JP2013545632A - 自動車内装材用多層構造物およびその製造方法 - Google Patents
自動車内装材用多層構造物およびその製造方法 Download PDFInfo
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Abstract
【選択図】図1
Description
120 ポリプロピレン発泡シート
140 補強シート
160 コーティング膜
Claims (28)
- ポリプロピレン発泡シート(120);
前記ポリプロピレン発泡シート(120)の少なくとも一面に積層され、天然繊維および合成繊維を含んでニードルパンチングした後、熱ローラー工程によって製造された補強シート(140);および
前記補強シート(140)の外側面に形成されるコーティング膜(160)を含む自動車内装材用多層構造物。 - 前記コーティング膜(160)の外側面に積層され、ポリオレフィン系またはポリエステル系からなる不織布形態の表皮層(180)をさらに含む、請求項1に記載の自動車内装材用多層構造物。
- 前記ポリプロピレン発泡シート(120)は、ポリプロピレン50〜80重量部に線形低密度ポリエチレンまたはエラストマー20〜50重量部を混合して構成される、請求項1に記載の自動車内装材用多層構造物。
- 前記ポリプロピレン発泡シート(120)の発泡倍率は3〜40倍である、請求項1に記載の自動車内装材用多層構造物。
- 前記ポリプロピレン発泡シート(120)は、一重または二重でラミネーションして形成される、請求項1に記載の自動車内装材用多層構造物。
- 前記補強シート(140)は、天然繊維および合成繊維が1:9〜9:1の比率で混合される、請求項1に記載の自動車内装材用多層構造物。
- 前記天然繊維および前記合成繊維の長さは40〜120mmである、請求項1に記載の自動車内装材用多層構造物。
- 前記補強シート(140)は、密度が0.3〜1.0g/cm3である、請求項1または6に記載の自動車内装材用多層構造物。
- 前記天然繊維は、黄麻、洋麻(KENAF)、サイザル麻または竹のうち少なくとも一つである、請求項1または6に記載の自動車内装材用多層構造物。
- 前記合成繊維は、低融点ポリエステル、ポリエチレンテレフタレート(PET)、ポリプロピレンまたは生分解性樹脂繊維のうち少なくとも一つである、請求項1または6に記載の自動車内装材用多層構造物。
- 前記生分解性樹脂繊維は、ポリ乳酸(polylactic acid;PLA)またはセルロースアセテート(cellulose acetate;CA)である、請求項10に記載の自動車内装材用多層構造物。
- 前記コーティング膜(160)は、紫外線硬化樹脂または熱硬化型バイオゲルで形成される、請求項1に記載の自動車内装材用多層構造物。
- 前記紫外線硬化樹脂は、光開始剤、光重合オリゴマー、光重合モノマーおよび添加剤を含み、
前記光重合オリゴマーは、一液型ウレタンアクリル系オリゴマー、二液型ウレタンアクリル系オリゴマー、エポキシアクリル系オリゴマー、ポリエステルアクリル系オリゴマーまたは混合型アクリル系オリゴマーのうち少なくとも一つである、請求項12に記載の自動車内装材用多層構造物。 - ポリプロピレン発泡シート(120)を形成する第1ステップ(S100);
天然繊維および合成繊維を含んでニードルパンチングした後、熱ローラー工程によって補強シート(140)を製造する第2ステップ(S200);
前記補強シート(140)の外側面にコーティング膜(160)を形成させる第3ステップ(S300);および
前記ポリプロピレン発泡シート(120)の少なくとも一面に前記補強シート(140)を積層させる第4ステップ(S400)を含む自動車内装材用多層構造物の製造方法。 - 前記第4ステップ後に、
前記コーティング膜(160)の外側面にポリオレフィン系またはポリエステル系からなる不織布形態の表皮層(180)を積層させる第5ステップ(S500)をさらに含む、請求項14に記載の自動車内装材用多層構造物の製造方法。 - 前記ポリプロピレン発泡シート(120)は、ポリプロピレン50〜80重量部に線形低密度ポリエチレンまたはエラストマー20〜50重量部を混合して構成される、請求項14に記載の自動車内装材用多層構造物の製造方法。
- 前記ポリプロピレン発泡シート(120)の発泡倍率は3〜40倍である、請求項14に記載の自動車内装材用多層構造物の製造方法。
- 前記ポリプロピレン発泡シート(120)は、一重または二重でラミネーションして形成される、請求項14に記載の自動車内装材用多層構造物の製造方法。
- 前記補強シート(140)は、天然繊維および合成繊維が1:9〜9:1の比率で混合される、請求項14に記載の自動車内装材用多層構造物の製造方法。
- 前記天然繊維および前記合成繊維の長さは40〜120mmである、請求項14に記載の自動車内装材用多層構造物の製造方法。
- 前記補強シート(140)は、密度が0.3〜1.0g/cm3である、請求項14または19に記載の自動車内装材用多層構造物の製造方法。
- 前記天然繊維は、黄麻、洋麻(KENAF)、サイザル麻または竹のうち少なくとも一つである、請求項14または19に記載の自動車内装材用多層構造物の製造方法。
- 前記合成繊維は、低融点ポリエステル、ポリエチレンテレフタレート(PET)、ポリプロピレンまたは生分解性樹脂繊維のうち少なくとも一つである、請求項14または19に記載の自動車内装材用多層構造物の製造方法。
- 前記生分解性樹脂繊維は、ポリ乳酸(polylactic acid;PLA)またはセルロースアセテート(cellulose acetate;CA)である、請求項23に記載の自動車内装材用多層構造物の製造方法。
- 前記第3ステップは、
前記補強シート(140)の外側面に紫外線硬化樹脂を塗布し、紫外線を照射してコーティング膜(160)を形成させるステップである、請求項14に記載の自動車内装材用多層構造物の製造方法。 - 前記紫外線硬化樹脂は、光開始剤、光重合オリゴマー、光重合モノマーおよび添加剤を含み、
前記光重合オリゴマーは、一液型ウレタンアクリル系オリゴマー、二液型ウレタンアクリル系オリゴマー、エポキシアクリル系オリゴマー、ポリエステルアクリル系オリゴマーまたは混合型アクリル系オリゴマーのうち少なくとも一つである、請求項25に記載の自動車内装材用多層構造物の製造方法。 - 前記第3ステップは、
前記補強シート(140)の外側面に熱硬化型バイオゲルを塗布し、熱を加えて硬化させてコーティング膜(160)を形成させるステップである、請求項14に記載の自動車内装材用多層構造物の製造方法。 - 前記第2ステップおよび前記第3ステップは連続工程によってなされる、請求項25または27に記載の自動車内装材用多層構造物の製造方法。
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