JP2019043101A - Skin material - Google Patents

Abstract

To provide a skin material excellent in molding processability and further excellent in abrasion resistance.SOLUTION: A skin material has larger present amount of a binder in one main surface A side than another main surface B side in a base mat constituting the skin material, and a resin layer on whole area on the main surface A. Thereby the skin material is excellent in molding processability since the main surface B side which has less binder is easy to follow a shape of a mold when supplied to a molding processing such as an injection molding. There is provided a skin material having a main surface excellent in abrasion resistance, such that fuzz due to rubbing is hardly generated, since further constituting fibers in the main surface A side which may become a surface of the skin material in contact with human adheres to binder more strongly, and the constituting fiber of the main surface A side of the skin material is protected by the resin layer.SELECTED DRAWING: None

Description

  The present invention relates to a skin material that can be used for interior materials for vehicles such as ceiling materials, door trims, dash outers, pillar garnishes, partitions, and wallpaper. In particular, the present invention relates to a skin material that can be suitably used as a vehicle interior material that requires high wear resistance, such as a door trim, a dash outer, and a pillar garnish.

  Conventionally, a nonwoven fabric is used as a material constituting the skin material. In addition, in order to prevent deterioration of the skin material due to friction, the skin material is required to have wear resistance.

  For this reason, the applicant of the present invention, as a skin material having abrasion resistance using a non-woven fabric, impregnates the binder punched surface with a binder, and then attaches a binder with less tack on the opposite surface of the needle punched surface. An interior skin material made by impregnation (Patent Document 1) has been proposed.

  The skin material according to Patent Document 1 has a wear resistance because it is less likely to cause fuzz due to friction, and is a skin material that can be molded, but it is particularly suitable for vehicles such as door trims that require a high wear resistance. Abrasion resistance was insufficient for use as a skin material for interior materials.

Japanese Patent Laid-Open No. 62-257472

  The present invention has been made under such circumstances, and an object thereof is to provide a skin material which is excellent in molding processability and further excellent in wear resistance.

  The present invention provides: "In the base mat formed by bonding constituent fibers to each other with a binder, the amount of the binder present on one main surface A side is larger than that on the other main surface B side, and the base mat In which the resin layer is provided on the entire surface of the one main surface A.

  In the skin material of the present invention, the amount of the binder on one main surface A side in the base mat constituting the skin material is larger than that on the other main surface B side. Is not strongly bonded by the binder than the constituent fibers on the main surface A side, and is easy to move. Therefore, when the skin material of the present invention is subjected to a molding process such as injection molding, the main surface B side with a small amount of binder easily follows the shape of the mold and has excellent molding processability. In addition, because the constituent fibers on the principal surface A side that can be the surface of the skin material that comes into contact with each other are strongly bonded to each other by the binder, the skin material has a major surface that has excellent wear resistance, such as being less prone to fluff due to friction. is there.

  Furthermore, the skin material of the present invention has a resin layer on the entire main surface A of the base mat constituting the skin material. For this reason, the constituent fiber on the main surface A side of the skin material is protected by the resin layer, so that the skin material is more excellent in wear resistance, such as being less likely to generate fuzz due to friction.

  Therefore, the skin material of the present invention is excellent in molding processability and more excellent in wear resistance.

  The base mat constituting the skin material of the present invention refers to a sheet-like fiber structure such as a woven fabric, a knitted fabric, or a nonwoven fabric, in which fibers are bonded together with a binder. In particular, it is preferable that the base mat constituting the present invention is derived from a non-woven fabric because it is a flexible base mat that can easily follow the shape of the mold, and therefore can provide a skin material excellent in molding processability.

  The constituent fibers of the base mat in the present invention are not particularly limited, and examples thereof include polyester fibers, nylon fibers, acrylic fibers, vinylon fibers, and rayon fibers. Among these, it is preferable that the polyester fiber which is excellent in heat resistance, light resistance, antifouling property, etc. and / or the rayon fiber which is excellent in a flame retardance are included. In addition, the constituent fiber may be a single fiber or a composite fiber containing two or more kinds of resins such as a core-sheath type or a side-by-side type. For example, it is preferable to use latent crimped fibers (such as side-by-side type composite fibers) because the fibers are crimped by heat and the base mat structure becomes dense by using the fibers that have been crimped. . Furthermore, the cross-section of the constituent fibers may be circular, or may be an ellipse, a quadrangle, or an irregular shape such as a Y-shaped cross section. In addition, fibrillated fibers may be included.

  As will be described later, when thermocompression bonding is performed at the time of manufacturing the base mat, in order to improve the wear resistance and to form a clear print, as a constituent fiber of the base mat, the dry heat shrinkage is 4% or more. It is preferable that it contains polyester stretched short fibers (preferably 4.5 to 20%, more preferably 5 to 10%). The “dry heat shrinkage” is in accordance with JIS L1015 (2010) 8.15b) dry heat dimensional change rate except that the initial load is 1.3 mg and the temperature is 140 ° C. for 10 minutes. This is the value measured.

  The constituent fibers may be white or colored. When the constituent fiber is colored, the fiber itself may be a primary fiber containing a pigment and / or dye in the constituent resin, or may be a fiber colored with a pigment and / or dye. Since the fiber is not easily discolored by friction, it is preferable to use an original fiber.

  The fiber length of the constituent fibers of the base mat in the present invention is appropriately adjusted. However, since the base mat has excellent moldability, the fiber length of the constituent fibers is preferably 38 to 114 mm, and preferably 38 to 76 mm. More preferably, it is 38-52 mm. The “fiber length” refers to a value measured in accordance with JIS L1015 (2010) 8.4.1c) direct method (Method C).

  In addition, the fineness of the constituent fibers of the base mat in the present invention is also adjusted as appropriate. However, if the fibers are too thick, it becomes difficult to obtain a skin material with a smooth surface, and the skin material with a rough surface gets caught by friction. It tends to be poor in wear resistance such as fluffing because it is easy. On the other hand, if the fibers are too thin, pills are generated during the production of the base mat, and the productivity tends to deteriorate. Therefore, the fineness of the constituent fibers of the base mat is preferably 0.2 to 6 dtex, more preferably 0.8 to 4 dtex, and further preferably 1 to 2 dtex.

  The skin material of the present invention may be a base mat constituted by a single fiber layer or a base mat constituted by laminating a plurality of fiber layers. In the base mat formed by laminating a plurality of fiber layers, fiber layers having the same fiber composition may be laminated, or fiber layers having different fiber compositions may be laminated. Among these, a base mat composed of a single fiber layer is preferable because it can provide a skin material that does not cause delamination during molding and has excellent moldability.

  The base mat of the present invention is constructed by bonding constituent fibers with a binder. As an aspect in which the constituent fibers are bonded to each other by the binder, for example, an aspect in which the binder adheres to the intersection of the constituent fibers and the binder bonds the constituent fibers to each other, or an aspect in which the binder exists between the fibers and is bonded. Etc.

  The type of binder used in the present invention is not particularly limited and can be adjusted as appropriate. Examples thereof include polyurethane resins, acrylic resins, and polyester resins. Among these, an acrylic resin (particularly, a self-crosslinking acrylic resin) is preferable because it softens moderately at the time of molding, has excellent followability to the mold, and hardly generates wrinkles and fine irregularities. Among acrylic resins, a soft acrylic resin having a low glass transition temperature is suitable because it is easily stretched and has excellent moldability. On the other hand, if the glass transition temperature of the acrylic resin is too low, the adhesive strength of the binder is improved, but the breaking strength of the binder resin is inferior, so that the abrasion resistance is inferior. Therefore, the glass transition temperature is preferably −40 ° C. or higher and 10 ° C. or lower, more preferably −20 ° C. or higher and 5 ° C. or lower, and further preferably −10 ° C. or higher and 5 ° C. or lower. The “glass transition temperature” in the present invention refers to a temperature corresponding to the intersection of the tangent line of the base line in the DTA curve measured by a differential thermal analyzer (DTA) and the tangent line of the steeply descending position of the endothermic region due to the glass transition.

The base mat constituting the skin material of the present invention is characterized in that the amount of the binder present on one main surface A side is larger than that on the other main surface B side. In the present invention, “the amount of binder present on the main surface A side (or main surface B side)” is 20% from the main surface A (or main surface B) of the base mat with respect to the thickness of the entire base mat. It means the amount of binder present in the region up to the thickness. With this configuration, on the main surface A side, the fluff due to friction is less likely to occur and the wear resistance is excellent, and the constituent fibers on the main surface B side are strongly bonded by the binder as compared to the main surface A side. Since it is easy to move, it is possible to provide a skin material with excellent moldability.
In addition, as a method for confirming the amount of the binder, for example, the binder contained in the base mat is colored with a dye such as Kayastein Q (manufactured by Nippon Kayaku Co., Ltd.), and a cross section in the thickness direction of the base mat is used. The binder distribution in can be confirmed by visual observation or observation with an optical microscope.

  The distribution mode of the amount of binder contained in the base mat may be adjusted as long as the amount of the binder present on one main surface A side of the base mat is larger than that on the other main surface B side. However, if the amount of the binder present is continuously reduced from the main surface A side to the main surface B side, the amount of the binder present in the base mat continuously changes, and the distribution of the amount of the binder present is Since it does not concentrate on a very small part of the base mat, it is preferable because peeling is unlikely to occur at the portion where the binder is concentrated and other portions, and the wear resistance and molding processability are excellent.

When the amount of the binder contained in the base mat increases, the wear resistance tends to be more excellent. Therefore, the amount of the binder is preferably ² g / m ² or more, more preferably 10 g / m ² or more, and 15 g / m ² or more. Is more preferable. On the other hand, if the amount of the binder contained in the base mat is too large, the skin material tends to be hard and the moldability tends to deteriorate, and therefore it is preferably 30 g / m ² or less, and 20 g / m ^2. The following is more preferable.

  The skin material of the present invention is excellent in wear resistance, such as being less likely to generate fuzz due to friction on the main surface A side due to the structure having the resin layer on one main surface A of the base mat. The “entire surface on one main surface A” of the present invention refers to the entire one main surface A of the base mat that is visible when the base mat is viewed from directly above the one main surface A of the base mat. Point to.

  The resin layer of the present invention can be a layer composed of the following resins. Examples of the resin include the same resins as the binder resin described above. For example, a polyurethane resin, an acrylic resin, or a polyester resin can be used. Among these, an acrylic resin (particularly a self-crosslinking acrylic resin) that softens moderately at the time of molding, has excellent followability to the mold, and hardly generates wrinkles and fine irregularities is preferable. Among acrylic resins, a soft acrylic resin having a low glass transition temperature is suitable because it is easily stretched and has excellent moldability. On the other hand, if the glass transition temperature of the acrylic resin is too low, the adhesive strength of the binder is improved, but the breaking strength of the binder resin is inferior, so that the abrasion resistance is inferior. Therefore, the glass transition temperature is preferably −40 ° C. or higher and 10 ° C. or lower, more preferably −20 ° C. or higher and 5 ° C. or lower, and further preferably −10 ° C. or higher and 5 ° C. or lower.

  In addition, if the difference in glass transition temperature between the resin contained in the binder and the resin contained in the resin layer is 10 ° C. or less, there is a difference in how the base mat portion and the resin layer portion in the skin material extend in the molding process. By making it difficult to come out, delamination does not easily occur between the base mat and the resin layer, and it is possible to provide a skin material that is more excellent in molding processability, which is preferable. The difference in glass transition temperature between the resin contained in the binder and the resin contained in the resin layer is more preferably 5 ° C. or less, further preferably 3 ° C. or less, and most preferably the same temperature. In addition, the “resin layer” of the present invention refers to a layer that includes a resin-only region and completely covers one main surface A of the base mat. Moreover, the area | region only of resin is observed as a film-like layer, when the cross section of the thickness direction of a skin material is observed. The resin layer may be configured only by the resin-only region, or may be configured to include a region where fibers and the resin are mixed in addition to the resin-only region.

As the amount of the resin layer of the skin material increases, the abrasion resistance tends to be more excellent. Therefore, the amount of the resin layer is preferably 5 g / m ² or more, more preferably 10 g / m ² or more, and 15 g / m ² or more. Is more preferable. Further, if the amount of the resin layer is too large, it tends to impair the texture, feel and molding processability of the skin material, and therefore it is preferably 20 g / m ² or less. Further, since the thickness of the resin layer of the skin material tends to be more excellent in wear resistance, the thickness of the resin layer is preferably 0.001 mm or more, more preferably 0.002 mm or more, and 0.004 mm. The above is more preferable. Further, if the thickness of the resin layer is too thick, it tends to impair the texture, feel and molding processability of the skin material, and is preferably 0.02 mm or less. The thickness of the resin layer can be measured by observing a cross section in the thickness direction of the skin material with an electron microscope, and the arithmetic average value of the thickness of the resin layer at 10 randomly selected points is represented by the “resin layer” of the present invention. Thickness ".

  The skin material of the present invention may be provided with a pattern by printing so as to be more excellent in wear resistance and so as to be excellent in the design property of the skin material. Since the pattern by printing becomes clear and the wear resistance of the skin material can be improved by the presence of the print, the print exists on the main surface A side derived from the base mat with a relatively large amount of binder. Is preferred. In addition, as for the printing mode, printing is performed on the main surface of the base mat, and the resin layer covers the print from above, or on the main surface of the skin material (the main layer with the resin layer exposed). The surface is printed on the main surface A of the base mat so that the print is not easily peeled off by friction, and the resin layer covers the print from above. Are preferred.

  The printed pattern of the skin material of the present invention is not particularly limited. For example, as disclosed in JP 2012-179985, a printed pattern in which the color difference gradually changes, utility model registration No. 3072493. It can be a printed pattern having a three-dimensional pattern, as disclosed in No. 1. Note that there may be one type of print or two or more types.

  The composition of the print applied to the skin material of the present invention is appropriately prepared. The type of the composition is composed of the same resin as the above-described binder resin, for example, a resin such as polyurethane resin, acrylic resin, or polyester resin. I can do it. Also, the print may contain a pigment, and the color, type and amount of the pigment can be adjusted as appropriate.

When the amount of the resin contained in the print is increased, there is a tendency to become a skin material having more excellent abrasion resistance. Therefore, the amount of the resin contained in the print is preferably 3 g / m ² or more, more preferably 5 g / m ² or more. Preferably, 9 g / m ² or more is more preferable. Further, if the amount of the resin contained in the print is too large, the sharpness of the pattern by the print and the molding processability tend to be impaired, and therefore it is preferably 20 g / m ² or less.

The binder, the resin layer, and the print can contain a functional material in addition to the above-described resin. For example, since the skin material can be colored by including a pigment, the design of the skin material is improved. In addition, by including a water-repellent resin such as a resin containing silicone or a resin containing fluorine, the skin material is less likely to become dirty, and wear resistance can be improved. Furthermore, various functions can be imparted to the skin material by including an inorganic compound such as a flame retardant, an antibacterial agent, a deodorant, a VOC generation inhibitor, and an inorganic powder.

The basis weight and thickness of the skin material of the present invention are adjusted as appropriate according to the intended use, required strength, etc., but if the skin material weight is too light, the skin material may be broken during molding, resulting in deterioration of molding processability. and the basis weight is too great force is required for molding heavy, since the molding processability is deteriorated, and the basis weight is preferably from 140~260g / ^{m 2,} more preferably from 150 to 250 g / ^{m 2} 160 to 250 g / m ² is more preferable. In addition, if the thickness of the skin material is too thin, the molding processability deteriorates, and if it is too thick, it becomes difficult to handle. Therefore, the thickness is preferably 1 to 2 mm, and preferably 1.5 to 1.8 mm. More preferably, it is 1.5-1.6 mm. In addition, the “thickness” of the skin material, the base mat, and the needle punched nonwoven fabric described in the examples in the present invention refers to the value of the length between two main surfaces at 100 g / 5 cm ² load, and was selected at random. It means the arithmetic average value of thickness at 10 points.

The 20% modulus of the skin material of the present invention is appropriately adjusted depending on the intended use, but if the 20% modulus in the vertical direction, which tends to be higher than the horizontal direction due to the orientation of the fibers, is too high, the molding processability deteriorates. Because of this tendency, the 20% modulus in the vertical direction is preferably 90 N / 3 cm width or less, more preferably 80 N / 3 cm width or less, and even more preferably 70 N / 3 cm width or less. If the 20% modulus is too low, the fibers are not sufficiently entangled, and the molding processability and wear resistance deteriorate, so the lower limit of the 20% modulus in the longitudinal direction is 50 N / 3 cm. preferable. Further, the 20% modulus ratio in the vertical direction and the horizontal direction is 3/2 to 3/1 in the vertical / horizontal direction because it is easy to set in a mold and is excellent in molding processability. Is preferred. The “longitudinal direction” in the present invention refers to the production direction (flow direction) during the production of the nonwoven fabric, and the “lateral direction” refers to a method orthogonal to the longitudinal direction, that is, the width direction.

  Next, the method for manufacturing the skin material of the present invention will be illustrated and described.

  First, a fiber structure such as a woven fabric, a knitted fabric, or a nonwoven fabric is manufactured using the above-described fibers. Although the manufacturing method of the fiber structure is not particularly limited, when the fiber structure is a woven fabric or a knitted fabric, the fiber structure can be manufactured by weaving or knitting the above-described fibers. When the fiber structure is a non-woven fabric, for example, a dry method in which fibers are entangled by using the above-mentioned fibers in a card device or an air array device, a wet method in which fibers are dispersed in a solvent to form a sheet, and the fibers are entangled, Using a direct spinning method [melt blow method, spun bond method, electrostatic spinning method, a method of spinning by spinning a spinning stock solution and a gas flow in parallel (for example, a method disclosed in JP2009-287138A), It is possible to manufacture the fiber by spinning the fiber and collecting it, etc., but it is preferable to have a certain amount of bulk so that the molding processability is excellent. It is preferable to employ a dry method of combining them.

The fiber structure formed as described above is preferably entangled with a water flow or a needle so as to be easy to handle. In particular, it is preferable to entangle with a needle so as not to impair the thickness and, as a result, the moldability. The needle entanglement conditions that are suitable are not particularly limited, but are preferably entangled at a needle density of 300 to 1000 / cm ² , more preferably 300 to 600 / cm ² .

  If necessary, after forming the fiber structure, the constituent fibers may be subjected to thermocompression bonding before being bonded with a binder. The term “thermocompression bonding” does not mean that the fibers are melted or plasticized and bonded, but the inter-fiber voids are reduced by heat and pressure, and the fibers adhere to each other with high density. It means that it is in the state. In particular, when the fiber structure contains a polyester stretched short fiber having a dry heat shrinkage rate of 4% or more as described above, it is slightly shrunk microscopically and the surface becomes smooth when thermocompression bonded. Since the fibers are not easily caught by friction, the wear resistance is excellent, and since a clear print can be formed when printing is performed, it is preferable to perform thermocompression bonding before the constituent fibers are bonded to each other with a binder.

  Such a stretched polyester fiber having a dry heat shrinkage rate of 4% or more can have a dry heat shrinkage rate of 4% or more, for example, by appropriately adjusting the temperature at the time of heat setting when producing the fiber. . Specifically, after stretching the fiber, the heat-shrinkage can be set to 4% or more by heat setting at a temperature higher than the glass transition temperature of the polyester, that is, at a temperature of 70 ° C. or higher.

  Next, a binder resin liquid is applied from one main surface A side of the fiber structure by a method such as foaming impregnation, coating, or spraying, and then dried to bond the constituent fibers of the fiber structure with a binder. A base mat in which the amount of binder present on one main surface A side is greater than that on the other main surface B side is manufactured.

  A method for producing a base mat in which the amount of binder present on one main surface A side is larger than that on the other main surface B side is appropriately selected, but the foam weight is 90 to 150 g / kg from one main surface side of the fiber structure. It can be produced by impregnating a foamed binder solution of L and passing it through two rollers having an adjusted interval between the rolls. At this time, the side to which the binder is applied becomes the main surface A side. The “foam weight” refers to the weight (g) of the foamed binder per 1 L of volume. When foamed binder liquid with too light foam weight is used, the binder tends to hardly penetrate into the fiber structure. When foamed binder liquid with too heavy foam weight is used, the binder penetrates into the entire fiber structure. There is a tendency that a base mat having a larger amount of binder on one main surface A side than on the other main surface B side cannot be manufactured. Therefore, it is more preferable to employ a foamed binder liquid foam weight applied to the fiber structure of 100 to 130 g / L.

  After applying the binder to the fiber structure, the dispersion medium / solvent is removed from the binder liquid. The method for removing the dispersion medium / solvent is appropriately prepared. For example, the dispersion medium / solvent can be removed by heating with a dryer. The type of the dryer is not particularly limited, but a can dryer or a dryer with a tenter pin is preferable in order to suppress shrinkage due to drying.

  Finally, a skin material is manufactured by applying a resin layer coating solution, which is a dispersion / solution of a resin constituting the resin layer, over the entire main surface A of the base mat to form a resin layer. The coating method of the resin layer coating liquid is not particularly limited, but for example, a cylinder with a through hole is prepared on the entire surface, such as a cylindrical silk screen, and the resin layer coating liquid is passed through the through hole of this cylinder. It is applied onto the main surface A, and the dispersion medium / solvent is removed from the applied resin layer coating solution. The dispersion medium / solvent removal method is suitably prepared. For example, the dispersion medium / solvent can be removed by heating with a floating dryer or a dryer with a tenter pin that does not contact the surface of the skin material and drying the skin material.

In addition, when printing on a skin material, a printing process can be performed on the main surface of a base mat, or the surface of a resin layer. The arrangement of the print is not particularly limited, but can be performed by a conventionally known method. For example, it is possible to prepare a cylinder having an opening corresponding to a desired pattern, print a printing liquid through the cylinder, and dry and place the print. Further, when two or more kinds of print resins are arranged, they can be arranged by repeating the above operation. The print has a relatively large amount of binder because the print pattern is clear and the print covers a part of one main surface, making the skin material excellent in wear resistance. It is preferable to apply to the surface A side. Further, in order to prevent the print from being peeled off by friction, it is preferable to apply the print on the main surface of the base mat and cover the print with a resin layer thereon.

  The skin material of the present invention can be used as a skin material such as a vehicle interior material. The molding method is not particularly limited. For example, a molding method in which a skin material is put into a mold and pressure or heat is applied together with a urethane resin or a glass sheet, or a skin material is put into a mold, and a gap between the skin material and the mold is used. A method such as injection molding in which a resin is poured into the substrate and pressure or heat is applied can be employed.

Further, the skin material can be subjected to secondary processing in which other knitted fabrics, woven fabrics, and nonwoven fabrics are laminated on the skin material, or the skin material is cut out so that the skin material can be applied to various applications.

  Examples of the present invention will be described below, but the present invention is not limited to the following examples.

(Preparation of needle punched nonwoven fabric)
Using 100 mass% of original polyester fiber (fineness: 2.2 dtex, fiber length: 38 mm, color: gray), a fiber web is formed by a card machine, and then a needle with a needle density of 400 / cm ² from one side is used. Punch processing was performed. Then, the needle punched nonwoven fabric was manufactured by thermocompression-bonding the fiber web which carried out the needle punch process by supplying between thermal calender rolls with a temperature of 170 ° C. and a roll interval of 0.4 mm (weight per unit: 140 g / m ² , thickness (S: 1.2 mm).

(Preparation of binder liquid A)
A binder dispersion blended at the following ratio was prepared.
(1) Acrylic binder [Boncoat (registered trademark) E-240N, manufactured by DIC Corporation, glass transition temperature: −5 ° C.] 15 parts by weight (2) Thickener [Serogen (registered trademark) WS-C , Daiichi Kogyo Seiyaku Co., Ltd.] ... 0.2 parts by weight (3) Surfactant [Neogen (registered trademark) S-20D, Daiichi Kogyo Seiyaku Co., Ltd.] ... 0.2 wt Part (4) Ammonia water: 0.1 part by weight (5) Water: 84.5 parts by weight The obtained dispersion was foamed to prepare binder liquid A. The foam weight of the binder liquid A was 120 g / L.

(Preparation of binder liquid B)
A binder dispersion blended at the following ratio was prepared.
(1) Acrylic binder [Boncoat (registered trademark) E-240N, manufactured by DIC Corporation, glass transition temperature: −5 ° C.] 8 parts by weight (2) Thickener [Serogen (registered trademark) WS-C , Daiichi Kogyo Seiyaku Co., Ltd.] ... 0.2 parts by weight (3) Surfactant [Neogen (registered trademark) S-20D, Daiichi Kogyo Seiyaku Co., Ltd.] ... 0.2 wt Part (4) Ammonia water: 0.1 part by weight (5) Water: 91.5 parts by weight The obtained dispersion was foamed to prepare binder liquid B. The foam weight of the binder liquid B was 200 g / L.

(Preparation of print liquid A)
A printing liquid A, which was blended at the following ratio, was prepared.
(1) Thickener [Carbopol (registered trademark) 940, manufactured by Nippon Lubrizol Co., Ltd.] 0.36 parts by weight (2) Antifoaming agent [Shin-Etsu Silicone KM-73, Shin-Etsu Chemical Co., Ltd.] Product] ... 0.5 part by weight (3) Acrylic binder [Boncoat (registered trademark) AB-886, manufactured by DIC Corporation, glass transition temperature: -40 ° C] ... 18 parts by weight (4) Thickening Agent [Nicazole (registered trademark) VT-253, manufactured by Nippon Carbide Industries, Ltd.] ... 0.28 parts by weight (5) Ammonia water ... 1 part by weight (6) Water ... 79.62 parts by weight (7) Black pigment [RW BLACK RC (V), manufactured by DIC Corporation] 0.24 parts by weight

(Preparation of print liquid B)
A printing liquid B, which was blended at the following ratio, was prepared.
(1) Thickener [Carbopol (registered trademark) 940, manufactured by Nippon Lubrizol Co., Ltd.] 0.36 parts by weight (2) Antifoaming agent [Shin-Etsu Silicone KM-73, Shin-Etsu Chemical Co., Ltd.] Product] ... 0.5 part by weight (3) Acrylic binder [Boncoat (registered trademark) AB-886, manufactured by DIC Corporation, glass transition temperature: -40 ° C] ... 12.3 parts by weight (4) Thickener [Nicazole (registered trademark) VT-253, manufactured by Nippon Carbide Industries, Ltd.] ... 0.28 parts by weight (5) Ammonia water ... 1 part by weight (6) Water ... 83.38 Part by weight (7) Black pigment [RW BLACK RC (V), manufactured by DIC Corporation] 0.18 part by weight (8) Silicone resin [YMR-7212, manufactured by GE Toshiba Silicone Corporation] ... 2 parts by weight

(Preparation of resin layer coating solution)
A resin layer coating solution blended at the following ratio was prepared. In addition, after adding materials other than ammonia water and stirring sufficiently, ammonia water is dropped while stirring and the viscosity is adjusted to 9000 to 11000 cp under the condition of a B-type viscometer 20 rpm. Prepared.

(1) Thickener [Carbopol (registered trademark) 940, manufactured by Nippon Lubrizol Co., Ltd.] 0.36 parts by weight (2) Antifoaming agent [Shin-Etsu Silicone KM-73, Shin-Etsu Chemical Co., Ltd.] Product] ... 1.6 parts by weight (3) Acrylic binder [Boncoat (registered trademark) E-240N, manufactured by DIC Corporation, glass transition temperature: -5 ° C] ... 7.5 parts by weight (4) Thickener [Nicazole (registered trademark) VT-253, manufactured by Nippon Carbide Industries, Ltd.] ... 1 part by weight (5) Ammonia water ... 1 part by weight (6) Water ... 88.54 parts by weight

Example 1
The binder liquid A foamed on a needle punched nonwoven fabric is applied and infiltrated, and the binder liquid A is infiltrated from the main surface A side to the B side through the needle punched nonwoven fabric between two rollers having a gap between rolls of 0.3 mm. It was. Thereafter, the base mat (weight per unit: 155 g / m ² , thickness: 1.2 mm) was prepared by drying with a can dryer at a temperature of 160 ° C. (the side on which the binder liquid was applied was the main surface A side, and the main surface A side) The opposite surface is the main surface B side). In addition, when the cross section of the base mat was dyed with Kayastein Q (manufactured by Nippon Kayaku Co., Ltd.) and the abundance of the binder was confirmed with an optical microscope, more binder was found on the main surface A side than on the main surface B side. It was an aspect in which the binder amount was continuously reduced from the main surface A side to the main surface B side.
Subsequently, in order to form a resin layer on the main surface A side of the base mat, the resin layer coating solution was uniformly applied over the entire main surface A. After apply | coating the said resin layer coating liquid, it used for the dryer apparatus of temperature 160 degreeC, and dried and prepared the skin material.

(Example 2)
A base mat is prepared in the same manner as in Example 1, and the printing liquid A is printed on the main surface A side using a cylinder, and the linear shape is formed obliquely upward to the right at an angle of 30 ° from the width direction of the base mat. A first print area (line width: 0.3 mm, line interval: 1 mm) is formed, and printing liquid B is printed using another cylinder, and the right angle is -30 ° from the width direction of the base mat. A second print region (line width: 0.3 mm, line interval: 1 mm) extending linearly in a diagonally downward direction was formed. Then, it was dried with a 160 ° C. dryer.
Subsequently, in the same manner as in Example 1, the resin layer coating solution was uniformly applied to the entire main surface A on the main surface A side of the base mat where the prints were present. After apply | coating the said resin layer coating liquid, it used for the dryer apparatus of temperature 160 degreeC, and dried and prepared the skin material.

(Example 3)
A needle punched nonwoven fabric was produced in the same manner as in Example 1 except that the basis weight was different. (Weight: 180 g / m ² , thickness: 1.5 mm). Thereafter, the binder liquid A foamed on the needle punched nonwoven fabric is applied and infiltrated, and the binder liquid A is directed from the main surface A side to the B side through the needle punched nonwoven fabric between two rollers having a spacing of 0.25 mm between rolls. Infiltrated. Then, it dried with the can dryer of the temperature of 160 degreeC, and manufactured the base mat (A basis weight: 185 g / m < ² >, thickness: 1.5 mm).
Next, a skin material was prepared in the same manner as in Example 2 except that the coating amount of print A was 4 g / m ² and the coating amount of print B was 5 g / m ² .

(Comparative Example 1)
A base mat having no resin layer was prepared in the same manner as in Example 1 except that the resin layer coating solution was not applied.

(Comparative Example 2)
After the resin layer coating solution was not applied, and the binder solution A was applied and infiltrated, the needle punched nonwoven fabric was passed between two rollers with a gap of 10 mm between the rolls, and the coating amount of the binder solution A was 50 g / m ^2. Except for the above, a base mat (weight per unit: 190 g / m ² , thickness: 1.4 mm) without a resin layer was prepared in the same manner as in Example 1. In addition, when the cross section of the base mat was dyed with Kayastein Q (manufactured by Nippon Kayaku Co., Ltd.) and the abundance of the binder was confirmed with an optical microscope, more binder was found on the main surface A side than on the main surface B side. It was an aspect in which the binder amount was continuously reduced from the main surface A side to the main surface B side.

(Comparative Example 3)
Using the same method as in Example 2 except that the resin layer coating solution was not applied, there was no resin layer on the main surface A of the base mat, and instead printing was performed on the main surface A of the base mat. A base mat including prints was prepared in the same manner as the skin material having a resin layer partially but not entirely.

(Comparative Example 4)
A skin material was prepared in the same manner as in Example 1 except that the resin layer coating solution was uniformly applied to the entire surface from the main surface B side of the base mat using a cylinder. In addition, when the cross section of the base mat was dyed with Kayastein Q (manufactured by Nippon Kayaku Co., Ltd.) and the abundance of the binder was confirmed with an optical microscope, more binder was found on the main surface A side than on the main surface B side. It was an aspect in which the binder amount was continuously reduced from the main surface A side to the main surface B side.

(Comparative Example 5)
The said binder liquid B foamed to the needle punch nonwoven fabric was apply | coated, and the binder was osmose | permeated the whole nonwoven fabric. Thereafter, the base mat was prepared by drying with a can dryer at a temperature of 160 ° C. (Similar to Example 1, the side coated with the binder liquid was the main surface A side, and the opposite surface of the main surface A side was the main surface B side. To do). In addition, when the cross section of the base mat was dyed with Kaya stain and the amount of binder present was confirmed with an optical microscope, the amount of binder present on the main surface A side and main surface B side was the same.
Subsequently, in the same manner as in Example 1, the resin layer coating solution was applied from the main surface A side and dried to prepare a skin material.

Table 1 shows the nonwoven fabric basis weight of the examples and comparative examples, the binder amount, the printed amount, the resin amount of the resin layer, the basis weight of the skin material or base mat, and the thickness of the skin material or base mat. Table 2 shows the position, the thickness of the resin layer, and the binder distribution. Moreover, the skin material or base mat of an Example and a comparative example was evaluated with the following method.

(Evaluation of skin material or base mat)
(1) Measurement of 20% modulus strength (i) From the skin material or the base mat, three rectangular samples having a width of 30 mm and a length of 200 mm were taken in the vertical and horizontal directions.
(Ii) The sample was fixed between the chucks (distance: 100 mm) of a tensile strength tester (Orientec, Tensilon UTM-III-100), and then pulled at a pulling speed of 200 mm / min. The stress value at the time of 20% elongation) was read.
(Iii) The stress was measured for each of the three samples, and the arithmetic average value was defined as the 20% modulus strength in the vertical and horizontal directions.

(2) Performance evaluation method and abrasion resistance evaluation method of skin material or base mat The skin material or base mat is fixed to a Gakushin friction tester (manufactured by Daiei Kagaku Seisakusho Co., Ltd., RT-200). In the case of materials, the side having the resin layer (Examples 1 to 3, Comparative Example 5 is the main surface A side, and Comparative Example 4 is the main surface B side). Applying a load of 1 kg to a friction element (20 mm x 25 mm) with hook-and-loop fasteners (male type, Kuraray Fastening Co., Ltd., A hook for sewing, 100% polyester), 20 reciprocations (60 reciprocations / The main surface of the skin material or the base mat was rubbed.
Thereafter, the surface condition of the skin material or the base mat after rubbing was observed, and the wear resistance was evaluated according to the following criteria.
(Evaluation criteria for wear resistance)
5: No change 4: Fluffing can be partially confirmed, and fluff height is 0 mm or more and 5 mm or less. The color of the base mat can be confirmed visually.
3: Fluffing can be confirmed as a whole, and the fluffing height is from 0 mm to 5 mm. The color of the base mat can be confirmed visually.
2: Fluffing can be confirmed as a whole, and the fluff height exceeds 5 mm and is 10 mm or less. The color of the base mat can be confirmed visually.
1: Fluffing can be confirmed as a whole, and the fluffing height exceeds 5 mm and is 10 mm or less. The color of the base mat cannot be visually confirmed due to fuzz.
Only those satisfying 3 or more according to the above-mentioned evaluation criteria for wear resistance were evaluated for the following moldability. Of the examples and comparative examples, the skin materials of Examples 1 to 3 and Comparative Example 5 satisfied the abrasion resistance evaluation criteria.

Molding processability evaluation method Injection molding was performed using a fully automatic injection molding machine (UBE MAX MB450-IV-I13 1.6.5B, manufactured by Ube Industries Co., Ltd.).
After fixing the skin material with a pin in a molding die (vertical: 19 cm, horizontal: 31 cm) provided with a recess (vertical: 4 cm, horizontal: 8 cm, depth: 1 cm) near the center of the mold The mold interval was set to 5 mm, and a polypropylene molten resin (polyolefin resin manufactured by Sumitomo Chemical Co., Ltd., product number: AZ864E4 white) was injected to the side having no resin layer of the skin material, and then 30 at a pressure of about 5 tons. A press was performed for 2 seconds, injection molding was performed, and a molded product was created. After cooling the molded product to room temperature, the surface state of the molded product on the side having the resin layer derived from the skin material was observed, and the molding processability of the skin material was evaluated according to the following criteria.
(Evaluation criteria for moldability)
○: The molded product was not torn at all, and the molding processability was good. ×: The molded product was torn and the molding processability was poor. −: The wear resistance evaluation criteria did not satisfy 3 or more. , Did not evaluate moldability

Based on the above results, comprehensive evaluation was performed on the performance of the skin material.
(Comprehensive evaluation criteria)
○: Excellent both in abrasion resistance and molding processability ×: Not both in abrasion resistance and molding processability

The evaluation results are shown in Table 3.

※比較例１〜３は、それぞれベースマットの目付・ベースマットの厚さのことを指す。

* Comparative Examples 1 to 3 indicate the basis weight of the base mat and the thickness of the base mat, respectively.

  From the above results, the skin material of the example was excellent in both wear resistance and molding processability, while the skin material of the comparative example was not excellent in both wear resistance and molding processability.

  From the result of comparing the abrasion resistance evaluation of Example 1 having a resin layer on the entire main surface A of the base mat and Comparative Examples 1 and 2 having no resin layer, Example 1 is more resistant to abrasion. It was excellent in nature. Moreover, from the result of comparing the abrasion resistance evaluation of Example 2 having a print and having a resin layer on the entire main surface A of the base mat, and Comparative Example 3 having a print but no resin layer. Example 2 was superior in wear resistance. Further, Example 1 having a resin layer on the entire surface of one main surface A of the base mat and a comparison having prints in the same manner as those having a resin layer on a part of one main surface A of the base mat. From the result of comparing the abrasion resistance evaluation of Example 3, the direction of Example 1 was superior in abrasion resistance. From these things, it turned out that the skin material which has a resin layer on the whole surface on one main surface A of a base mat is excellent in abrasion resistance.

  And, from the results of comparing the wear resistance evaluation of Example 1 having a resin layer on the main surface side with a large amount of binder and Comparative Example 4 having a resin layer on the main surface side with a small amount of binder, Example 1 was superior in wear resistance. From this, it was found that the skin material having a resin layer on the main surface side where the amount of binder present in the base mat is excellent in wear resistance.

  Further, in Example 1 in which the amount of the binder present on one main surface A side is greater than that on the other main surface B side, the amount of binder present is on one main surface A side and the other main surface B side. From the result of comparing the molding processability evaluation of the same Comparative Example 5, Example 1 was superior in molding processability. From this, it was found that the skin material in which the amount of the binder on the one main surface A side in the base mat is larger than that on the other main surface B side is excellent in molding processability.

From the above, it was found that the skin material having the configuration of the present invention is a skin material having excellent molding processability and further excellent wear resistance.

  The skin material of the present invention is highly wear resistant, for example, for interior materials for vehicles such as ceiling materials, door trims, dash outers, pillar garnishes, partitions, wallpaper, etc., particularly for door trims, dash outers, pillar garnishes, etc. Can be suitably used as an interior material for a vehicle.

Claims (1)

In the base mat formed by bonding the constituent fibers together with a binder, the amount of the binder present on one main surface A side is greater than that on the other main surface B side,
A skin material comprising a resin layer on the entire surface of the one main surface A of the base mat.