor non-foamed layer 13. A skin material 22 is laminated through a hot melt adhesive 18 on a laminated sheet 25 in which a hot melt adhesive 18 is laminated on the non-foamed layer 11.

  The noise prevention layer 20 is a member that is laminated on the outermost outermost layer of the automobile interior material molded body 40, and is a portion that comes into contact with the vehicle body steel plate of the automobile, and is due to contact between the automobile interior material molded body 40 and the automobile steel plate. A function of preventing rubbing noise is required, and a fiber material is preferably used.

As the noise prevention layer 20, any non-woven fabric or woven fabric material can be used. The nonwoven fabric used for the noise preventing layer 20 may be of any type as long as the raw material fibers are joined by an adhesive, molten fiber, or a mechanical method. The type of the raw fiber is not particularly limited, and any of synthetic fiber, semi-synthetic fiber, or natural fiber can be used. Specifically, for example, synthetic fibers such as polyester, polypropylene, polyamide (nylon), polyacrylonitrile, and natural fibers such as wool, cotton, and cellulose can be used. Among them, polyester fibers are preferable, and particularly heat resistance. High polyethylene terephthalate fibers are preferred. Examples of the type of non-woven fabric include a bonded binder-bonded fabric, a needle punched fabric, a spun pond fabric, a spray fiber fabric, a water needle fabric, and a stitch bond fabric, and any non-woven fabric can be used.
The reason why the nonwoven fabric containing synthetic fiber is preferable as the noise preventing layer 20 is that it is easy to manufacture, can be manufactured in a large amount at a low cost, and can effectively prevent rubbing noise with relatively light weight.

In consideration of quality and cost, the nonwoven fabric used for the noise prevention layer 20 preferably has a basis weight of 12 to 70 g / m ² and has a basis weight of 20 to 60 g / m ² . Is more preferable. If the basis weight of the nonwoven fabric used for the noise preventing layer is less than 12 g / m ² , the function of preventing rubbing noise due to contact with the automobile body steel plate tends to be reduced. On the other hand, when the basis weight of the nonwoven fabric exceeds 70 g / m ² , the weight increases unnecessarily and the cost tends to increase.

  The width of the noise preventing layer 20 laminated on the outdoor non-foamed layer 13 side is preferably 30 mm or shorter or 100 mm or shorter from the both ends of the width of the foamed layer 10 constituting the foamed laminated sheet. That is, the noise prevention layer 20 is preferably laminated from both ends in the width direction of the foamed layer to the outside of 30 mm or less or the inside of 100 mm or less.

  If the width of the noise prevention layer 20 is also laminated on the outside of the foam layer by more than 30 mm from the both ends in the width direction, the part protruding from the foam sheet will be caught by the conveying clamp pin and become a foreign material, forming There is a tendency to cause poor appearance by adhering to and mixing in products. On the other hand, if the width of the noise preventing layer 20 is stacked only from the both ends to the inside of more than 100 mm in the width direction of the foamed layer 10, the width of the noise preventing layer becomes narrower than the predetermined width of the molded product, thereby preventing noise. There is a tendency that the effect of preventing rubbing sound, which is the original role of the layer, cannot be expressed.

  As a method of laminating the noise preventing layer 20 on the outdoor non-foamed layer 13, as shown in FIG. 1, abnormal noise is applied to the outdoor non-foamed layer 13 via the noise preventing layer laminating adhesive layer 16. There is a method of bonding the prevention layer 20.

The adhesive layer 16 for stacking the anti-noise layer has a weight per unit area of 3 to 30 g / m ^{2 in} consideration of maintaining the adhesion quality between the outdoor non-foamed layer 13 and the anti-noise layer 20 and cost. Preferably, it has a basis weight of 5 to 25 g / m ² . If the basis weight of the noise preventing layer laminating adhesive layer 16 is less than 3 g / m ^2, there is a tendency that the adhesion between the noise preventing layer 20 and the outdoor non-foamed layer 13 cannot be maintained. On the other hand, when the basis weight of the adhesive layer 16 for stacking the anti-noise layer exceeds 30 g / m ² , the cost increases and the light weight effect tends to be reduced.

  The width of the noise prevention layer 20 laminated on the surface of the outdoor non-foaming layer 13 is not particularly limited to the width of the foaming layer 10 and the outdoor non-foaming layer 13. It is preferable to be laminated inside the laminated sheet with respect to the width of the non-foamed layer 13, and the effect of preventing abnormal noise of the automotive interior molded body 40 obtained by molding from the laminated sheet 30 for automotive interior materials can be expressed. If it exists, the lamination position of the width direction inner side of the foaming layer 10 and the outdoor side non-foaming layer 13 can be selected suitably.

As a method for joining the noise preventing layer 20 and the outdoor non-foamed layer 13 through the noise preventing layer laminating adhesive 16, a film-like or powdery solid adhesive such as hot melt is used. Examples include a method of laminating, a method of laminating via a liquid adhesive such as a latex adhesive, and the like.
Specific examples of hot melt adhesives include polyolefin, modified polyolefin, polyurethane, ethylene-vinyl acetate copolymer resin, polyamide, polyester, thermoplastic rubber, styrene-butadiene copolymer, styrene-isoprene. Examples of the main component include a resin such as a copolymer system.

  As a method of laminating the fiber structure of the noise preventing layer 20 through a film-like or powder-like solid adhesive layer such as a hot-melt adhesive, the hot-melt adhesive layer is previously formed on the outdoor non-foamed layer 13. A method in which the adhesive layer is heat-softened by a thermal lamination method and bonded by pressure bonding to the noise preventing layer 20, and a hot melt is applied during binder lamination processing of the foamed layer 10 and the outdoor non-foamed layer 13. There is a method in which the adhesive layer is sandwiched between the outdoor non-foamed layer 13 and the noise preventing layer 20 and bonded by pressure bonding.

Specific examples of the latex adhesive used in the present invention include polystyrene resin (PS resin) latex, styrene-butadiene copolymer (SB resin) latex, carboxylated modified styrene-butadiene copolymer resin. Latex (hereinafter referred to as “carboxylated modified SB resin latex”), carboxylated modified acrylonitrile-styrene copolymer resin latex (hereinafter referred to as “carboxylated modified AS resin latex”), and the like. Although these can be used alone, in order to satisfy various required characteristics as the automobile interior material molded body 40, it is preferable to use a mixture of several kinds of latexes.
Among them, by using a mixture of binder latex with good low-temperature film formability and resin latex with high heat resistance, stable and strong initial adhesive strength and latex adhesion independent of drying processing conditions in the manufacturing process It is more preferable because the heat resistance of the agent layer can be made compatible and the handleability in the production process can be improved by improving the mechanical stability.

  As the binder latex in the present invention, a latex having a carboxylated modified SB resin as a constituent resin is preferable from the viewpoint of good mechanical stability and compatibility with the outdoor non-foamed layer 13.

The mixing ratio of the resin latex in the latex mixture in the present invention is preferably 20 to 50% by weight, and more preferably 30 to 50% by weight.
When the mixing ratio of the resin latex is less than 20% by weight, the heat resistance of the adhesive layer may be lowered and may not reach a level required as a practical characteristic of the interior material. Without forming a phase, the minimum film forming temperature of the latex mixture becomes 20 ° C. or higher, and there is a possibility that film formation does not occur due to drying at room temperature, resulting in poor adhesion.

  The minimum film forming temperature of the latex mixture in the present invention is preferably 20 ° C. or less, and more preferably 0 ° C. or less. When the minimum film formation temperature of the latex mixture exceeds 20 ° C., film formation does not occur due to drying at room temperature, and adhesion failure may occur.

  As a method for bonding the outdoor non-foamed layer 13 and the noise-preventing layer 20 with the latex adhesive in the present invention, a) the latex adhesive is applied to the surface of the outdoor non-foamed layer 13 and the undried application surface is applied. A method in which the abnormal noise prevention layer 20 is laminated and dried, temporarily adhered, and then bonded by heat pressing. B) A latex adhesive is applied to the abnormal noise prevention layer 20 in advance, and the dried surface is applied. There is a method in which the laminated sheet is dried and temporarily bonded so that the outdoor non-foamed layer 13 is in contact with the outer non-foamed layer 13 and then heated and pressed.

  It is also required by heating press at a heating temperature at which the foamed layer 10 is not thermally damaged by applying a latex adhesive and laminating the outdoor non-foamed layer 13 and the noise preventing layer 20 in an undried state. The adhesiveness is expressed stably.

  As the latex adhesive in the present invention, any latex adhesive known to those skilled in the art for carpet backing, coated paper, and nonwoven fiber treatment can be used.

  The solid content concentration in the latex stock solution is usually 40% by weight or more, but it can be used after optionally diluting with water in accordance with the coating amount and coating method. However, if the concentration of the solid content of the latex water diluted solution is too low, drying in the process becomes insufficient and may cause poor adhesion, so 20% by weight or more is preferable.

  The binder latex and resin latex used in the present invention are preferably latexes having good mechanical stability because they are subjected to mechanical operations without interruption such as pumping, stirring during blending, shearing by a roll coater during coating in the production process. .

  Measures to improve the mechanical stability of latex adhesives include increasing the amount of emulsifier added, adjusting the pH to the alkali side, carboxylating the latex, etc., but carboxylation modification is the most effective. Therefore, the use of carboxylated modified latex is preferred.

  Examples of the latex application method in the present invention include various roll coater methods, spray methods, foam spray methods, and the like, which are selected depending on the application amount and the shape of the application surface.

  The latex in the present invention is added as a compounding additive, if necessary, stabilizer, anti-aging agent, vulcanization accelerator, dispersant, filler, thickener, colorant, antifoaming agent, gelling agent, freezing agent. You may contain an inhibitor, a softening agent, a thickening resin, etc.

The amount of the constituent resin applied to the latex as the adhesive layer 16 for stacking the anti-noise layer in the present invention is arbitrarily selected depending on the type of thermoplastic resin used and the required adhesive strength with the anti-noise layer 20. However, generally, 3 to 50 g per 1 m ² is preferable as the solid content in the mixed latex, and 5 to 20 g is more preferable.
If the application amount of the constituent resin of the adhesive layer 16 for stacking the anti-noise layer is less than 3 g, the adhesive effect may not be exhibited. If it exceeds 50 g, the anti-noise layer 20 from the anti-noise layer 20 during molding There is a possibility that the latex which is the laminating adhesive layer 16 oozes out and contaminates the mold.

  The skin laminated sheet 30 of the present invention is laminated with a skin material 22 serving as a design layer via a hot melt adhesive layer 18.

  Examples of the hot melt adhesive layer 18 used in the skin laminate sheet 30 of the present invention include a film-like or solid adhesive on a powder, and the use of a film-like is preferable from the viewpoint of ease of processing.

  Specific examples of hot melt adhesives include polyolefin, modified polyolefin, polyurethane, ethylene-vinyl acetate copolymer resin, polyamide, polyester, thermoplastic rubber, styrene-butadiene copolymer, styrene-isoprene. Examples of the main component include a resin such as a copolymer system.

The hot melt adhesive layer 18 in the present invention has a weight per unit area of ^{20 to} 80 g / m ^{2 in} consideration of keeping the adhesion quality between the indoor non-foamed layer 11 and the skin material 22 and cost. Preferably, it has a basis weight of 30 to 60 g / m ² .
If the basis weight of the hot melt adhesive layer 18 is less than 20 g / m ^2, there is a tendency that the adhesiveness between the skin material 22 and the indoor non-foamed layer 11 cannot be maintained. On the other hand, when the basis weight of the hot-melt adhesive layer 18 exceeds 80 g / m ² , the cost increases, the heating is insufficient during the molding process, and the light weight effect tends to decrease.

  The width of the hot melt adhesive layer 18 laminated on the surface of the indoor non-foamed layer 11 is preferably 30 to 100 mm shorter from both ends than the width of the foamed layer 10 constituting the foamed laminated sheet. That is, it is preferable that the hot melt adhesive layer 18 is laminated from the both end portions in the width direction of the foamed layer to the inside of 30 to 100 mm. (Hot-melt adhesive layer 18 is preferably not laminated on the inner side by 30 to 100 mm from both end portions in the width direction of the foamed layer.)

  When the hot melt adhesive layer 18 is laminated to the inner side within 30 mm from both ends in the width direction of the foamed layer 10, the foamed layer 10 and the indoor non-foamed layer 11 and the skin material 22 are integrally laminated. When the pins are pierced at both ends in the width direction of the laminated sheet 30, the skin material 22 laminated and integrated with the skin laminated sheet 30 is composed of a relatively soft material, so the pins do not pierce steadily, and the skin material 22 resists. As a result, the gripping by pin piercing to the laminated sheet 25 becomes insufficient, or the laminated sheet 25 is detached from the pin once stuck into the laminated sheet 25, and the skin laminated sheet 30 is removed from the endless belt or endless chain during transportation. Is undesirably removed, and falls into the heating furnace, resulting in troubles during molding, which prevents good molding.

  If the hot melt adhesive layer 18 is laminated only to the inside of more than 100 mm from the both ends in the width direction of the foamed layer 10, the portion where the skin material 22 is not integrated in the width direction of the laminated sheet 25 increases, and molding processing is performed. A portion in which the skin material 22 is not integrated is generated in the width direction of the automotive interior material molded body 40 obtained in this way, and the skin material 22 that is a design layer peels off from the automotive interior material molded body 40, which is not preferable.

  The skin material 22 in the present invention is a member that is laminated on the outermost layer on the indoor side of the automobile interior material molded body 40, and is disposed in a portion that can be seen and touched from the interior of the automobile. Texture, color, etc. are required.

  As the skin material 22 in the present invention, any material can be used as long as it is a cloth-like material obtained by bonding raw fibers to an adhesive, a molten fiber, or a mechanical method. Synthetic fibers and semi-synthetic fibers can be used as the type of raw fiber. Specifically, synthetic fibers such as polyester, polypropylene, polyamide (nylon), polyacrylonitrile and the like can be used as raw material fibers. Among these, polyester fibers are preferable, and polyethylene terephthalate fibers having particularly high heat resistance are preferable. preferable.

  Examples of the type of nonwoven fabric include a bonded binder-bonded fabric, a needle punched fabric, a spun pond fabric, a spray fiber fabric, and a stitch bond fabric, and any nonwoven fabric can be used depending on the manufacturing and processing method.

  In order to join the raw fibers and ensure the abrasion resistance of the skin material, as an adhesive layer for joining the constituent fibers of the nonwoven skin material, a binder resin is applied from the surface or the back surface of the skin material, by coating, etc. There is a method of impregnation.

  Examples of the binder resin include water-soluble, solvent-soluble, viscose liquid, emulsion, and synthetic resin powder. Among these, emulsions are preferably used from the viewpoints of water resistance, flexibility and workability. As the emulsion type, for example, acrylo-nitrile-butadiene latex, styrene-butadiene latex, acrylate latex, vinyl acetate latex and the like can be used alone or as a mixture of two or more.

The skin material 22 used in the present invention preferably has a basis weight of 100 to 280 g / m ² considering the balance between quality such as the appearance of the skin material and cost, and is preferably 130 to 250 g / m ^2. It is more preferable to have the basis weight. When the basis weight of the nonwoven fabric is less than 100 g / m ² , there is a tendency that the appearance defect such as scaling and unevenness due to variation in the stretchability of the skin during the molding process is likely to occur. On the other hand, if the basis weight of the nonwoven fabric exceeds 280 g / m ² , the light weight effect tends to be reduced.

Basis weight of the laminated sheet 25 constituting the skin laminated sheet 30 of the present invention is preferably ^{235~760g / m 2, 300~600g / m} 2 is more preferable. If the overall basis weight of the laminated sheet 30 for automobile interior materials is within the range of 235 to 760 g / m ² , both lightness and rigidity can be achieved.

  The width of the skin material layer 22 laminated on the indoor side non-foamed layer 11 side is preferably 20 mm or less longer or 20 mm or less shorter from the both ends of the width of the foam layer 10 constituting the foam laminated sheet. That is, it is preferable that the skin material layer 22 is laminated | stacked from the both ends in the width direction of a foaming layer to the outer side of 20 mm or less thru | or the inner side of 20 mm or less, respectively.

  When the width of the skin material layer 22 is also laminated on the outer side exceeding 20 mm from the both ends in the width direction of the foamed layer 10, the part protruding from the foamed sheet is bent by the laminated sheet, and the laminated sheet is entrained. There is a tendency for the positioning accuracy of the transport unit to decrease. On the other hand, if the width of the skin material layer 22 is laminated only to the inside of more than 20 mm from the both ends in the width direction of the foamed layer 10, the laminated sheet on which the skin material 22 is not laminated during heating is directly exposed to a high temperature, Softening due to overheating and accompanying reduction in rigidity of the laminated sheet may cause the laminated sheet to be detached from the clamp pin and torn, leading to conveyance troubles such as dropping from the conveyance jig.

  Next, the manufacturing method of the skin lamination sheet 30 of this invention is demonstrated.

The foam layer 10 (primary foam layer) used in the present invention can be produced, for example, as follows.
That is, what was blended with various additives as necessary to the modified PPE resin as the base resin is melted and kneaded at a resin temperature of 150 to 400 ° C. using an extruder. Next, 2.0 to 5.0 parts by weight of a hydrocarbon-based blowing agent is added to 100 parts by weight of the modified PPE resin into an extruder under high temperature and high pressure (resin temperature 150 to 400 ° C. and resin pressure 3 to 50 MPa). After press-fitting and further adjusting the resin temperature to an appropriate foaming temperature range (150 to 300 ° C.), it is extruded and foamed into a low-pressure zone (usually in the atmosphere) using a circular die or the like. Then, it can be manufactured by a method such as winding it after forming it into a sheet shape by cutting it at a speed of 0.5 to 40 m / min while making it contact with a mandrel (cylindrical cooling cylinder), etc. .

With respect to the foam layer 10, the non-foam layers 11 and 13, the noise prevention layer 20 via the noise prevention layer laminating adhesive layer 16, and the skin material 22 via the hot melt adhesive layer 18. As a method of laminating, for example, the base resin of the indoor non-foamed layer 11 in a molten state supplied from an extruder is fed into a film or powder while feeding out the foamed layer 10 that has been foamed and wound in advance. A method of laminating in a form sandwiched between the hot melt adhesive layer 18 and then pressure bonding with a cooling roller or the like (extrusion laminating method), the foamed layer 10 and a molten outdoor non-foamed layer 13 supplied from the extruder A layered resin in a form sandwiched between the anti-noise layer 20 via the foam layer 10 and the anti-noise layer laminating adhesive layer 16, and then pressure-bonded with a cooling roller or the like,
Etc. can be manufactured.
Especially, the method of laminating by carrying out extrusion foaming sheet shaping | molding of the foaming layer 10 and extrusion of the non-foaming layers 11 and 13 in-line is preferable at the point of simplification of a manufacturing process.

  As a molding method for obtaining an automobile interior material molded body 40 (secondary foamed laminated molded body) by shaping from the obtained skin laminated sheet 30 (primary foamed laminated sheet), the skin is provided at the center of a heating furnace having upper and lower heaters. The laminated sheet 30 is guided by being held by a conveying jig, heated to a temperature suitable for molding (for example, the surface temperature of the foamed laminated sheet is 120 to 150 ° C.), and then press-cooled with a temperature-controlled mold. And a method of forming.

  Regarding the heating of the skin laminate sheet in the heating furnace and the molding of the heat-skinned skin laminate sheet with the mold, the skin material is placed on the upper side to prevent the skin from peeling off and falling off from the laminate sheet during heat softening. It is preferable to arrange.

  As a method of gripping the skin laminate sheet (primary foam laminate sheet) 30 with the conveying jig, a pair of endless chains or belts having pins fixed to the outer peripheral surface at predetermined intervals are used. There is a method of piercing and grasping at predetermined intervals in the vicinity of both ends in the width direction of the skin laminate sheet (primary foam laminate sheet) 30 with pins.

In order to improve the yield by securing the minimum width necessary to obtain a predetermined molded product while firmly grasping the laminated sheet, when piercing and grasping the skin laminated sheet with the clamp pin laid on the endless chain or belt The clamp pins are preferably disposed at positions 12 mm to 28 mm inside from both ends in the width direction of the skin laminated sheet, and grip the skin laminated sheet.
When the clamp pin positions from both ends in the width direction of the skin laminate sheet are less than 12 mm, the gripping distance from both ends in the width direction of the laminate sheet is short, and there is a tendency for the pin to fall off during transportation. In this case, the yield tends to decrease.

  The conveyance speed of the endless chain or belt on which the clamp pin is laid is preferably 40 m / min to 150 m / min, more preferably 60 m / min to 120 m / min from the viewpoint of productivity. When the conveyance speed is less than 40 m / min, the molding cycle time becomes long, and the productivity tends to decrease. On the other hand, when the conveyance speed is higher than 150 m / min, the laminated sheet receives wind pressure from the forward direction during conveyance, and the laminated sheet that is lifted off the pin is lifted off the pin by the wind pressure. They tend to come into contact with each other and be able to perform good conveyance and molding.

  In addition, as timing which hold | grips the width direction both ends of the skin laminated sheet (primary foaming laminated sheet) 30 with a holding jig, before heating the skin laminated sheet (primary foaming laminated sheet) 30 with a heating furnace is continuous. It is preferable because productivity is improved by supply.

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

  The skin laminated sheet 30 in the present invention can prevent cooling due to contact with a mold in molding of the base material by laminating the noise preventing layer 20 on the outdoor non-foamed layer 13. Processing distortion of a molded product using the material can be reduced. Furthermore, by arranging the anti-noise layer 20 on the outdoor non-foamed layer 13, the rubbing noise generated by rubbing between the automobile interior material molded body 40 and the automobile body due to automobile vibration or the like is prevented by the layer. be able to.

In the present invention, when the foamed layer 10 (primary foamed sheet) constituting the skin laminated sheet 30 is subjected to secondary foaming by heating, secondary foaming is usually performed 1.2 to 4 times the primary foamed sheet. It is preferable to perform secondary foaming 1.5 to 3 times.
Accordingly, the foaming ratio of the foamed layer (secondary foamed sheet) after the secondary foaming is preferably 19 to 100 times, more preferably 24 to 66 times, and even more preferably 26 to 55 times. If the secondary foaming ratio is less than 1.2 times, the flexibility tends to be inferior and breakage due to bending or the like tends to occur. When the secondary expansion ratio exceeds 4 times, the strength tends to decrease.

The thickness of the foamed layer (secondary foam sheet) after secondary foaming is preferably 1.2 to 20 mm, more preferably 2.5 to 10.0 mm, and even more preferably 3.5 to 8.0 mm.
If the thickness of the foamed layer after the secondary foaming is less than 1.2 mm, the strength and heat insulating properties are inferior and may not be suitable as the automobile interior material molded body 40. If the thickness exceeds 20 mm, the shape development at the time of molding is inferior, and the vehicle interior tends to be more bulky than necessary and narrow.

The molded mass per unit area of the automobile interior material formed body 40 obtained in this manner is preferably 335~1040g / ^{m 2,} more preferably 435~905g / ^{m 2.}
If the overall weight of the automobile interior material molded body is less than 335 g / m ² , the strength is inferior, damage due to bending or the like tends to occur, and the heat insulation performance tends to decrease. When it exceeds 1040 g / m ² , the handleability (operator handling properties) associated with the increase in weight tends to decrease, and the lightness tends to be inferior.

  As described above, various aspects of the skin laminated sheet, the molding method, and the molded body according to the present invention have been described, but the present invention is not limited to the above-described aspects. For example, the skin laminate sheet can be used as a base material for interiors such as trains, airplanes, and interiors of buildings as applications, and should be interpreted broadly. In addition, the present invention can be carried out in a mode in which various improvements, changes, and modifications are added based on the knowledge of those skilled in the art without departing from the spirit of the present invention.

Hereinafter, the present invention will be described in more detail based on examples, but the present invention is not limited by these.
The resins used in Examples or Comparative Examples are shown in Table 1.

In addition, the description regarding each code | symbol shown in Table 1 is as follows.
PPE: Polyphenylene ether resin PS: Polystyrene resin HIPS: High impact polystyrene resin SB: Styrene-butadiene copolymer resin

  The evaluation methods carried out in the examples or comparative examples are shown below.

(Foamed layer, thickness of molded product)
About the obtained primary foamed sheet and molded article, the thickness at 20 locations in the width direction was measured, and the average value of the measured values was calculated.

(Foaming ratio)
The density df of the obtained primary foamed sheet was measured according to JIS K7222, and the density dp of the modified PPE resin was separately measured according to JIS K7112, and calculated according to the formula: foaming ratio = dp / df.

(Cell diameter)
The cross section of the obtained foamed layer of the primary foamed sheet was observed with an optical microscope to measure 20 cell diameters, and the average value of the measured values was calculated.

(Closed cell rate)
The closed cell ratio of the obtained primary foamed sheet was measured using a multi-pycnometer (manufactured by Beckman) according to ASTM D-2859.

(Weight)
A test piece having a size of 100 mm square was cut out from any five locations of the used materials, and after measuring their weight, an average value was calculated and converted to m ² .

(Transportability)
In the operation of transporting the laminated sheet to the heating furnace and the shaping part in <Molding of automobile ceiling material>, the transportability was evaluated from the following criteria according to the dropping state of the laminated sheet from the clamp pin.
○: There is no separation of the laminated sheet from the clamp pin.
Δ: Part of the laminated sheet coming off from the clamp pin is recognized, but no drop off from the conveying chain occurs.
X: The laminated sheet comes off from the clamp pin and falls off from the conveying chain.

(Appearance of molded body)
The appearance of the obtained molded body (automobile ceiling material) was evaluated according to the following criteria.
○: No significant appearance abnormality such as wrinkles, chipping, tearing, skin material floating / peeling, etc. Δ: Some wrinkles are observed in the skin and the noise prevention layer ×: Wrinkles, chipping, and tearing occur. The predetermined shape is not expressed. Skin layer lift / peeling is observed.

In addition, regarding the width of each constituent material of the skin laminated sheet in the example and the comparative example, as shown in FIG. 2, the end in the width direction of the foamed layer 10 is used as a reference position in the width direction of each constituent material. It is displayed as the distance from the edge. The actual measurement value was indicated as plus when the end of each constituent material was present inside the end of the foamed layer 10, and was indicated as minus when present at the outside.
In addition, as for the alphabet of a code | symbol, U is the distance with the edge part of an indoor non-foaming layer, S is the distance with the edge part of an outdoor non-foaming layer, I is the distance with the edge part of a noise prevention layer, H is The distance from the end of the hot melt adhesive layer is shown. Furthermore, the numbers attached to the reference numerals are 1 on the left side (L) in the width direction of the skin laminate sheet and 2 on the right side (R).

Example 1
<Manufacture of foam layer>
With respect to 100 parts by weight of a mixed resin obtained by mixing 57.1 parts by weight of PPE resin (A) and 42.9 parts by weight of PS resin (B) so as to be 40% by weight of PPE resin component and 60% by weight of PS resin component 3.8 parts by weight of a hydrocarbon-based foaming agent mainly composed of iso-butane (iso-butane / n-butane = 85/15% by weight) and 0.32 parts by weight of talc were brought to a resin temperature of 270 ° C. by an extruder. Kneaded, cooled to a resin temperature of 195 ° C., extruded with a circular die at a pressure of 15 MPa, wound up into a take-up roll via a take-up roll, a primary foam layer thickness of 2.3 mm, and a foam layer width of A roll of a primary foamed sheet having 1315 mm, primary foaming ratio of 15.5 times, closed cell ratio of 87%, cell diameter of 0.16 mm and basis weight of 150 g / m ² was obtained.
<Lamination of outdoor non-foamed layer and noise-preventing layer>
While feeding the primary foam sheet from the roll, 14.3 parts by weight of PPE resin (A) so that the PPE resin component is 10.0% by weight, the PS resin component is 79.3% by weight, and the rubber component is 10.7% by weight. And a mixed resin in which 85.7 parts by weight of HIPS resin (C) are mixed is melted and kneaded at a resin temperature of 240 ° C. using an extruder, extruded into a film using a T-die, and a film-like chamber is formed in a molten state. The outer non-foamed layer was laminated on the primary foamed sheet to form a modified PPE resin non-foamed layer having a basis weight of 120 g / m ² .
At that time, a carboxylated modified SB resin latex adhesive (F) [manufactured by JSR Co., Ltd., 0569] was applied as an anti-noise layer during lamination of the modified PPE resin outdoor outside non-foamed layer (application weight: 5 g) / ^m 2 -dry) has been basis weight 20 g / ^{m 2,} thickness 0.3mm spunlaced nonwoven fabric (G) [(Ltd.) a friendly Ltd., Ceres R8020] was laminated.
<Lamination of indoor non-foamed layer and hot melt adhesive layer>
The resulting modified PPE-based resin outdoor side non-foamed layer was formed into a foamed laminated sheet having a PPE resin component of 15.0% by weight, a PS resin component of 84.4% by weight and a rubber component of 0.6% by weight. A mixed resin obtained by mixing 21.4 parts by weight of the resin (A), 73.6 parts by weight of the PS resin (B) and 5 parts by weight of the HIPS resin (C) is extruded into a film shape so that the resin temperature becomes 240 ° C. On the opposite surface of the foam sheet on which the outer non-foamed layer was formed, a modified PPE-based resin room inner non-foamed layer with a basis weight of 120 g / m ² was formed.
When extruding a modified PPE resin non-foamed layer into a film shape with a T-die and laminating it, a Teflon (registered trademark) surface-treated laminate roll side obliquely above the hot roll adhesive layer has a basis weight of 30 g / m. ^{2. Using} a hot melt film (E) having a width of 1220 mm [manufactured by Kurashiki Boseki Co., Ltd., Clanbetter X2200], the hot melt film is fed out from a feeding machine, and passed through a roll for scooping, laminating roll and back roll They were stacked so that they were sandwiched between them.

<Lamination of skin material layer>
The hot-melt adhesive layer of the foamed laminated sheet in which the indoor / outdoor non-foamed layer, the noise-preventing layer, and the hot-melt adhesive layer are laminated is heat-softened to obtain a plain needle punch nonwoven fabric (D) [(stock) with a basis weight of 140 g / m ² ) Manufactured by Otsuka] was pressure-bonded to obtain a skin laminated sheet (laminated sheet for automobile interior materials) in which a design surface skin material was laminated on a laminated sheet.
In addition, the width | variety of a skin laminated sheet (laminated sheet for motor vehicle interior materials) was 1304 mm. The end of the indoor non-foamed layer was 3 mm inside (U ₁ ) on the left side and 2 mm inside (U ₂ ) on the right side from both ends of the foamed layer. The end portions of the hot melt adhesive layer were 2 mm inside (F ₁ ) on the left side and 0 mm inside (F ₂ ) on the right side from both ends of the foam layer. The end of the skin layer was 50 mm inside (H ₁ ) on the left side and 48 mm inside (H ₂ ) on the right side from both ends of the foam layer. The end of the outdoor non-foamed layer was 5 mm inside (S ₁ ) on the left side and 6 mm inside (S ₂ ) on the right side from both ends of the foamed layer. The end portions of the noise preventing layer were 12 mm inside (I ₁ ) on the left side and 14 mm inside (I ₂ ) on the right side from both ends of the foam layer.

<Molding of molded body (car ceiling material)>
For forming a molded body (car ceiling material), as a conveying means, a heating furnace and a shaping part having a pair of endless chains having clamp pins with a height of 25 mm fixed to the outer peripheral surface at intervals of 200 mm are provided. A molding machine was used.
After the obtained skin laminated sheet (laminated sheet for automobile interior materials) is cut into a sheet having a length of 2150 mm, the upper surface side is arranged to be a design surface skin material layer and the lower surface is a nonwoven fabric layer for preventing abnormal noise, By driving the chain at a speed of 80 m / min with the pin of the chain being pierced and held at a position 25 mm inside from both ends of the laminated sheet for automobile interior material, a skin laminated sheet (laminated sheet for automobile interior material) ) In a heating furnace of the molding machine and heated for 40 seconds so that the surface temperature of the skin laminate sheet (laminated sheet for automobile interior materials) is 170 ° C. on the surface of the design side skin material and 145 ° C. on the surface of the anti-noise layer. did.
After heating, it is continuously transported to the forming part and plugged with a mold clearance for automobiles using a mold for automobile molding ceiling (mold of width 1120mm x length 1800mm, upper convex mold, lower concave mold) Molding was performed, and trimming and punching were performed to obtain a molded body (car ceiling material).
After the skin laminated sheet (laminated sheet for automobile interior materials) was held by the pins, there was no dropout of the laminated sheets from the pins with respect to the conveyance to the heating furnace and the shaping part, and no problem was found in the molding process.
Table 2 shows the evaluation results regarding the transportability and the appearance of the obtained molded body.

(Example 2)
A skin laminated sheet (laminated sheet for automobile interior materials; width 1304 mm) was obtained in the same manner as in Example 1 except that the hot melt adhesive layer was laminated with a width of 1200 mm, and a molded body (automobile ceiling material) was formed. The car ceiling material was obtained. In addition, the distance with respect to the foam layer end part of each laminated | stacked layer was as having shown in Table 2.
In <molding of automobile ceiling material>, when the molding process was performed by the same operation as in Example 1, after holding the skin laminated sheet (laminated sheet for automobile interior material) on the pin, to the heating furnace and the shaping part During transportation, the laminated sheet did not fall off from the pins.
Table 2 shows the evaluation results regarding the transportability and the appearance of the obtained molded body.

(Example 3)
A skin laminated sheet (laminated sheet for automobile interior materials; width 1304 mm) was obtained in the same manner as in Example 1 except that the hot melt adhesive layer was laminated with a width of 1150 mm, and a molded body (automobile ceiling material) was formed. The car ceiling material was obtained.
In addition, the distance with respect to the foam layer end part of each laminated | stacked layer was as having shown in Table 2.
In <molding of automobile ceiling material>, when the molding process was performed by the same operation as in Example 1, after holding the skin laminated sheet (laminated sheet for automobile interior material) on the pin, to the heating furnace and the shaping part During transportation, the laminated sheet did not fall off from the pins.
Table 2 shows the evaluation results regarding the transportability and the appearance of the obtained molded body.

Example 4
Except for laminating the hot melt adhesive layer with a width of 1280 mm, a skin laminated sheet (laminated sheet for automobile interior materials; width 1304 mm) was obtained in the same manner as in Example 1 to form a molded body (automobile ceiling material). The car ceiling material was obtained.
In addition, the distance with respect to the foam layer end part of each laminated | stacked layer was as having shown in Table 2.
In <molding of automobile ceiling material>, when the molding process is performed by the same operation as in Example 1, after gripping the laminated sheet for automobile interior material to the pin, in the conveyance to the heating furnace and the shaping part, from the pin There was no dropout of the laminated sheet.
Table 2 shows the evaluation results regarding the transportability and the appearance of the obtained molded body.

(Comparative Example 1)
A skin laminate sheet (laminated sheet for automobile interior materials; width 1304 mm) was obtained in the same manner as in Example 1 except that the hot melt adhesive layer was laminated with a width of 1330 mm, and a molded body (automobile ceiling material) was molded. The car ceiling material was obtained.
In addition, the distance with respect to the foam layer end part of each laminated | stacked layer was as having shown in Table 2.
In <molding of automobile ceiling material>, when the molding process is performed by the same operation as in Example 1, the laminated sheet is detached from the pin together with the chain drive, and the laminated sheet is dropped from the pin before being inserted into the heating furnace. However, it could not be molded.
Table 2 shows the evaluation results regarding the transportability and the appearance of the obtained molded body.

(Comparative Example 2)
A self-skin laminated sheet (laminated sheet for automobile interior materials; width 1304 mm) was obtained in the same manner as in Example 1 except that the hot melt adhesive layer was laminated with a width of 1120 mm. Molding was performed to obtain an automobile ceiling material.
In addition, the distance with respect to the foam layer end part of each laminated | stacked layer was as having shown in Table 2.
In <molding of automobile ceiling material>, molding was performed by the same operation as in Example 1.
The appearance of the obtained automobile ceiling material was a state where the skin material was floated at positions 15 mm inside from both ends in the width direction of the molded body, and was not integrated, and a molded body with a good appearance could not be obtained. .
Table 2 shows the evaluation results regarding the transportability and the appearance of the obtained molded body.

DESCRIPTION OF SYMBOLS 10 Foam layer 11 Indoor non-foam layer 13 Outdoor non-foam layer 16 Adhesive layer for anti-noise layer lamination 18 Hot-melt adhesive layer 20 Anti-noise layer 22 Skin material layer 25 Laminated sheet 30 Skin laminate sheet 40 Automotive ceiling in wood U ₁ skin laminated sheet left, at a distance U ₂ skin laminated sheet right between the edges of the indoor-side non-foamed layer of the foaming agent layer, the end portion and the outdoor-side non-foamed layer of the foaming agent layer Distance from the end S ₁ Distance between the end of the foaming agent layer and the end of the outdoor non-foaming layer on the left side of the skin ₁ laminated sheet S ₂ Edge of the foaming agent layer and the outdoor side on the right side of the S2 skin lamination sheet Distance between the edge of the non-foamed layer I ₁ Distance between the edge of the foaming agent layer and the edge of the anti-noise layer on the left side of the ₁ skin laminate sheet I ₂ Edge of the foaming agent layer on the right side of the skin laminate sheet and at a distance H ₁ skin laminated sheet left between the end of the anti-rattle layer, and the end of the foaming agent layer relieved At a distance H ₂ skin laminated sheet right to the end portion of the melt adhesive layer, at a distance F ₁ skin laminated sheet left between the edges of the foaming agent layer and the hot-melt adhesive layer, a foaming agent layer Distance between edge and edge of skin material layer F ₂ Distance between edge of foaming agent layer and edge of skin material layer on right side of skin laminate sheet

Claims (4)

A modified polyphenylene ether resin non-foamed sheet is laminated and integrated on both sides of the modified polyphenylene ether resin foam sheet, and the skin material is attached to one of the modified polyphenylene ether resin non-foamed sheets via a hot melt adhesive layer. A laminated skin sheet,
A skin laminate sheet, characterized in that a hot melt adhesive layer is not laminated on the inner side of both ends from 30 to 100 mm in the width direction of the skin laminate sheet. A modified polyphenylene ether resin non-foamed sheet is laminated and integrated on both sides of the modified polyphenylene ether resin foam sheet, and the skin material is attached to one of the modified polyphenylene ether resin non-foamed sheets via a hot melt adhesive layer. Forming a skin laminate sheet that is heated and thermoformed by transporting the laminated skin laminate sheet in a state of being gripped using a pair of endless chains or belts having pins fixed to the outer peripheral surface at predetermined intervals. A method,
Place the skin laminate sheet so that the skin material is on the upper side, and in the width direction of the skin laminate sheet, pierce the pin into the portion where the hot melt adhesive layer is not laminated on the inner side of both ends from 30 to 100 mm. A molding method characterized by the above.   A molded body obtained by thermoforming the laminated sheet according to claim 1.   A molded article obtained by the molding method according to claim 2.

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