JP2021098340A - Skin material and method for producing the same, and interior material - Google Patents

Abstract

To provide a skin material and a method for producing the same, and an interior material.SOLUTION: A skin material 100 includes a skin layer 11 and a filler layer 12 provided on one surface side of the skin layer. Activated carbon 12a is contained in the filler layer. When the total amount of the activated carbon is 100 mass%, a content ratio of the activated carbon with a particle diameter of 100-300 μm is 90 mass% or more. A method for producing a skin material includes a latex coating step of coating synthetic resin latex containing activated carbon to one surface side of the skin layer, and a filler layer formation step of removing a medium contained in the coated synthetic resin latex, and forming the filler layer. A plus sieve with an opening of 100 μm and a minus sieve with an opening of 300 μm are used as the activated carbon. The skin material can be used as an interior material, and can be also used as an interior material having a skin material and a backing material laminated on the filler layer.SELECTED DRAWING: Figure 1

Description

The present invention relates to a skin material, a method for producing the same, and an interior material. More specifically, the present invention relates to a skin material having deodorant properties, a method for producing a skin material having a specific step, and an interior material using the skin material as a skin layer.

In recent years, due to the improvement of the airtightness in the interior of vehicles such as automobiles and buildings, it tends to be difficult to obtain the deodorizing effect by exchanging the outside air and the inside air, and it is necessary to deodorize the odor indoors. There is. In order to cope with such deodorization, conventionally, a toughing carpet in which a deodorizing action and an antibacterial action are imparted to a sealing layer is known (see, for example, Patent Document 1). Further, there is known an epidermis material having a sealing layer containing activated carbon impregnated with an adsorbent for adsorbing an odor (see, for example, Patent Document 2).

Japanese Unexamined Patent Publication No. 2008-20802 Japanese Unexamined Patent Publication No. 2011-98188

However, the tufting carpet described in Patent Document 1 may not have a sufficient deodorizing effect. For example, under a situation where the environmental temperature changes, a carboxylic acid-based substance such as acetic acid adsorbed at room temperature may be re-released at a high temperature, particularly at a temperature of 60 ° C. or higher. Such a problem becomes a particular problem in an environment such as an automobile in which the indoor temperature changes drastically. Further, in the skin material described in Patent Document 2, a stable and sufficient deodorizing action is maintained, but there is a concern that fine particles of activated carbon may seep into the surface layer of the sealing layer and the design property may be deteriorated. To.
The present invention has been made in view of the above-mentioned conventional technique, and an object of the present invention is to provide a skin material in which an excellent deodorant action and designability are maintained.

The present invention is as follows.
1. 1. An epidermis material including an epidermis layer and a sealing layer provided on one surface side of the epidermis layer.
Activated carbon is contained in the sealing layer,
An epidermis material characterized in that the content ratio of activated carbon having a particle size of 100 to 300 μm is 90% by mass or more when the total amount of the activated carbon is 100% by mass.
2. The activated carbon is impregnated with an amine compound. The skin material described in.
3. 3. The sealing layer is a synthetic resin layer having a continuous foam structure. Or 2. The skin material described in.
4. The epidermis layer is made of a tufted cloth, and the basis weight of the base cloth constituting the tufted cloth is 80 to 150 g / m ² . To 3. The skin material according to any one of the above.
5. The skin layer is made of a non-woven fabric, and the basis weight of the non-woven fabric is 100 to 1000 g / m ² . To 3. The skin material according to any one of the above.
6. The above 1. To 5. The method for producing an epidermis material according to any one of the above.
A latex coating step of applying a synthetic resin latex containing activated carbon to the one side of the epidermis layer,
A sealing layer forming step of removing the medium contained in the applied synthetic resin latex to form the sealing layer is provided.
A method for producing an epidermis material, which comprises using as the activated carbon on a sieve having an opening of 100 μm and under a sieve having an opening of 300 μm.
7. 6. Using activated carbon obtained by washing the upper and lower sieves with water. The method for producing an epidermis material described in 1.
8. The synthetic resin latex is a mixture of a synthetic resin and a medium and is foamed. Or 7. The method for producing an epidermis material described in 1.
9. The above 1. To 5. An interior material comprising the skin material according to any one of the above items.
10. 9. The skin material and the backing material laminated on the sealing layer are provided. Interior materials listed in.

According to the skin material of the present invention, since the sealing layer contains a predetermined amount of activated carbon in a specific particle size range, an excellent deodorizing action is maintained and a deterioration in design is sufficiently suppressed.
Further, when the activated carbon is impregnated with an amine compound, the desorption of the adsorbed odor is sufficiently suppressed even when the atmospheric temperature rises, and an excellent deodorizing action is maintained.
Further, when the sealing layer is a synthetic resin layer having a continuous foam structure, the odor easily penetrates into the sealing layer and is adsorbed by a large amount of activated carbon, so that the deodorizing action is improved.
Further, the skin layer is made of tufted fabric, if the basis weight of the base fabric constituting the tuft cloth is 80 to 150 g / ^{m 2,} and the skin layer comprises a nonwoven fabric, the basis weight of the nonwoven fabric is 100 to 1000 g / ^{m 2} In this case, the activated carbon is easily retained in the sealing layer, the seepage of the activated carbon into the surface layer of the sealing layer is suppressed, and the deposition of the activated carbon in the sealing layer is also prevented.
According to the method for producing a skin material of the present invention, an excellent deodorizing action is maintained because the activated carbon is provided on a sieve having a mesh size of 100 μm and a sieve having a mesh size of 300 μm is used as the activated carbon. At the same time, it is possible to easily produce a skin material in which deterioration of design is sufficiently suppressed.
When activated carbon that has been washed with water on and under the sieve is used, the extremely fine activated carbon that adheres to the sieve and is not under the sieve is removed, and the fine particles of the activated carbon are immersed in the surface layer of the sealing layer. The squeeze is surely prevented and the design is not deteriorated.
Further, when the synthetic resin latex is a mixture of the synthetic resin and the medium and is foamed, it can be used as a sealing layer having a continuous foam structure, and activated carbon can be easily penetrated into the sealing layer. Can be made to.
According to the interior material of the present invention, a sufficient deodorizing action is maintained, and a comfortable interior atmosphere without odor can be obtained, particularly when used as an interior material for the interior of a vehicle, a building, or the like.
Further, when the interior material includes a skin material and a backing material laminated on the sealing layer, the strength of the interior material can be improved, and depending on the material of the backing material, there is no water permeability or At least, it can be an interior material having suppressed water permeability.

It is a schematic cross-sectional view of an example of the skin material of this invention whose skin layer is made of a tuft cloth. It is a schematic cross-sectional view of the epidermis material in which the backing material is laminated on the sealing layer of the epidermis material of FIG. It is a schematic cross-sectional view of another example of the skin material of this invention whose skin layer is made of a non-woven fabric.

Hereinafter, the present invention will be described in detail with reference to the drawings.
The matters shown here are exemplary and are intended to illustrate embodiments of the present invention. It is described for the purpose of providing what seems to be the most effective and effortlessly understandable explanation of the principles and conceptual features of the present invention. In this regard, it is not intended to provide structural details of the invention beyond what is necessary for a fundamental understanding of the invention, and some embodiments of the invention are practiced by the following description. It is intended to clarify to those skilled in the art how it is embodied.

[1] Skin Material The skin material 100 of the present invention is a skin material including a skin layer 11 and a sealing layer 12 provided on one surface side of the skin layer 11, and activated carbon 12a is contained in the sealing layer 12. It is contained, and when the total amount of the activated carbon 12a is 100% by mass, the content ratio of the activated carbon having a particle size of 100 to 300 μm is 90% by mass or more.

(1) Epidermis layer The epidermis layer 11 is a layer constituting the epidermis portion of the epidermis material 100, and is usually a fiber layer whose surface can be raised. The structure of the skin layer 11 is not particularly limited, and for example, a tufted cloth (see reference numeral 11 in FIGS. 1 and 2), a non-woven fabric (see reference numeral 11 in FIG. 3), a woven fabric, a knitted fabric, or the like can be used.

As shown in FIG. 1, the tufted cloth is a cloth in which a pile yarn 112 is tufted on a base cloth 111. Further, the cloth may be a cloth in which another layer is laminated on the base cloth 111 and the pile yarn 112 is tufted on the laminated body. Examples of the other layer include a sound absorbing layer, a heat insulating layer, a cushion layer, and the like, and only one layer may be used or two or more layers may be used in combination. Further, the base cloth 111 and the other layers can be bonded and laminated by using an appropriate adhesive depending on the material of each layer.

The base cloth 111 constituting the tuft cloth is not particularly limited, and various non-woven fabrics, woven cloths and the like can be used, but non-woven fabrics are preferable. Further, as the non-woven fabric, a non-woven fabric produced by a spunbond method, a melt blow method, or the like in which the non-woven fabric is directly produced from the spinning process is particularly preferable. Further, the material of the base cloth 111 is not particularly limited, and examples thereof include polyester, polyamide, and polyolefin, and polyester is preferable. That is, as the base cloth 111, a polyester non-woven fabric manufactured by a spunbond method, a melt blow method, or the like is preferable. When the base cloth 111 is a non-woven fabric produced by the spunbond method, its basis weight is not particularly limited, but is 50 to 150 g / m ² , particularly 80 to 150 g / m ² , and further 80 to 120 g / m ² . Is preferable.

On the other hand, as the pile yarn 112, a loop pile having a loop-shaped tip, a cut pile having a cut tip (see FIGS. 1 and 2) and the like can be used. Only one of these may be used, or two or more thereof may be used in combination. Further, it is preferable that the tip portion of the pile yarn 112 on the sealing layer 12 side protrudes in a U shape toward the sealing layer 12 side as shown in FIGS. 1 and 2. As a result, the sealing layer 112 can sufficiently prevent the pile yarn 112 from falling off. Further, the material of the pile yarn 112 is not particularly limited, and examples thereof include polyamide, polyester, and polyolefin, and polyamide is preferable.

When a non-woven fabric is used as the skin layer 11 (see FIG. 3), the non-woven fabric is not particularly limited, and may be a non-woven fabric manufactured by the above-mentioned spunbond method, melt blow method, or the like. It may be a non-woven fabric manufactured by the above. Further, by needle punching the manufactured non-woven fabric, it is also possible to use a non-woven fabric in which brushed fabric such as velor tone is formed. Further, the material of the non-woven fabric is not particularly limited, and examples thereof include polyester, polyamide, and polyolefin, and polyester is preferable.

As the non-woven fabric, a non-woven fabric made of polyester and brushed by a needle punch is preferable. It is also possible to use a twin needle punched non-woven fabric or the like in which two non-woven fabrics are laminated and needle punched. When the base cloth 111 is a non-woven fabric, the fineness of the fibers constituting the non-woven fabric is not particularly limited, but is preferably 2.2 to 17 dtex, particularly 6.6 to 11 dtex.

When a non-woven fabric is used as the skin layer 11, other layers may be laminated on the non-woven fabric. Examples of the other layer include a sound absorbing layer, a heat insulating layer, a cushion layer, and the like, and only one layer may be used or two or more layers may be used in combination. Further, the skin layer 11 and the other layers can be adhered and laminated by using an appropriate adhesive depending on the material of each layer.

The sound absorbing layer, which is another layer laminated on the non-woven fabric used as the base cloth 111 of the tuft cloth and the skin layer 11, is not particularly limited as long as it has sound absorbing properties. As the sound absorbing layer, for example, a non-woven fabric made of polyester that has been subjected to needle punching treatment can be used. In this case, in order to exhibit particularly excellent sound absorption characteristics, the fineness of the fibers used in the non-woven fabric is preferably 2.2 to 17 dtex, particularly preferably 6.6 to 11 dtex.

Further, as an adhesive layer for adhering these layers, which is interposed between the respective layers, a layer composed of only an adhesive, a layer in which an adhesive is applied to a breathable film, and a heat-sealing layer (layers by heating). A layer made of a thermoplastic resin or the like that melts in the above). Only one type of these layers may be used, or two or more types may be used in combination.

(2) Sealing layer The sealing layer 12 is a layer that seals the fibers constituting the epidermis layer 11 and also contains activated carbon 12a. The sealing layer 12 may be capable of sealing fibers and may contain activated carbon 12a, and its composition is not particularly limited, but has a function of sealing fibers and fixing the contained activated carbon 12a. It suffices to have, and usually, various synthetic resins are the main components.

Further, the sealing layer 12 containing a synthetic resin as a main component preferably has an appropriate air permeability so that the odor penetrates into the sealing layer 12, is adsorbed by the activated carbon, and is efficiently deodorized. This breathability may be imparted in any way, but can be imparted, for example, by foaming a synthetic resin and appropriately forming a continuous foam structure. As a result, the sealing layer 12 can be formed so that the odor can be efficiently brought into contact with the activated carbon while having a sufficient sealing function for the fibers constituting the skin layer 11.

(3) Activated carbon The sealing layer 12 contains activated carbon 12a. The raw material of the activated carbon 12a is not particularly limited, and various raw materials can be used. Examples of the raw material include coconut shell, sawdust, coal, charcoal, resin and the like, and activated carbon 12a activated by a known method using these raw materials can be used. As the activated carbon 12a, the activated carbon 12a using a coconut shell as a raw material is preferable from the viewpoint of having a large specific surface area and a large amount of fine pores having a diameter of 2 nm or less.

Further, the form of the activated carbon 12a is granular, and when the total amount of the activated carbon 12a is 100% by mass, the content ratio of the activated carbon 12a having a particle size of 100 to 300 μm is 90% by mass or more. When the activated carbon 12a having a particle size of 100 to 300 μm is used, the entire surface thereof is not covered with the synthetic resin constituting the sealing layer 12, and the activated carbon 12a is sufficiently suppressed from falling off from the sealing layer 12. Further, when the sealing layer 12 is formed, the activated carbon 12a is prevented from settling in the lower layer region of the sealing layer 12, and the activated carbon 12a is prevented from being unevenly distributed on one side in the formed sealing layer 12.

The particle size of the activated carbon 12a is more preferably 100 to 250 μm, particularly 120 to 230 μm, and the content ratio of the activated carbon 12a having a particle size of 100 to 250 μm is 90% by mass or more, particularly 95% by mass or more, and further 98% by mass or more. Is particularly preferable. With the activated carbon 12a having such a particle size and a content ratio, it is more surely prevented that the entire surface is covered with the synthetic resin, and the activated carbon falls off from the sealing layer 12 and the activated carbon in the sealing layer 12. Uneven distribution of 12a is also more reliably prevented.

(4) Adsorbent for amine compounds, etc. By containing activated carbon 12a in the sealing layer 12, normal odors are adsorbed and deodorized, but volatile organic compounds (VOCs), especially aldehydes, are adsorbed. , It is preferable to impregnate the activated carbon 12a with an amine compound in order to remove it from the atmosphere. As the amine-based compound, various compounds having a low boiling point, which are easily desorbed by a temperature rise after impregnation and which do not evaporate can be used. In particular, the interior of the vehicle may have a considerably high temperature of, for example, about 60 ° C. depending on the season, weather, region, etc., and an amine compound that is stably adsorbed and fixed to the activated carbon 12a is preferable.

Examples of amine compounds include chloramine, methanolamine, ethanolamine, diethylamine, isopropylamine, butylamine, proline, hydroxyproline, dicyanodiamide, ethyleneimine, ethylenediamine, propylenediamine, diethylenetriamine, 2-diethylaminoethanol and 2-dimethylamino. Examples thereof include ethanol, 1,2-diaminopropane and 1,3-diaminopropane.

In addition, triethylenetetramine, tetraethylenepentamine, iminobispropylamine, tetramethylenediamine, guanidine carbonate, glycine, alanine, sarcosine, glutamate, hexamethylenediamine, melamine, morpholin, 2-amino-4,5-dicyanoimidazole, 4-Amino-1,2,4-Triazole, 3-azahexane-1,6-diamine, hexamethylenediamine, 2-acrylamide-2-methylpropanesulfonic acid, α-amino-ε-caprolactam, acetoguanamine, guanine, Examples thereof include acetaldehyde ammonia, 4,7-diazadecan-1,10-diamine, pyrrolidine, piperidine, piperidine, polyethyleneimine, polyallylamine, polyvinylamine and the like.

In addition, aminobenzoate, thiourea, methylurea, ethylurea, dimethylurea, diethylurea, ethyleneurea, acetylurea, guanylurea, guanylthiourea, azodicarboxylicamide, glycolylurea, acetylurea, formamide, acetamide, benzamide. , Oxamide, pyrrolidone, pyrrolidone carboxylic acid, oxamic acid, succinate amide, dicyandiamide, oxazolidone, malonamide, succinimide, phthalimide, maleimide, succinateimide, hydrantine, barbituric acid, 1-methylol-5,5-dimethylhydranthin, isocyanul. Examples include acid and aniline.
As the amine compound, a primary amine having an amino group is preferable. Further, only one type of amine compound may be used, or two or more types may be used in combination.

The mass ratio of the amine compound attached to the activated carbon 12a is not particularly limited, but when the total of the activated carbon 12a and the amine compound is 100% by mass, the amine compound is 1 to 50% by mass, particularly 5 to 20. It is preferably mass%, more preferably 5 to 10 mass%. Further, examples of the substance adsorbed by the attached amine-based compound include aldehyde-based compounds such as acetaldehyde, formaldehyde, and propionaldehyde. Hydrocarbon-based substances such as toluene, xylene, and ethylbenzene are also adsorbed due to the adsorption performance originally possessed by the activated carbon 12a.

In addition to the amine compound, the activated carbon 12a can be impregnated with a compound for adsorbing a specific odorous component. Examples of such a compound include an alkali metal carbonate for adsorbing a carboxylic acid-based substance which is an odor component. The activated carbon 12a originally has a property of adsorbing a carboxylic acid-based substance, but by impregnating it with an alkali metal carbonate, it is possible to suppress the re-release of the carboxylic acid-based substance at a high temperature. Examples of the alkali metal carbonate include lithium carbonate, sodium carbonate, potassium carbonate, lithium hydrogen carbonate, sodium hydrogen carbonate and potassium hydrogen carbonate, and potassium carbonate and potassium hydrogen carbonate are preferable, and potassium carbonate is more preferable.

The mass ratio of the alkali metal carbonate attached to the activated carbon 12a is not particularly limited, but when the total of the activated carbon 12a and the alkali metal carbonate is 100% by mass, the alkali metal carbonate is 10 to 25 mass. It is preferably%. If the mass ratio of the carbonate of the alkali metal is less than 10% by mass, the re-release of the carboxylic acid-based substance at high temperature may not be suppressed, and if it exceeds 25% by mass, other than the carboxylic acid-based substance. The ability to adsorb odors may decrease. Further, the mass ratio of the carbonate of the alkali metal is more preferably 10 to 20% by mass. If the mass ratio is within this range, it is possible to improve the ability to adsorb other odors while suppressing the re-release of the carboxylic acid-based substance.

Further, the activated carbon 12a can be impregnated with other compounds as long as the ability of the amine compound and the carbonate of the alkali metal to adsorb the odor is not impaired. Examples of other compounds include halides of alkali metals and other salts excluding carbonates of alkali metals. Examples of the halogen constituting the halide include bromine and iodine, and examples of the other salt other than the carbonate include hydroxide and the like. Only one of these compounds may be used, or two or more of these compounds may be used in combination.

Further, the activated carbon 12a can be impregnated with a compound for adsorbing a basic gas. Such compounds are not particularly limited, and examples thereof include acidic substances. Examples of this acidic substance include a water-soluble acid component (a component such as phosphoric acid and sulfuric acid that dissolves in water and exhibits acidity). Only one of these components may be used, or two or more of these components may be used in combination. Examples of the basic gas adsorbed include ammonia, trimethylamine and pyridine.

[2] Method for producing skin material The method for producing skin material of the present invention includes a latex coating step of applying a synthetic resin latex containing activated carbon 12a on one surface side of the skin layer 11, and a method of coating the coated synthetic resin latex. It is characterized by comprising a sealing layer forming step of removing the medium to be formed and forming a sealing layer 12, and using the activated carbon 12a on a sieve having an opening of 100 μm and under a sieve having an opening of 300 μm. To do.

In the latex application step, a synthetic resin latex containing activated carbon 12a is applied to one surface side of the skin layer 11. The synthetic resin latex is not particularly limited, but various synthetic resins and activated carbon 12a can be prepared by dissolving or dispersing them in a dispersion medium. The synthetic resin is not particularly limited, and examples thereof include a polyolefin resin such as an acrylic resin, a urethane resin, a polyvinyl chloride resin, polyethylene, polypropylene, and an ethylene-vinyl acetate copolymer. As the synthetic resin, an acrylic resin, particularly a water-soluble acrylic resin is preferable. Only one kind of these synthetic resins may be used, or two or more kinds thereof may be used in combination.

As the dispersion medium, water and an organic solvent such as alcohols such as methanol and ethanol can be used, but water is preferable from the viewpoint of the environment when the dispersion medium is removed from the latex. Further, when the dispersion medium is water, many synthetic resins are not dissolved and are dispersed. For example, if it is a water-soluble acrylic resin, it is dissolved and the activated carbon 12a is uniformly dispersed in a more homogeneous latex. can do. Further, in the latex, the pH can be adjusted in order to disperse the synthetic resin more uniformly as needed, and a sedimentation inhibitor for suppressing the sedimentation of activated carbon can be blended.

Further, the method of applying latex is not particularly limited, and various methods such as roll coater, bar coater, spray coating and dipping can be applied. Although not particularly limited coating amount in terms only by solids of the latex, 5 to 200 g / ^{m 2,} it is particularly preferably 50 to 100 g / ^{m 2.}

In the sealing layer forming step, the synthetic resin latex containing activated carbon 12a applied to one surface side of the skin layer 11 is heated as necessary to remove the dispersion medium, and the sealing layer 12 is formed. Further, as the activated carbon 12a, a sieve having a mesh size of 100 μm and a sieve having a mesh size of 300 μm is used. Further, as the activated carbon 12a, it is preferable to use it by washing the sieve with a mesh opening of 100 μm and under the sieve having a mesh opening of 300 μm with water. By using such activated carbon 12a, the entire surface is not covered with the synthetic resin, the falling off from the sealing layer 12 and the uneven distribution in the sealing layer 12 are suppressed, and extremely fine activated carbon is also removed. Therefore, the exudation of fine particles of the activated carbon 12a onto the surface layer of the sealing layer 12 is prevented, and the deterioration of the design is also prevented.

Further, as described above, the sealing layer 12 is preferably breathable, and it is preferable that the latex is kneaded and foamed at the time of preparing the synthetic resin latex. By kneading and foaming at the time of preparing the latex, the sealing layer 12 formed becomes porous, and not only a single foam but also a continuous foam structure is formed, and the sealing layer 12 has air permeability. As a result, the odor easily penetrates into the sealing layer 12, and the activated carbon 12a is sufficiently contacted with the contained activated carbon 12a, so that the activated carbon 12a functions more effectively and the skin material 100 has excellent deodorizing performance. Can be done.

The blending ratio of the synthetic resin and the activated carbon 12a in the synthetic resin latex is not particularly limited, but when the total of the synthetic resin and the activated carbon 12a is 100% by mass, the activated carbon 12a is 20 to 70% by mass, particularly 30 to 30 to 70. It is preferably 60% by mass, more preferably 30 to 50% by mass. If the activated carbon 12a has such a blending ratio, the activated carbon 12a can be sufficiently fixed in the sealing layer 12 while reducing the ratio of the surface of the activated carbon 12a being covered with the synthetic resin, and the activated carbon 12a can be sufficiently fixed. Can function effectively.

As described above, the sealing layer 12 is preferably formed by using a latex containing a synthetic resin and activated carbon 12a. The dispersed state of the synthetic resin and the activated carbon 12a in the latex may be maintained by the pH. In such a case, the dispersed state of the latex can be better maintained by using the activated carbon 12a having less fluctuation in pH. it can. From this point of view, the pH when only the activated carbon 12a is dispersed in the dispersion medium is preferably 6 to 9. When such activated carbon 12a is used, the pH of the latex can be easily maintained at 6 to 9, and the dispersed state of the synthetic resin and activated carbon 12a can be maintained better, which is preferable.

Further, if the pH of the latex fluctuates due to the blending of activated carbon 12a, the pH can be adjusted. As the pH adjustment, when adjusting to the acidic side, citric acid, phosphoric acid, sulfuric acid, hydrochloric acid and the like can be blended and adjusted. On the other hand, when adjusting to the basic side, sodium hydroxide, magnesium hydroxide, potassium hydroxide, ammonia and the like can be used.

Further, in order to improve the dispersibility of the synthetic resin and the activated carbon 12a in latex, a surfactant may be added. As the surfactant, any of anionic, cationic, nonionic and amphoteric surfactants can be used. Only one of these may be used, or two or more thereof may be used in combination. Further, the latex may be blended with a thickener in order to adjust its viscosity, or may be blended with a sedimentation inhibitor for suppressing the sedimentation of the activated carbon 12a.

[3] Interior Material The interior material of the present invention includes the skin material 100 of the present invention. The interior material may consist of only the skin material 100, or may include other constituent layers such as a backing material laminated on the sealing layer 12. Further, the interior material may be in the form of being laminated on a substrate made of a resin molded body or the like.

The backing layer 13 (see FIG. 2) made of a backing material is laminated on the sealing layer 12 and functions as a sound insulation layer that insulates noise and the like from the back surface side of the interior material 100, improving the shape retention of the interior material 100. You can also let it. Further, the backing layer 13 may be composed of only one layer or may be composed of a plurality of layers. The backing layer 13 having multiple layers using a plurality of backing materials may be composed of any number of layers, but is usually 2 to 5 layers, and often 2 to 3 layers. When it is composed of a plurality of layers, each layer can be a backing layer 13 having different functions such as soundproofing and waterproofing.

The material of the backing material is not particularly limited, and examples thereof include synthetic resin, elastomer, and synthetic rubber. Thereby, the skin material 100 having excellent sound insulation, water insulation and the like can be obtained. The synthetic resin is preferably a thermoplastic resin, and examples of the thermoplastic resin include a polyolefin resin and a polyvinyl chloride resin. Only one of these may be used, or two or more thereof may be used in combination. Further, as the thermoplastic resin, a polyolefin resin is preferable, polyethylene is more preferable, and low density polyethylene is particularly preferable. Low-density polyethylene has sufficient strength, flexibility, and workability, and has excellent sound insulation, water insulation, and the like.

Examples of the elastomer include olefin-based thermoplastic elastomers, styrene-based thermoplastic elastomers, urethane-based thermoplastic elastomers, polyester-based thermoplastic elastomers, and polyamide-based thermoplastic elastomers. Only one of these may be used, or two or more thereof may be used in combination. Further, examples of the synthetic rubber include polybutadiene rubber, styrene-butadiene rubber, acrylonitrile-butadiene rubber, ethylene-propylene rubber, ethylene-propylene-diene rubber, isoprene rubber and chloroprene rubber. Only one of these may be used, or two or more thereof may be used in combination.

The backing material may be breathable, but is preferably not breathable. As a result, not only excellent sound insulation but also water insulation can be further improved, and a rust preventive action can be exhibited. When the backing layer 13 is composed of a plurality of layers, it is preferable that at least one layer is made of a backing material having no air permeability.

Examples of the interior material include vehicle interior materials, building interior materials, and the like. Examples of vehicle interior materials include floor mats, floor carpets, luggage mats, and the like. Further, in a building, an interior material such as a door, a wall, and a ceiling using the skin material 100 as a skin layer can be mentioned.

Hereinafter, the present invention will be described in detail with reference to Examples.
[1] Activated carbon (1) Preparation of activated carbon in a predetermined particle size range As the activated carbon, activated carbon obtained by activating crushed coconut shells with steam is sieved by a sieve having a mesh size of 100 μm, and then sieved. It was sieved by a sieve having a mesh size of 300 μm, and the under-sieving was used. When the particle size of the activated carbon sieved in this manner was measured by the above-mentioned method, the content ratio of the particle size of 100 to 300 μm was 95% by mass when the total amount of the activated carbon was 100% by mass. This activated carbon was used in Example 1.

(2) Activated carbon impregnated with an amine compound 4-Amino-1,2,4-triazole as an amine compound is added to the activated carbon in the predetermined particle size range of (1) above, and the total of the activated carbon and the amine compound is added. In Example 2, the impregnated activated carbon impregnated at a ratio of 7.4 mass% when 100 mass% was used was used.

(3) Activated carbon having a low content ratio in a predetermined particle size range The activated carbon obtained in the same manner was used except that it was crushed under strong conditions to be finer than in (1) above. Further, when the particle size range of the activated carbon was measured in the same manner as in (1) above, when the total amount of the activated carbon was 100% by mass, the content ratio of the particle size of 100 to 300 μm was 85% by mass. This activated carbon was used in Comparative Example 1.

[2] Production of skin material (1) Preparation of latex Each of the activated carbons (1), (2) and (3) above and the acrylic resin are added to water and mixed to have a solid content concentration of 50% by mass. , PH 8.5 latex was prepared. When the total of the activated carbon and the acrylic resin contained in this latex was 100% by mass, the activated carbon was 40% by mass and the acrylic resin was 60% by mass.

(2) the production basis weight 100 g / m ² of needle punching base fabric surface comprising brushed the nonwoven of the skin material of deodorant performance evaluation, the skin layer formed by tufting a pile yarn in basis weight 450 g / m ² The latex prepared in (1) above was kneaded on the back surface, and the foamed latex was coated with a ^{roll coater at a solid content equivalent of 60 g / m 2.} Then, it was dried at a temperature of 170 ° C. for 5 minutes to form a sealing layer, and a skin material having a sealing layer formed on the back surface side of the skin layer was produced. Further, polyethylene is extruded from a T-die attached to an extrusion molding machine, pressure-bonded to a sealing layer, then heated at 180 ° C. for 2 minutes, cooled, and a non-breathable backing ^{having a texture of 350 g / m 2.} A layer was formed.

[3] Evaluation of deodorant performance (1) Measurement of reduction amount of odorous gas after 24 hours The three types of skin materials manufactured in [2] and (2) above have dimensions of 210 x 297 mm (A4 size). It was cut into test pieces. After that, each test piece and 250 liters of pure air were put into a gas bag (GL Science Co., Ltd.) having a volume of 300 liters, and then the seven types of odorous gases (acetoaldehyde, toluene, xylene, ethylbenzene, etc.) shown in Table 1 were charged. (Stylene, benzene and tetradecane) (temperature 25 ° C.) (xylene is o-xylene, m-xylene, p-xylene) 1000 μg / m ³ (250 μg / gas bag, but xylene only isomers total 750 μg / gas bag) ) Infused. Then, the concentration of the odorous gas 24 hours after the injection is based on the JASO-M902 method, and the gas in the gas bag is sampled for aldehydes in a DNPH cartridge and hydrocarbons in a Tenax tube, and a high performance liquid chromatograph. And measured using a gas chromatograph mass spectrometer. The results are also shown in Table 1.

The formula for calculating the amount of odor gas reduction is as follows.
Amount of odor gas reduction = Blank concentration-Concentration in gas bag after 24 hours Blank concentration; Odor gas 250 μg (750 μg of xylene only) + Odor gas in gas bag after 24 hours when a skin material containing no activated carbon is used concentration

According to Table 1, it can be seen that in the skin materials of Examples 1 and 2, the amount of adsorption (reduction amount) of each of the odorous gases is large, and an excellent deodorizing action is exhibited. In particular, in Example 2 using impregnated activated carbon, the adsorption performance of acetaldehyde was higher than that in Example 1 using unimpregnated activated carbon, supporting the extremely excellent deodorizing action of the amine compound on a specific odorous gas. There is. On the other hand, in Comparative Example 1 in which the content ratio of the activated carbon having a particle size of 100 to 300 μm is lower than the lower limit of the present invention, the adsorption amount of any odorous gas is considerably lower and inferior to that of Examples 1 and 2. I understand.

It should be noted that the above description is for the purpose of explanation only and is not construed as limiting the present invention. Although the present invention has been described with reference to typical embodiments, the wording used in the description of the invention is understood to be descriptive and exemplary rather than limiting wording. As described in detail here, modifications can be made within the scope of the appended claims without departing from the scope or spirit of the invention in that form. Although specific structures, materials and embodiments have been referred to herein in detail of the invention, it is not intended to limit the invention to the disclosures herein, rather the invention is claimed in the accompanying claims. It shall cover all functionally equivalent structures, methods and uses within the scope.

The skin material of the present invention can be suitably used as a skin material for various interior materials and equipment in the interior of automobiles, railroad vehicles, ships, aircraft, etc., indoors of buildings, and the like. Among these, as automobile applications, for example, it can be used in a wide range of applications such as floor mats. Further, as a building application, it can be used as an indoor mat, an indoor carpet, a skin material for a chair, or the like.

100; skin material, 11; skin layer, 111; base cloth, 112; bile yarn, 12; sealing layer, 12a; activated carbon, 13; backing layer.

Claims (10)

An epidermis material including an epidermis layer and a sealing layer provided on one surface side of the epidermis layer.
Activated carbon is contained in the sealing layer,
An epidermis material characterized in that the content ratio of activated carbon having a particle size of 100 to 300 μm is 90% by mass or more when the total amount of the activated carbon is 100% by mass. The skin material according to claim 1, wherein an amine compound is impregnated with the activated carbon. The skin material according to claim 1 or 2, wherein the sealing layer is a synthetic resin layer having a continuous foam structure. The skin material according to any one of claims 1 to 3, wherein the skin layer is made of a tuft cloth, and the basis weight of the base cloth constituting the tuft cloth is 80 to 150 g / m ^2. The skin material according to any one of claims 1 to 3, wherein the skin layer is made of a non-woven fabric, and the weight of the non-woven fabric is 100 to 1000 g / m ^2. The method for producing an epidermis material according to any one of claims 1 to 5.
A latex coating step of applying a synthetic resin latex containing activated carbon to the one side of the epidermis layer,
A sealing layer forming step of removing the medium contained in the applied synthetic resin latex to form the sealing layer is provided.
A method for producing an epidermis material, which comprises using as the activated carbon on a sieve having an opening of 100 μm and under a sieve having an opening of 300 μm. The method for producing an epidermis material according to claim 6, wherein activated carbon obtained by washing the upper and lower sieves with water is used. The method for producing an epidermis material according to claim 6 or 7, wherein the synthetic resin latex is a mixture of a synthetic resin and a medium and foamed. An interior material comprising the skin material according to any one of claims 1 to 5. The interior material according to claim 9, further comprising the skin material and a backing material laminated on the sealing layer.

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