JP2019077134A - Interior substrate, interior material, and interior - Google Patents

Abstract

To provide an interior substrate capable of exhibiting rigidity and feeling property suitable when compressed by heating press molding, an interior material, and an interior capable of achieving enhancement of feeling property while maintaining rigidity.SOLUTION: An interior substrate 10 has an elastic layer 11 consisting of a foam elastic foam and a reinforcement layer 12 consisting of a fiber material, and having a ratio of 50% compressive strength between the fiber material and the foam elastic foam (fiber material/foam elastic foam) of over 0.26/100 and less than 25/100, an interior material 20 is obtained by layering an unwoven fabric-made skin material 21 on a single surface or double surface of the interior substrate 10, and further an interior 30 is obtained by heat press molding the interior material 20 to a prescribed shape, and a ratio of thickness between the reinforcement layer 12 by the fiber material and the elastic layer 11 by the foam elastic foam (reinforcement layer/elastic layer) is over 1/100 and less than 55/100.SELECTED DRAWING: Figure 4

Description

  The present invention is obtained by forming an interior base material used for a material of an interior material such as a car, an aircraft, and a building material, an interior material obtained using the interior base material, and the interior material thereof into a predetermined shape. It relates to interior materials.

Usually, the interior material is obtained by forming a sheet-like interior material obtained by laminating a skin material on the surface of an interior substrate into a predetermined shape by heat press molding. In many cases, a fiber material such as glass wool is used as the interior base material, and a non-woven fabric or a woven fabric is used as the skin material (for example, Patent Document 1). However, as in Patent Document 1, in the interior material using only a fiber material such as glass wool as the interior substrate, the fiber material compressed by heat press molding becomes very hard, the touch is poor, and the touch is inferior. Therefore, it is difficult to use as a material for interior materials that users touch, such as automobile instrument panels.
Therefore, a flexible foamed elastic foam is used as an interior material of an interior material that requires touch. However, when the foamed elastic foam is used alone as an interior material, it becomes inferior in rigidity, for example, it can be bent when it is compressed at the time of heat press molding and a desired shape retention can not be obtained. For this reason, the foamed elastic foam is formed by laminating a fiber material for reinforcement, a non-woven fabric, and a woven fabric as an interior material.
For example, the interior material for vehicles of patent document 2 uses as a surface material what laminated | stacked the air-permeable skin material on the surface of a soft polyurethane foam sheet, and uses as a base material what consists of thermoplastic synthetic resin fiber cotton and a fiber reinforcement material. There is.
The sound absorbing material of Patent Document 3 comprises a polyurethane foam, a surface material laminated on one side of the polyurethane foam, and a thermosetting resin-containing felt laminated on the surface of the polyurethane foam opposite to the surface material. Integrated and shaped by heat pressing.

Unexamined-Japanese-Patent No. 08-142077 Unexamined-Japanese-Patent No. 03-147830 JP, 2006-78709, A

  Interior materials using foamed elastic foams as in Patent Document 2 and Patent Document 3 are compressed into a foamed elastic foam, a fiber material, and the like when heated and press-formed into an interior material. There is a problem that it does not have rigidity. This is because there is a difference in compressive strength between the foamed elastic foam and the fiber material, and the difference in compressive strength affects the compression ratio of the foamed elastic foam and the fiber material. And when the foamed elastic foam is compressed more than expected, the desired touch can not be obtained, while when the fiber material is not compressed more than expected, the desired rigidity can not be obtained.

  The present invention has been made in view of the problems existing in such prior art. An object of the present invention is to provide an interior base material and an interior material capable of exhibiting suitable rigidity and feel when compressed by heat press molding, and while maintaining rigidity, feel and feel. To provide interior materials that can improve the

As means for solving the above-mentioned conventional problems, the invention of the interior base material according to claim 1 is an interior base material having an elastic layer made of a foamed elastic foam and a reinforcing layer made of a fiber material, The gist is that the ratio of 50% compression strength of the fiber material to the foamed elastic foam (fiber material / foamed elastic foam) is more than 0.26 / 100 and less than 25/100.
The invention according to claim 2 is that, in the invention according to claim 1, a material used for the foamed elastic foam is a melamine resin or a polyurethane.
The invention of the interior material according to claim 3 includes the interior substrate according to claim 1 or 2, and a non-woven surface covering material laminated on one side or both sides of the interior substrate. I assume.
The invention of an interior material according to claim 4 is obtained by heat-pressing the interior material according to claim 3 into a predetermined shape, and a reinforcing layer comprising the fiber material and an elastic layer comprising the foamed elastic foam. The gist of the present invention is that the thickness ratio (reinforcing layer / elastic layer) is greater than 1/100 and less than 55/100.

[Function]
According to the interior base of the present invention, the interior base having the elastic layer made of the foamed elastic foam and the reinforcing layer made of the fiber material has 50% compression strength of the fiber material and the foamed elastic foam. The ratio (fiber material / foamed elastic foam) is set to be more than 0.26 / 100 and less than 25/100.
Here, the 50% compressive strength of the present invention refers to the compressive stress at 50% strain specified in 7.2.3 of JIS K 6767. The lower the 50% compressive strength, the easier it is to be crushed during compression, so the thickness tends to be small, and the higher the 50% compressive strength, the more difficult to be compressed during compression, so the thickness tends to be large.
The interior base material focuses on the ratio of 50% compressive strength of the foamed elastic foam to the fiber material (fiber material / foamed elastic foam), and the ratio is more than 0.26 / 100 and less than 25/100. By setting, it is possible to compress the foamed elastic foam and the fiber material in a suitable balance at the time of hot press molding. For this reason, it is possible to suppress that the fiber material can not function as a reinforcing layer or the foamed elastic foam can not function as an elastic layer due to insufficient compression or excessive compression, and the rigidity is maintained by the reinforcing layer, It is possible to improve the touch by the elastic layer (claim 1).
Moreover, when the material used for the said foaming elastic body foam is a melamine resin or a polyurethane, a flame retardance and heat resistance can be provided (Claim 2).
According to the interior material of the present invention, the surface material made of non-woven fabric is laminated on one side or both sides of the interior substrate, so that the elastic layer and the reinforcing layer are not exposed to the outside, and design can be improved. (Claim 3).
According to the interior material of the present invention, the thickness ratio (reinforcing layer / elastic layer) of the reinforcing layer made of the fiber material and the elastic layer made of the foamed elastic foam is more than 1/100 and less than 55/100. Therefore, while the reinforcing layer has a thickness sufficient to maintain the rigidity, the elastic layer can have a thickness having sufficient flexibility to improve the touch (claim 4).

〔effect〕
According to the present invention, there is provided an interior base material and an interior material capable of exhibiting suitable rigidity and feel when compressed by heat press molding, and while maintaining the rigidity, it is possible to provide an interior material and an interior material. An interior material that can be improved can be provided.

Sectional drawing which shows the interior base material of embodiment. Sectional drawing which shows the interior material of embodiment. Sectional drawing which shows the interior material of another form. Sectional drawing which shows the interior material of embodiment.

An embodiment of the present invention will be described below.
As shown in FIG. 1, the interior base material 10 has an elastic layer 11 made of a foamed elastic foam and a reinforcing layer 12 made of a fiber material.
The elastic layer 11 is for exerting a suitable feel by the sense of elasticity (feeling of elasticity) and cushioning due to the flexibility possessed by the foamed elastic foam in the compressed state when compressed by heat press molding. It is.
The reinforcing layer 12 is for reinforcing the elastic layer 11 to suppress bending or deformation by the rigidity of the compressed fiber material when compressed by heat press molding.

The foamed elastic foam is a foam using a synthetic resin as a material from the viewpoint of exerting a suitable feel in a compressed state, and a soft flexible foam is used.
Examples of the synthetic resin include melamine resin, polyurethane, polystyrene, polyolefin such as polyethylene and polypropylene, phenol resin, polyvinyl chloride, urea resin, silicone resin, polyimide and the like. Among these, melamine resins and polyurethanes are easily available, and since they are thermosetting resins, they have flame retardancy and heat resistance, and have the advantage of being highly elastic and having a good feel in a compressed state. Thus, the material used for the foamed elastic foam is preferably melamine resin or polyurethane.

There are foams of an open cell structure and a closed cell structure, and both foam elastic foams can be used. However, the foam having a closed cell structure has a possibility that the walls separating the cells break (break) at the time of compression, and the 50% compressive strength may greatly change, so the foam has an open cell structure. It is preferred to use one of
In particular, a foam having an open cell structure has air permeability and is preferable as a foamed elastic foam from the viewpoint of being able to impart sound absorption performance utilizing this air permeability.

The foamed elastic foam has a 50% compressive strength of preferably more than 5 N from the viewpoint of making it as difficult to collapse as possible during compression to increase thickness, in order to exert a suitable touch in the compressed state by heat press molding. , 6N or more is more preferable, and 7N or more is more preferable. If the 50% compressive strength is excessively low, it may be crushed at the time of compression to reduce its thickness, resulting in a hard material having poor flexibility, which may make it impossible to exhibit desired feel.
The upper limit of the 50% compressive strength of the foamed elastic foam is not particularly limited, but is preferably 25 N or less, more preferably 15 N or less, and still more preferably 10 N or less. If the 50% compressive strength is excessively high, it is difficult to be compressed and the formability is poor, and on the contrary, there is a possibility that problems such as inferior in touch feeling, and easy occurrence of bending or deformation may occur.

In the foamed elastic foam, the mass per unit area (hereinafter, also abbreviated as “unit area mass”) is appropriately set according to the synthetic resin to be used, the expansion ratio and the desired 50% compression strength, and is particularly limited. I will not. The unit area mass is preferably 100 g / m ^{2 to} 500 g / m ² , and more preferably 120 g / m ² , in view of achieving weight reduction while maintaining 50% compressive strength in the above range and maintaining appropriate flexibility. 400 g / ^{m 2,} more preferably from ^{140g / m 2 ~350g / m 2} . When the unit area mass is excessively small, it becomes excessively soft, and when the unit area mass is excessively large, it becomes hard with poor flexibility and it becomes difficult to reduce the weight.
The thickness of the foamed elastic foam is appropriately set according to the desired thickness of the interior material, the desired 50% compressive strength, the synthetic resin to be used, the expansion ratio and the like, and is not particularly limited. Usually, the thickness of the foamed elastic foam is preferably set to be equal to or greater than the desired thickness of the interior material, and from the viewpoint of setting the 50% compressive strength in the above range, It is more preferable to set in the range of 10 mm-30 mm.

The fibers used for the fiber material are not particularly limited, and specific examples thereof include inorganic fibers such as glass wool (glass fiber), rock wool (Iwacotta), asbestos fibers, carbon fibers, ceramic fibers, metal fibers, whiskers, etc. Biodegradation consisting of synthetic fibers such as polyester fiber, polyethylene fiber, polypropylene fiber, polyamide fiber, acrylic fiber, urethane fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, acetate fiber, starch extracted from plants such as corn and sugar cane Natural fibers such as fibers (polylactic acid fibers), pulp, cotton, palm fibers, hemp fibers, bamboo fibers, kenaf fibers, or regenerated fibers obtained by disintegrating scraps of fiber products using these fibers Be These fibers are not limited to using only one kind, and may be used by mixing two or more kinds.
Among the above-mentioned fibers, glass wool and polyester fibers are preferable as fibers used for the fiber material from the viewpoint of high heat resistance, high flame retardancy, easy availability, and easy handling.

The fiber may be mixed with a heat-resistant synthetic fiber having a melting point of 250 ° C. or more from the viewpoint of improving heat resistance. Specific examples of heat resistant synthetic fibers include aramid fibers such as polymetaphenylene isophthalamide fibers and poly-p-phenylene terephthalamide fibers, polyarylate fibers, polyetheretherketone fibers, polyphenylene sulfide fibers and the like.
In addition, a low melting point thermoplastic fiber having a melting point of 180 ° C. or less may be mixed with the fiber from the viewpoint of improving the binding property between the fibers. Specific examples of the low melting point thermoplastic fiber include polyolefin fibers such as polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, polyvinyl chloride fiber, polyurethane fiber, polyester fiber, polyester co-weight Examples thereof include united fibers, polyamide fibers, polyamide copolymer fibers and the like.

Non-woven fabric, woven fabric, lace, felt and the like can be mentioned as a specific example of the form of the fiber material. Among them, non-woven fabrics are preferable as the form of the fiber material from the viewpoint of easy availability, easy handling, and easy compression at the time of heat press molding.
Nonwoven fabrics include a needle punching method in which a sheet or mat of fibers is entangled by needle punching, a thermal bonding method in which a sheet or mat of fibers is heated and the layers are fused to melt, a sheet or web of fibers What is manufactured by the chemical bond method which bonds mat | matte with a synthetic resin binder, the stitch bond method which stitch | stains the sheet | seat or mat of the web by a fiber, etc. is used. Among these, the non-woven fabric by the chemical bonding method or the needle punching method is preferable as a fiber material because it is easy to adjust the mass per unit area and the like and is easy to manufacture.

The fiber material has a 50% compressive strength of 5 N or less from the viewpoint that the fiber material is compressed as much as possible so as to be compressed as easily as possible in order to exert suitable rigidity in the compressed state by heat press molding. Is preferably, 3N or less is more preferable, and 2N or less is more preferable. If the 50% compressive strength is excessively high, it may be difficult to be crushed and the compression may be insufficient, so that sufficient rigidity may not be exhibited.
The lower limit of the 50% compressive strength of the fiber material is not particularly limited, but the lower limit is usually more than 0 N, preferably 0.02 N or more, more preferably 0.1 N or more. When the 50% compressive strength is excessively low, the fiber material is compressed endlessly, so that the reinforcing layer 12 can not have a sufficient thickness to reinforce the elastic layer 11.

In the fiber material, the unit area mass is appropriately set according to the form of the fiber or fiber material to be used and the desired 50% compressive strength, and is not particularly limited. Unit area weight, while those appropriate stiffness in compression, in terms of suppressing the 50% compressive strength is too high, preferably greater than 100 g / m ^2, less than 800 g / m ^2, more preferably ^{150g / m 2 ~500g / m 2} , more preferably from ^{200g / m 2 ~400g / m 2} . When the unit area mass is excessively small, the rigidity in the compressed state is inferior, and when the unit area mass is excessively large, the 50% compressive strength becomes excessively high.
The thickness of the fiber material is appropriately set according to the desired thickness of the interior material, the desired 50% compressive strength, the thickness of the foamed elastic foam to be used, and the like, and is not particularly limited. In general, the thickness of the fiber material is preferably set to the same level as the thickness of the foamed elastic foam to be used, and from the viewpoint of making the 50% compressive strength in the above range, specifically, 10 mm to 30 mm It is more preferable to be set to

In the interior substrate 10, the ratio of the 50% compressive strength of the fiber material to the foamed elastic foam (fiber material / foamed elastic foam) is a suitable balance between the foamed elastic foam and the fiber material at the time of heat press molding. From the viewpoint of compression, it is more than 0.26 / 100 and less than 25/100, preferably not less than 0.5 / 100 and less than 25/100, and more preferably 1/100 to 20/100.
In other words, when the 50% compressive strength of the foamed elastic foam is 100, the ratio of the 50% compressive strength of the fiber material is in the range of more than 0.26 and less than 25, preferably 0.5 or more. It is in the range of less than 25 and more preferably in the range of 1 to 20. That is, the 50% compressive strength of the fiber material is more than 0.26 / 100 and less than 25/100 (preferably 1⁄4) of the 50% compressive strength of the foamed elastic foam, preferably 100 minutes More than 0.5 (one-hundredths) and less than twenty-fives (one-quarter), and more preferably one-hundredths to one-hundredths (one-fifths).
When the ratio of 50% compressive strength of the fiber material is excessively small when 50% compressive strength of the foamed elastic foam is 100, the elastic layer 12 of the fiber material in the compressed state is formed of the foamed elastic foam The layer 11 can not be sufficiently reinforced. Also, when the 50% compressive strength of the foamed elastic foam is 100, when the ratio of the 50% compressive strength of the fiber material is excessively large, the elastic layer 11 made of the foamed elastic foam in a compressed state is suitable for the feel. Can not exert

From the viewpoint of setting the ratio of the 50% compressive strength of the fiber material to the foamed elastic foam in the above range, for example, when the fiber used for the fiber material is glass wool and the material used for the foamed elastic foam is polyurethane. The fiber material preferably has a thickness of 15 ± 5 mm and a unit area mass of 300 ± 50 g / m ² , and the foamed elastic foam preferably has a thickness of 15 ± 5 mm and a unit area mass of 300 ± 50 g / m ² .
When the fiber used for the fiber material is glass wool and the material used for the foamed elastic foam is a combination of melamine resin, the fiber material has a thickness of 15 ± 5 mm, a unit area mass of 300 ± 50 g / m ^2, and foam elasticity. The body foam preferably has a thickness of 15 ± 5 mm and a unit area mass of 160 ± 50 g / m ² .
When the fiber used for the fiber material is a polyester fiber and the material used for the foamed elastic foam is a combination of polyurethane, the fiber material has a thickness of 20 ± 5 mm, a unit area mass of 300 ± 50 g / m ² , and a foamed elastic material. The body foam preferably has a thickness of 15 ± 5 mm and a unit area mass of 300 ± 50 g / m ² .
When the fiber used for the fiber material is a polyester fiber and the material used for the foamed elastic foam is a combination of melamine resin, the fiber material has a thickness of 20 ± 5 mm, a unit area mass of 300 ± 50 g / m ² , and a foam The elastic foam preferably has a thickness of 15 ± 5 mm and a unit area mass of 160 ± 50 g / m ² .

In the interior substrate 10, the foamed elastic foam and the fiber material are bonded to each other. The bonding method is not particularly limited.
As a specific example of the bonding method, a liquid foam precursor made of a synthetic resin is applied to a predetermined thickness on the surface of a fiber material, and dried by heating, thereby forming a foamed elastic foam from the foam precursor and foaming. The method of joining an elastic foam and a fiber material is mentioned.
Another example is a method of bonding the fibrous material and the foamed elastic foam produced in different steps to each other using an adhesive. Examples of the adhesive include hot melt adhesives, acrylic resin adhesives, acrylic resin adhesives, synthetic rubber adhesives, synthetic rubber adhesives and the like.

As shown in FIG. 2, the interior material 20 has the interior substrate 10 and a skin material 21 laminated on the surface of the elastic layer 11 which is one side of the interior substrate 10. This skin material 21 may be laminated on both sides of the interior base material 10, as shown in FIG.
The surface material 21 covers the surface of the elastic layer 11 or the surfaces of the elastic layer 11 and the reinforcing layer 12 so that the elastic layer 11 and the like are not visually recognized from the outside, thereby the design of the appearance of the interior material 20 Improve.

The surface material 21 is made of non-woven fabric made of fibers. The fibers are not particularly limited.
Specific examples of the fibers include polyester fibers, polyethylene fibers, polypropylene fibers, polyamide fibers, acrylic fibers, urethane fibers, polyvinyl chloride fibers, polyvinylidene chloride fibers, synthetic fibers such as acetate fibers, and extracted from plants such as corn and sugar cane Natural fiber such as biodegradable starch fiber (polylactic acid fiber), pulp, cotton, palm fiber, hemp fiber, bamboo fiber, kenaf fiber, etc. or disintegrating scrap of fiber products using these fibers The obtained regenerated fiber is mentioned. One or two or more of these fibers are used for the surface material 21.
In addition, the fibers have a melting point of 250 ° C. or more, or a heat resistant synthetic fiber mentioned in the fiber material from the viewpoint of improving the heat resistance or improving the binding property of the fibers, or the melting point is 180. Low melting thermoplastic fibers having a temperature of not higher than ° C may be mixed.

  As a non-woven fabric, a spun bond method is formed into a sheet while discharging a synthetic resin to be a material of synthetic fibers into a long fiber shape, a melt blowing method is formed into a sheet while blowing a synthetic resin by high speed and high temperature air, Of a web or a web made of fibers by a high pressure water flow, a chemical bonding method in which a sheet or a mat of a web made of fibers is impregnated or mixed with a synthetic resin binder, or a web made of fibers What is manufactured by the thermal bonding method which heat-softens a sheet or mat | matte, and ties fibers, the needle punching method etc. which intertwine the sheet | seat or mat of the web which consists of fibers by needle punching is used. Among these, the non-woven fabric by the spun bonding method is easy to manufacture and can be reduced in thickness, so that the influence of the compression of the surface material 21 on the elastic layer 11 and the reinforcing layer 12 is suppressed. It is preferable as the surface material 21 from the viewpoint that it is possible.

The surface material 21 can be impregnated with a thermosetting resin from the viewpoint of imparting heat resistance, improving rigidity, and improving formability and shape retention.
As the thermosetting resin, resol type phenolic resin, urethane type resin, melamine type resin, thermosetting type acrylic resin (in particular, one which forms an ester bond and is cured by heating), urea type resin, epoxy type resin, A thermosetting type polyester resin etc. are illustrated. In addition, urethane resin prepolymer, urea resin prepolymer (initial condensation product), phenol resin prepolymer (initial condensation product), diallyl phthalate prepolymer, acrylic oligomer, polyvalent isocyanate, methacrylic ester monomer, diallyl phthalate monomer And synthetic resin precursors such as prepolymers, oligomers, and monomers. It is preferable to use an aqueous solution, an aqueous emulsion, or an aqueous dispersion from the viewpoint of easy handling, although a thermosetting resin in the form of an organic solvent solution may be used. Moreover, you may mix and use 2 or more types for a thermosetting resin or a synthetic resin precursor.

Among the thermosetting resins exemplified above, a resol-type phenolic resin is desirable as a material to be impregnated into the skin material 21 from the viewpoints of easy availability, easy handling, high heat resistance, and the like. The resole type phenolic resin is obtained by reaction of an excess of formaldehydes with respect to a phenolic compound with an alkali catalyst, and is composed of a mixture of various phenol alcohols to which phenol and formaldehyde are added, and is usually provided in an aqueous solution Ru.
As the resol type phenolic resin, a phenol-alkyl resorcin co-condensate is more desirable, and in particular, a polyhydric phenol mixture obtained by dry distillation of Estonian oil shale has a long pot life and is inexpensive, and a 5-methyl resorcinol It is useful because it contains a large amount of various highly reactive alkylresorcins.
If necessary, a catalyst or a pH adjuster may be mixed with the resol-type phenolic resin, and further, a curing agent such as formaldehyde or an alkylolated triazone derivative may be added and mixed. In addition, the water-soluble resol type phenolic resin may be sulfomethylated and / or sulfimethylated for the purpose of improving the stability. The details of the sulfomethylated and / or sulfimethylated resin are described in, for example, Japanese Patent No. 339 3927 and Japanese Patent No. 3393959.

When the thermosetting resin is impregnated in the surface material 21, the thermosetting resin squeezed out of the surface material 21 at the time of heat press molding and exudes to the surface creates a plasticy texture such as gloss peculiar to the resin. This may reduce the appearance quality of the surface material 21 due to fibers. In order to suppress such a reduction in appearance quality, it is necessary to make the amount of the thermosetting resin impregnated into the surface material 21 appropriate.
The amount of impregnation of the thermosetting resin can be adjusted by setting the amount of application to the surface material 21. The coating amount in terms of solid content, preferably ^{10g / m 2 ~50g / m 2} , more preferably ^{10g / m 2 ~45g / m 2} , more preferably ^{10g / m 2 ~40g / m 2} . When the coating amount is excessively small, the thermosetting resin does not spread sufficiently on the entire surface of the surface material 21, and it becomes difficult to uniformly impregnate. When the coating amount is excessively large, the thermosetting resin easily exudes from the inside of the surface material 21 to the surface, and the appearance quality is degraded.

The amount of the thermosetting resin impregnated can also be adjusted by setting the air flow resistance of the surface material 21. This air flow resistance indicates the resistance when air passes through the surface material 21, and it is measured by an air permeability tester (product name: KES-F8-AP1, manufactured by Kato Tech Co., Ltd., steady flow differential pressure measurement method) It shall refer to the measured value.
The ventilation resistance of the surface material 21 is preferably 0.01 to 0.1 kPa · s / m, more preferably 0.015 to 0.08 kPa · s / m, from the viewpoint of suppressing deterioration in appearance quality. More preferably, it is 0.015 to 0.04 kPa · s / m. If the ventilation resistance is excessively low, the thermosetting resin will soak in more than necessary, and the appearance quality will tend to be degraded. If the ventilation resistance is too high, the thermosetting resin will not soak in easily, and the surface will be exfoliated. The material 21 can not be impregnated with the thermosetting resin uniformly.

Mass per unit area of the skin material 21 is not particularly limited, the ventilation resistance from the viewpoint of the above ^range, it is preferable to ^{10g / m 2 ~120g / m 2} , 15g / m 2 ~110g / m 2 it is more preferable ^that, it is more preferable to ^{15g / m 2 ~100g / m 2} . If the unit area mass is excessively small, the air flow resistance may be excessively lowered, and if the unit area mass is excessively large, the air flow resistance may be excessively high.
The setting of the air flow resistance in the skin material 21 is particularly useful when the foam elastic body foam is provided with a sound absorbing performance by using a foam having an open cell structure.

In the interior material 20, the skin material 21 and the interior substrate 10 are joined to each other. For this bonding, when the surface material 21 is impregnated with a thermosetting resin, the thermosetting resin can be used as an adhesive. Further, for bonding the surface material 21 and the interior base material 10, an adhesive such as a hot melt adhesive, an acrylic resin adhesive, an acrylic resin adhesive, a synthetic rubber adhesive, a synthetic rubber adhesive, etc. is used. You can also
When sound absorbing performance is provided using the foam of the open cell structure to the foamed elastic foam, powder is maintained from the viewpoint of maintaining the air permeability between the elastic layer 11 made of the foamed elastic foam and the surface material 21. It is desirable to use an adhesive in the form of dots and to disperse them in the form of dots. This powdered adhesive, from the viewpoint of ensuring air permeability, is preferably in the range of 80~500μm an average particle size by sieving method, spraying amount and ^2g / ^{m 2 ~40g} / m 2 it is preferable ^to, and more preferably to ^{5g / m 2 ~30g / m 2} .
When the interior material 20 is provided with sound absorption performance, the entire air flow resistance of the surface material 21 and the interior substrate 10 is 0.2 to 5.0 kPa from the viewpoint of making the sound absorption performance suitable. -It is preferable to set to s / m, It is more preferable to set to 0.25-4.5 kPa * s / m, It is still more preferable to set to 0.3-4.0 kPa * s / m.

  The fiber material and / or the surface material 21 may be a higher fatty acid such as stearic acid or palmitic acid, a higher alcohol such as palmityl alcohol or stearyl alcohol, or an ester of fatty acid such as butyryl stearate or glycerin monostearate. , Fatty acid amides, waxes such as carnauba wax and paraffins and paraffin oil, lubricants, fluoro resins and silicone resins, water repellent agents such as polyvinyl alcohol and grease, oil repellent agents, phosphorus compounds and nitrogen compounds and sulfur Flame retardants and flameproofing agents such as organic compounds, boron compounds, bromine compounds, guanidine compounds, phosphate compounds, phosphate compounds and amino resins, or pigments, dyes, antioxidants, antistatic agents, Crystallization accelerator, insect repellent, preservative, surface activity , Anti-aging agent, various agents may be added, or the like, such as UV absorbers.

As shown in FIG. 4, the interior material 30 has an elastic layer 11 made of a foamed elastic foam, a reinforcing layer 12 made of a fiber material, and a skin material 21 that covers the surface of the elastic layer 11. . The interior material 30 is obtained by heat-pressing the interior material 20 into a predetermined shape.
When the surface material 21 is touched on the surface of the interior material 30, the softness of the elastic layer 11 in the compressed state provides a suitable feel, and when the interior material 30 is transported, etc., it is compressed. The rigidity of the reinforcing layer 12 suppresses bending and deformation of the elastic layer 11.

At the time of heat press molding, by forming the interior material 30 to have a predetermined thickness, the reinforcing layer 12 made of a fiber material and the elastic layer 11 made of a foamed elastic foam are respectively compressed and have a predetermined thickness. Is formed.
The thickness ratio of the reinforcing layer 12 to the elastic layer 11 (reinforcing layer / elastic layer) is more than 1/100 and less than 55/100, preferably 2/100 to 50/100, more preferably 2 / 100 to 46/100.
In other words, when the thickness of the elastic layer 11 is 100, the thickness ratio of the reinforcing layer 12 is in the range of more than 1 and less than 55, preferably in the range of 2 to 50, and more preferably 2 to It is in the range of 46. That is, the thickness of the reinforcing layer 12 is more than one-hundredth of the thickness of the elastic layer 11 and less than fifty-five hundredth, preferably two-hundredths (one-fifth) or one-hundredths of fifty 1), and more preferably two hundredths (one-fifth of one hundredth) to one-hundredths of one hundred sixty.
When the thickness ratio of the reinforcing layer 12 is too small when the thickness of the elastic layer 11 is 100, the reinforcing layer 12 can not sufficiently reinforce the elastic layer 11, and the interior material is inferior in rigidity. Become. When the thickness ratio of the reinforcing layer 12 is excessively large when the thickness of the elastic layer 11 is 100, the flexibility of the elastic layer 11 is lost and the touch property is deteriorated.

The thickness of the interior material 30 is preferably 1 mm to 30 mm, more preferably 3 mm to 20 mm, and still more preferably 5 mm to 15 mm, as the thickness after heat press molding.
If the thickness of the interior material after heat-press molding is excessively small, the elastic layer 11 does not have a sufficient thickness to exhibit flexibility, and the interior material is likely to be inferior in feel. If the thickness of the interior material 30 after the heat press molding is excessively large, the reinforcing layer 12 is not compressed to a thickness sufficient to exert rigidity, and the rigidity is likely to be poor.
From the viewpoint of setting the thickness ratio between the reinforcing layer 12 and the elastic layer 11 in the above range, for example, the fiber used for the fiber material of the reinforcing layer 12 is glass wool and is used for the foamed elastic foam of the elastic layer 11 When the material is a combination of polyurethane or melamine resin, the thickness of the interior material is preferably 5 mm to 15 mm.
When the fiber used for the fiber material of the reinforcing layer 12 is a polyester fiber and the material used for the foamed elastic foam of the elastic layer 11 is a combination of polyurethane or melamine resin, the thickness of the interior material is 11 mm to 20 mm It is preferable to

  The present invention will be further described with reference to the following examples, but the present invention is not limited by these examples.

Example 1
Reinforcement layer: The fiber material of the material and performance shown in Table 1 was used.
Elastic layer: A foamed elastic foam of the material and performance shown in Table 1 was used.
Skin material: A spunbond nonwoven fabric (30 g / m ² unit area weight) made of polyester is coated / impregnated with an uncured liquid of resol-type phenolic resin so that the coating amount is 15 g / m ^2, and semi-cured What was pre-cured to the state (state B) was used.
Preparation of sample: After laminating the fiber material (reinforcement layer), the foamed elastic foam (elastic layer) and the skin material so that the fiber material and the foamed elastic foam become a combination of the materials shown in Table 2, the mold temperature The sample 1 (thickness: 5 mm) is obtained by performing heat press molding using a heat press molding machine at 180 ° C. and interposing a spacer between the upper mold and the lower mold of the mold at the time of the heat press molding. Sample 2 (thickness: 10 mm) and sample 3 (thickness: 15 mm) were produced.
50% compressive strength ratio: 50% compression of the foamed elastic foam from the 50% compressive strength A (N) of the foamed elastic foam and the 50% compressive strength B (N) of the fiber material for each of the samples 1 to 3 The ratio (= (B x 100) / A) to the 50% compressive strength of the fiber material when the strength was taken as 100 was calculated. The results are shown in Table 2.
Ratio of thickness between reinforcing layer and elastic layer: For samples 1 to 3, the thickness A (mm) of the elastic layer and the thickness B (mm) of the reinforcing layer were measured, and the thickness of the elastic layer was 100. The ratio to the thickness of the reinforcing layer (= (B x 100) / A) was calculated. The results are shown in Table 2.

Comparative Example 1 and Comparative Example 2
Reinforcement layer: The fiber material of the material and performance shown in Table 1 was used.
Elastic layer: A foamed elastic foam of the material and performance shown in Table 1 was used.
Skin material: The same one as in Example 1 was used.
Preparation of sample: After laminating the fiber material (reinforcing layer), the foamed elastic foam (elastic layer) and the skin material so that the fiber material and the foamed elastic foam become a combination shown in Table 2, Example 1 and Similarly, Sample 1 (thickness: 5 mm), Sample 2 (thickness: 10 mm), and Sample 3 (thickness: 15 mm) were produced.
50% compressive strength ratio: In the same manner as in Example 1, 50% compressive strength ratio was calculated for Samples 1 to 3. The results are shown in Table 2.
Ratio of thickness of reinforcing layer / elastic layer: In the same manner as in Example 1, the ratio of thickness was calculated for Samples 1 to 3. The results are shown in Table 2.

[Touch test]
With regard to Samples 1 to 3 of Example 1 and Samples 1 to 3 of Comparative Example 1, the touch of the elastic layer when the surface of each skin was touched with fingers was evaluated in the following five steps. The results are shown in Table 3.
◎: The elastic layer has sufficient flexibility and does not feel the hardness of the reinforcing layer even if pressed a little hard.
:: The elastic layer has sufficient flexibility, and the hardness of the reinforcing layer is felt when pressed slightly hard.
Δ: The elastic layer has flexibility, but the hardness of the elastic layer is felt when pressed a little hard.
X: When pressed a little hard, the flexibility of the elastic layer is lost, and the feel is dull and the touch is poor.
××: no effect of the reinforcing layer, very flexible and unable to maintain the formed shape.

From the results of Table 3, in Example 1, the evaluation was 又 は or 評 価, and the touch was good. According to this example 1, in the case where the 50% compressive strength ratio of the reinforcing layer (fiber material) to the elastic layer (foamed elastic foam) before compression is: reinforcing layer / elastic layer = 0.5 to 20/100, The ratio of thickness after compression is reinforcing layer / elastic layer = 2 to 50/100, and the elastic layer has a thickness larger than that of the reinforcing layer. For this reason, it was found that the hard touch due to the reinforcing layer was reduced, and a touch having elastic flexibility by the elastic layer was obtained as the touch.
On the other hand, in Comparative Example 1, the evaluation was x or Δ, and the touch was poor. According to this comparative example 1, when the 50% compression strength ratio (fiber material / foamed elastic foam) between the reinforcing layer (fiber material) and the elastic layer (foamed elastic foam) before compression is 25/100 or more, The ratio of thickness after compression (reinforcing layer / elastic layer) becomes 55/100 to 120/100, and the reinforcing layer exceeds half of the thickness of the elastic layer, and in some cases, the reinforcing layer exceeds the thickness of the elastic layer . For this reason, it turned out that the hard touch by a reinforcement layer comes to be transmitted rather than the softness | flexibility by an elastic layer, and a feeling becomes bad.
Further, in Comparative Example 2, all the evaluations were xx, and no rigidity was obtained. According to this comparative example 2, the 50% compression strength ratio (fiber material / foaming elastic foam) of the reinforcing layer (fiber material) and the elastic layer (foaming elastic foam) before compression is 0.26 / 100 or less In this case, the ratio of thickness after compression (reinforcing layer / elastic layer) becomes 0.5 / 100 to 1.0 / 100, and the thickness of the reinforcing layer becomes excessively thinner than the thickness of the elastic layer . For this reason, it has been found that the shape after molding can not be maintained by the reinforcing layer being bent or bent without being able to sufficiently reinforce the elastic layer.

  According to the present invention, there is provided an interior base material and an interior material capable of exhibiting suitable rigidity and feel when compressed by heat press molding, and while maintaining the rigidity, it is possible to provide an interior material and an interior material. Since the interior material which can aim at improvement can be provided, it is industrially applicable.

10 Interior base material 11 Elastic layer 12 Reinforcement layer 20 Interior material 21 Skin material 30 Interior material

Claims (4)

An interior substrate comprising an elastic layer comprising a foamed elastic foam and a reinforcing layer comprising a fiber material,
An interior base material characterized in that a ratio (fiber material / foamed elastic foam) of 50% compression strength of the fiber material and the foamed elastic foam is more than 0.26 / 100 and less than 25/100. .   The interior substrate according to claim 1, wherein the material used for the foamed elastic foam is melamine resin or polyurethane.   An interior material comprising the interior base material according to claim 1 or 2 and a non-woven surface covering material laminated on one side or both sides of the interior base material. A ratio (reinforcing layer / elastic layer) of a thickness of a reinforcing layer made of the fiber material and an elastic layer made of the foamed elastic foam is obtained by heating and pressing the interior material according to claim 3 into a predetermined shape. An interior material characterized by having a ratio of more than 100 and less than 55/100.

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