JP2021130228A - Face material - Google Patents

Abstract

To provide a face material made of a fabric (fiber layer) containing flame-retardant fibers and having excellent flame retardancy and moldability, in which a first fiber layer and a second fiber layer are laminated and integrated, and a problem such that moisture is absorbed thereto to easily become wet is hardly caused.SOLUTION: There is provided a face material, in which: a presence of a second fiber layer 2 containing low-hydrophilic fibers in a higher mass ratio than that of a first fiber layer 1 plays a role as a water-repellent layer and can prevent water from penetrating into the first fiber layer 1; and both the first fiber layer 1 and the second fiber layer 2 contain same fibers (low hydrophilic fiber) as a constituent fiber, the first fiber layer 1 and the second fiber layer 2 are sufficiently laminated and integrated, and therefore, the first fiber layer 1 and the second fiber layer 2 can be laminated and integrated without using a binder or by reducing an amount of the binder used.SELECTED DRAWING: Figure 2

Description

The present invention relates to a surface material.

Fabrics (for example, fiber webs, non-woven fabrics, woven fabrics, knitted fabrics, etc.) have been conventionally used as constituent members of interior materials that can be molded to prepare various interior materials.
As interior materials according to such conventional techniques, for example, Japanese Patent Application Laid-Open No. 09-70909 (Patent Document 1) includes heat-insoluble fibers such as rayon fibers (hereinafter, may be referred to as flame-retardant fibers) and flame-retardant fibers. An automobile interior material is disclosed in which a surface material composed of polyester fibers is laminated and integrated with a base sheet such as wood stock. Further, Patent Document 1 discloses that an automobile interior material having excellent flame retardancy can be realized by containing heat-insoluble fibers (particularly preferably rayon fibers) in the surface material.
As disclosed in Patent Document 1, the surface material provided with the fiber layer is excellent in moldability because it is highly flexible and easily follows a mold or the like.

Japanese Patent Application Laid-Open No. 09-70909 (Claims, 0007, 0013, 0017, 0028, etc.)

In order to provide an interior material having excellent flame retardancy and moldability, the applicant of the present application has examined an interior material having a surface material according to the above-mentioned prior art. Specifically, an interior material having a surface material made of a cloth (fiber layer) containing flame-retardant fibers was examined. Then, as a result of the examination, it was found that the interior material has a problem that it absorbs moisture and is easily wetted. In particular, this problem has become a major problem in applications such as floor interior materials where rainwater is likely to adhere.

The applicant of the present application considered that the reason why this problem occurs is that the interior material has a surface material made of a cloth (fiber layer) that easily absorbs and maintains moisture. Further, when the surface material contains highly hydrophilic flame-retardant fibers such as rayon fibers, the interior material absorbs moisture and becomes easily wet.
Therefore, there is a demand for a surface material that can provide an interior material that does not easily get wet by absorbing moisture even though it is a surface material made of a cloth (fiber layer) containing flame-retardant fibers. rice field.

The present invention is "a surface material in which the first fiber layer and the second fiber layer are laminated and integrated.
The first fiber layer contains flame-retardant fibers and low-hydrophilic fibers having lower hydrophilicity than the flame-retardant fibers as constituent fibers.
The second fiber layer contains the low hydrophilic fiber as a constituent fiber in a higher mass ratio than the first fiber layer.
Surface material. ".

In the surface material according to the present invention, the first fiber layer contains flame-retardant fibers and low-hydrophilic fibers having lower hydrophilicity than the flame-retardant fibers as constituent fibers. Therefore, since the first fiber layer contains low-hydrophilic fibers, it has a structure in which it is difficult to absorb water.
In addition, the second fiber layer has lower hydrophilic fibers than the first fiber layer, as compared with the first fiber layer, which contains flame-retardant fibers that cause the above-mentioned problems and easily absorbs moisture and becomes wet. Included in mass ratio. Therefore, the second fiber layer has a structure in which it is more difficult to absorb water. Therefore, even if rainwater or the like adheres to the second fiber layer side, for example, when the surface material is provided so that the second fiber layer side is exposed, the presence of the second fiber layer serves as a water repellent layer. It is possible to prevent water from penetrating into the first fiber layer.

Further, since both the first fiber layer and the second fiber layer contain low hydrophilic fibers as constituent fibers, the first fiber layer and the second fiber layer are sufficiently laminated and integrated. Specifically, even when the first fiber layer and the second fiber layer are adhered and laminated and integrated using a binder, both the first fiber layer and the second fiber layer are the same fibers as constituent fibers ( Since it contains (low hydrophilic fibers), the first fiber layer and the second fiber layer have similar bonding modes to the binder, and the amount of the binder used is reduced (for example, if a binder having inferior flame retardancy is used). However, the first fiber layer and the second fiber layer are laminated and integrated (with the decrease in flame retardancy minimized).

Further, even when the first fiber layer and the second fiber layer are laminated and integrated by fiber entanglement such as needle punching, both the first fiber layer and the second fiber layer are the same fibers as constituent fibers (low). Since it contains (hydrophilic fibers), fiber entanglement between the first fiber layer and the second fiber layer is efficiently performed, and the amount of binder used is reduced or without using a binder (for example, flame retardancy). Even if a binder inferior to the above is used, the first fiber layer and the second fiber layer can be laminated and integrated (with minimal reduction in flame retardancy). Therefore, it is possible to provide a surface material which is excellent in moldability and flame retardancy by preventing delamination from occurring between the first fiber layer and the second fiber layer.

From the above, although the surface material according to the present invention is a surface material made of a cloth (fiber layer) containing flame-retardant fibers and having excellent flame retardancy and moldability, it easily absorbs moisture and becomes wet. It is a surface material that can provide an interior material that is less likely to cause the problem (hereinafter, it may be abbreviated as easy to get wet).

It is a schematic cross-sectional view of the surface material which concerns on this invention. It is a schematic cross-sectional view of the interior material provided with the surface material and the base material which concerns on this invention.

In the present invention, various configurations such as the following configurations can be appropriately selected. Unless otherwise specified, the various measurements described in the present invention were carried out under atmospheric pressure. Moreover, the measurement was carried out under the temperature condition of 25 ° C. Then, unless otherwise specified, the various measurement results described in the present invention were measured to a value one digit smaller than the desired value, and the value to be obtained was calculated by rounding off the value. As a specific example, when the value up to the first minority is the value to be obtained, the value up to the second minority is calculated by measurement, and the value up to the first minority is calculated by rounding off the obtained second minority value. Then, this value was used as the desired value.
Then, the numerical range that can be adopted can be determined by arbitrarily combining each upper limit value and each lower limit value described below as desired.

The surface material according to the present invention will be described mainly with reference to FIG. 1, which is a schematic cross-sectional view of the surface material according to the present invention.
The surface material (10) of the present invention includes a first fiber layer (1) and a second fiber layer (2). The fiber layer referred to here means, for example, a layer of fibers composed of fiber webs, non-woven fabrics, woven fabrics, knitting, etc., in which fibers are entangled with each other. By including the fiber layer, it is possible to provide a surface material (10) having excellent moldability because it is highly flexible and easily follows a mold or the like. In order to provide the surface material (10) having more excellent moldability, at least one of the first fiber layer (1) and the second fiber layer (2) constituting the surface material (10) is made of fibers. It is preferable that the layer is made of a fiber web or a non-woven fabric that is randomly entwined, and it is more preferable that the surface material (10) is composed only of a layer made of a fiber web or a non-woven fabric in which fibers are randomly entangled with each other.

Further, in the surface material (10) of the present invention, the first fiber layer (1) and the second fiber layer (2) are laminated and integrated. The term "lamination integration" as used herein means that one main surface of the first fiber layer (1) and one main surface of the second fiber layer (2) are adjacent to each other and face each other.
・ A mode in which the main surfaces are bonded to each other by a binder,
A mode in which the fibers are adhered by the adhesive fibers contained in the first fiber layer (1) and / or the second fiber layer (2).
A mode in which the constituent fibers of the first fiber layer (1) and the second fiber layer (2) are entangled with each other beyond the layers of the first fiber layer (1) and the second fiber layer (2).
It means that the first fiber layer (1) and the second fiber layer (2) are not merely overlapped with each other. In addition, in FIG. 2 and FIG. 3 described later, the layer between the first fiber layer (1) and the second fiber layer (2) is illustrated by using a broken line.
The mode of laminating and integrating can be appropriately selected, but the first fiber layer (1) and the first fiber layer (1) can be provided so as to provide a surface material (10) having excellent flame retardancy because it does not contain a binder that may cause a decrease in flame retardancy. It is preferable that the constituent fibers of the second fiber layer (2) are laminated and integrated in a manner in which the constituent fibers are entangled with each other.

The first fiber layer (1) contains flame-retardant fibers. The flame-retardant fiber referred to here refers to a fiber containing a resin having no melting point (a resin that is not a thermoplastic resin) and / or a fiber containing a resin having a LOI value higher than 22.

The melting point is determined by the differential thermal analysis specified in JIS K7121: 1987, and refers to the temperature calculated from the peak of the melting temperature on the differential thermal analysis curve (DTA curve), and the melting temperature of the melting temperature. A resin having no peak and / or a resin whose melting point cannot be calculated is referred to as a "resin having no melting point". By containing a resin having no melting point on the fiber surface, even if the surface material (10) is in a high temperature atmosphere, the flame-retardant fiber has a fiber shape without melting the portion containing the resin. Can be maintained.

The LOI value is a critical oxygen index, and refers to a value obtained by the oxygen index measurement procedure specified in JIS K7201-1: 1999, JIS K7201-2: 2007, and JIS K7201-3: 2008. The higher the LOI value, the more excellent the flame retardancy of the fiber. Therefore, by containing the resin having a high LOI value, the flame-retardant fiber can maintain the fiber shape even when the surface material (10) is in a high temperature atmosphere.

Since the flame-retardant fiber has such a structure, the fiber shape can be maintained even when the surface material (10) is in a high temperature atmosphere. As a result, it is possible to provide a surface material (10) having excellent flame retardancy by containing the flame retardant fiber. It is a flame-retardant fiber composed only of a resin having no melting point and / or a difficulty composed only of a resin having a LOI value higher than 22 so that the effect can be exhibited more effectively. It is preferably a flammable fiber (more preferably, a flame-retardant fiber composed only of a resin having a LOI value of 25 or more).

Specific examples of such flame-retardant fibers include rayon fibers (consisting only of resins having no melting point, LOI value of 22 or less, usually about 17 to 19), polyclaric fibers (melting point). It is composed only of the resin having, and the LOI value is 25 or more and is usually about 26), and the amide acrylic fiber (it is composed only of the resin having a melting point and has the LOI value of 25 or more and is usually about 28 to 33. Aromatic polyamide fibers (consisting only of resins that do not have a melting point, LOI value is 25 or more and usually about 25 to 32), novoloid fibers (only resins that do not have a melting point) The LOI value is 25 or more, which is usually about 30 to 34), and the acrylic flame-resistant fiber (consisting only of a resin having no melting point, and the LOI value is 25 or more, which is usually about 30 to 34). It is about 42 to 52) and the like. Among these, from the finding that a surface material (10) having excellent flame retardancy can be realized, the first fiber layer (1) preferably contains rayon fiber, and the first fiber layer (1) contains it. It is more preferable that the flame-retardant fiber is only rayon fiber.

Further, the first fiber layer (1) contains low hydrophilic fibers having lower hydrophilicity than flame-retardant fibers. The low-hydrophilic fiber referred to here refers to a fiber having a resin having a higher water contact angle on the fiber surface than the resin constituting the fiber surface of the flame-retardant fiber. The contact angle of water is calculated by using a resin plate instead of the base glass which is a test piece in the contact angle measuring method specified in JIS R3257: 1999, and 4 μl of water droplets on the surface of the resin plate. Refers to the contact angle formed by. The contact angle of water in the resin plate A made of the resin constituting the fiber surface of the flame-retardant fiber and the resin prepared using the resin constituting the fiber surface of the fiber to be compared. Comparing with the contact angle of water on the plate B, when the contact angle of water is higher in the resin plate B than in the resin plate A, it is assumed that the fibers to be compared are low hydrophilic fibers.

When the low hydrophilic fiber has such a structure, it is possible to provide a surface material (10) that is difficult to absorb moisture and is difficult to get wet. In order to exert the effect more effectively, the fiber surface of the low hydrophilic fiber is composed only of a resin (resin having a high contact angle) capable of preparing a resin plate B having a higher water contact angle than the resin plate A. It is preferable that it is.

As a specific example of such a combination of flame-retardant fiber and low-hydrophilic fiber, when the flame-retardant fiber contained in the first fiber layer (1) is rayon fiber, polyethylene terephthalate fiber (polyethylene terephthalate fiber) is used as the low-hydrophilic fiber. It is composed only of a resin having a melting point, and an LOI value (22 or less) can be adopted.

The mass ratio of the flame-retardant fiber and the low-hydrophilic fiber contained in the first fiber layer (1) as constituent fibers can be adjusted as appropriate, and the flame-retardant fiber: low-hydrophilic fiber = 5% by mass: 95. It is preferably 70% by mass to 30% by mass, preferably 10% by mass: 90% by mass to 25% by mass: 75% by mass, and 15% by mass: 85% by mass to 20% by mass: 80. It is preferably mass%.

In the present invention, the mass ratio (unit: mass%) of the specific fiber to the constituent fibers can be calculated from the following formula.
X = 100 * B / A
X: Mass ratio of specific fibers to constituent fibers (unit: mass%)
A: Total mass of constituent fibers contained in the fiber layer (unit: g / m ² )
B: Mass of specific fiber contained in fiber layer (unit: g / m ² )
As a specific example, when the constituent fibers of the first fiber layer are only rayon fibers and polyethylene terephthalate fibers, the mass ratio (unit: mass%) of the rayon fibers to the constituent fibers of the first fiber layer is calculated by the following formula. Can be calculated from.
Y = 100 * D / C
Y: Mass ratio of rayon fibers to the constituent fibers of the first fiber layer (unit: mass%)
C: Total mass of rayon fiber and polyethylene terephthalate fiber contained in the first fiber layer (unit: g / m ² )
D: Mass of rayon fiber contained in the first fiber layer (unit: g / m ² )

The second fiber layer (2) contains low-hydrophilic fibers as constituent fibers, and contains low-hydrophilic fibers in a higher mass ratio than the first fiber layer (1). Here, "containing low-hydrophilic fibers at a higher mass ratio than that of the first fiber layer (1)" means that the mass ratio of low-hydrophilic fibers to the constituent fibers of the second fiber layer (2) is It means that it is higher than the mass ratio of the low hydrophilic fibers to the constituent fibers of the first fiber layer (1).

The first fiber layer (1) and the second fiber layer (2) constituting the surface material (10) according to the present invention can be determined by the following methods.

(Method of determining the first fiber layer (1) and the second fiber layer (2) 1)
1. 1. When each fiber layer constituting the surface material (10) can be separately collected, each fiber layer collected from the surface material (10) is subjected to the following determination method.
2. The two fiber layers with the main surfaces facing each other are dyed with a method using various analyzers such as FT-IR, element analysis and NMR, a method using an analyzer such as an electron microscope, and a dye such as kayastine. The types of fibers constituting each fiber layer and their mass ratios are obtained by using an analysis method or the like.
3. 3. The types of fibers constituting the two fiber layers are compared, and when both fibers are composed of the same resin (more preferably, the same fiber), the fiber is a low-hydrophilic fiber. Consider that there is.
4. Fibers other than the low-hydrophilic fibers contained in each fiber layer are selected, and if fibers having higher flame retardancy and higher hydrophilicity than the low-hydrophilic fibers are present, the fibers are flame-retardant. Considered to be a sex fiber.
5. Of the two fiber layers with the main surfaces facing each other, one fiber layer contains flame-retardant fibers and low hydrophilicity, the other fiber layer contains low hydrophilicity, and the other. When the fiber layer contains low hydrophilic fibers in a higher mass ratio than one fiber layer, it can be determined that the one fiber layer is the first fiber layer (1), and the other fiber layer is the second. It can be determined that it is the fiber layer (2).

(Judgment method 2 of the first fiber layer (1) and the second fiber layer (2))
1. 1. When each fiber layer constituting the surface material (10) cannot be easily separated and collected, the type of fiber constituting one main surface of the surface material (10) is determined.
2. From one main surface of the surface material (10) toward the other main surface, the fiber composition in the thickness direction is continuously confirmed, and the fiber layer portion in which the constituent fibers are the same as one main surface is formed. It is regarded as the fiber layer A and collected from the surface material (10).
3. 3. From the main surface newly formed by collecting the fiber layer A from the surface material (10), toward the other main surface, the fiber composition in the thickness direction is continuously confirmed, and newly formed. The fiber layer portion in which the main surface and the constituent fibers are the same is regarded as the fiber layer B and collected from the surface material (10). After that, the fiber layer is collected from the surface material (10) in the same manner.
4. By subjecting each of the collected fiber layers to the steps after item 2 described in (Method 1 for determining the first fiber layer (1) and the second fiber layer (2)), the first fiber layer (1) and the first fiber layer The two fiber layers (2) can be determined.

The second fiber layer (2) contains lower hydrophilic fibers in a higher mass ratio than the first fiber layer (1). Therefore, in the surface material (10) according to the present invention, the presence of the second fiber layer (2) plays a role as a water-repellent layer, and it is possible to prevent water from permeating into the first fiber layer (1). The mass ratio of the low hydrophilic fibers to the constituent fibers of the second fiber layer (2) is set to the first fiber layer (2) so that the role of the second fiber layer (2) as a water-repellent layer can be more effectively exerted. It is preferably 10% by mass or more, preferably 30% by mass or more, preferably 50% by mass or more, and 70% by mass or more higher than the mass ratio of the low hydrophilic fibers in the constituent fibers of 1). Is preferable, and it is preferable that the content is as high as 90% by mass or more. It is most preferable that the fibers constituting the second fiber layer (2) are only low-hydrophilic fibers so that the role of the second fiber layer (2) as a water-repellent layer is most effectively exerted.

The type of fiber constituting the surface material (10) according to the present invention is appropriately selected so as to satisfy the configuration according to the present invention. For example, a polyolefin resin (for example, polyethylene, polypropylene, polymethylpentene, etc.) A polyolefin resin having a structure in which a part of the hydrocarbon is replaced with a cyano group or a halogen such as fluorine or chlorine), a styrene resin, a polyvinyl alcohol resin, a polyether resin (for example, polyetheretherketone, polyacetal, modified polyphenylene). Ether, aromatic polyetherketone, etc.), polyester resins (eg, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polybutylene naphthalate, polycarbonate, polyarylate, total aromatic polyester resin, etc.), Polyamide-based resin, polyamideimide resin, polyamide-based resin (for example, aromatic polyamide resin, aromatic polyetheramide resin, nylon resin, etc.), resin having a ditryl group (for example, polyacrylonitrile), urethane-based resin, epoxy Based resin, polysulfone resin (for example, polysulfone, polyethersulfone, etc.), fluorine resin (for example, polytetrafluoroethylene, polyfluorovinylidene, etc.), cellulose resin (component of regenerated cellulose fiber such as rayon), poly Use known resins such as benzoimidazole resin, acrylic resin (for example, polyacrylonitrile resin obtained by copolymerizing acrylic acid ester or methacrylic acid ester, and mod acrylic resin obtained by copolymerizing acrylonitrile with vinyl chloride or vinylidene chloride). Can be configured.
These resins may be made of either a linear polymer or a branched polymer, the resin may be a block copolymer or a random copolymer, and the resin has a three-dimensional structure and crystallinity. However, there is no particular limitation. Further, a mixture of multi-component resins may be used.

When the surface material (10) is required to have further flame retardancy, the constituent fibers may contain a flame retardant resin. As such a flame-retardant resin, for example, a moda acrylic resin, a vinylidene resin, a polyvinyl chloride resin, a polyvinylidene fluoride resin, a novoloid resin, a polyclar resin, a polyester resin obtained by copolymerizing a phosphorus compound, and a halogen-containing monomer are copolymerized. Examples thereof include acrylic resins, aramid resins, and resins kneaded with halogen-based, phosphorus-based, or metal compound-based flame retardants. Further, it may be a fiber prepared by kneading a pigment or a dyed fiber such as a dyed fiber.

The constituent fibers are, for example, melt spinning method, dry spinning method, wet spinning method, direct spinning method (melt blow method, spun bond method, electrostatic spinning method, etc.), and by removing one or more kinds of resin components from the composite fiber. It can be obtained by a known method such as a method of extracting fibers having a small fiber diameter or a method of beating the fibers to obtain divided fibers.

The constituent fibers may be composed of one type of resin or may be composed of a plurality of types of resins. As the fiber composed of a plurality of types of resins, it can be generally referred to as a composite fiber, for example, a core-sheath type, a sea-island type, a side-by-side type, an orange type, a bimetal type, or the like.

Further, the constituent fibers may include irregular cross-section fibers in addition to substantially circular fibers and elliptical fibers. In addition, as the irregular cross-sectional fiber, a polygonal shape such as a hollow shape or a triangular shape, an alphabet character shape such as a Y shape, an amorphous shape, a multi-leaf shape, a symbolic shape such as an asterisk shape, or a plurality of these shapes It may be a fiber having a fiber cross section such as a bonded shape.

When the surface material (10) contains heat-sealing fibers as constituent fibers, it is preferable that the fibers can be heat-sealed to each other to impart strength and morphological stability to the surface material (10). Such a heat-fusing fiber may be a fully-fusing type heat-sealing fiber, or may be a partially-fusing type heat-sealing fiber having an embodiment such as the composite fiber described above. Is also good. As a component (resin) that exhibits heat-sealing properties in the heat-sealing fiber, for example, a heat-sealing fiber containing a low-melting-melt polyolefin resin or a low-melting polyester resin can be appropriately selected and used.

The surface material (10) may contain crimping fibers as constituent fibers, but the surface material (10) can maintain flame retardancy by maintaining dimensional stability even in the presence of flames or in a high temperature environment. ) Preferably does not contain crimped fibers, such as fibers in which latent crimped fibers capable of expressing crimping by heating are formed to develop crimping.

When each fiber layer constituting the surface material (10) is a fiber web or a non-woven fabric, for example, a dry method in which the fibers are entangled by providing the above-mentioned fibers to a card device, an air array device, or the like, or a sheet in which the fibers are dispersed in a solvent. Wet method in which the extracted fibers are entangled in a shape, direct spinning method (melt blow method, spunbond method, electrostatic spinning method, method of discharging a spinning stock solution and a gas flow in parallel to spin (for example, Japanese Patent Application Laid-Open No. 2009-287138). It can be prepared by spinning the fiber using the method disclosed in the publication) and collecting the fiber.

The constituent fibers of the prepared fiber web can be entangled and / or integrated to prepare a non-woven fabric. As a method of entwining and / or integrating the constituent fibers with each other, for example, a method of entwining with a needle or a water stream, or a fiber web being subjected to a heat treatment, the constituent fibers are bonded and integrated or melted by a binder or an adhesive fiber. Examples include a method of integrating.

The heat treatment method can be appropriately selected. For example, a method of heating or heating and pressurizing with a roll, a method of heating by applying to a heater such as an oven dryer, a far-infrared heater, a dry heat dryer, or a hot air dryer, and infrared rays under no pressure. A method of heating the contained resin by irradiating with the above can be used.

A binder may be used to bond the fibers constituting the first fiber layer (1) and the second fiber layer (2) to each other. The type of binder that can be used is appropriately selected, and for example, polyolefins (modified polyolefins, etc.), ethylene vinyl alcohol copolymers, ethylene-acrylate copolymers such as ethylene-ethyl acrylate copolymers, various rubbers, and derivatives thereof ( Styrene-butadiene rubber (SBR), fluororubber, urethane rubber, ethylene-propylene-diene rubber (EPDM), etc.), cellulose derivatives (carboxymethyl cellulose (CMC), hydroxyethyl cellulose, hydroxypropyl cellulose, etc.), polyvinyl alcohol (PVA), polyvinyl Butyral (PVB), polyvinylpyrrolidone (PVP), epoxy resin, polyvinylidene fluoride (PVdF), vinylidene fluoride-hexafluoropropylene copolymer (PVdF-HFP), acrylic resin (acrylic acid ester resin, acrylonitrile styrene co-weight) Combined resin, etc.), polyurethane resin, etc. can be used. When the binder contains an acrylic resin, it softens appropriately during thermoforming such as heat pressing using a mold, so that it is preferable to provide a surface material having excellent followability to the mold.

In addition to the above-mentioned resins, the binder contains additives such as flame retardants, fragrances, pigments, antibacterial agents, anti-mold materials, photocatalytic particles, emulsifiers, dispersants, surfactants, and thickeners. You may. In particular, it is preferable that the surface material (10) contains a flame retardant, so that the surface material (10) having more excellent flame retardancy can be provided. Further, it is preferable to provide a surface material (10) capable of providing an interior material in which the problem of easily absorbing moisture and getting wet is less likely to occur because the surface material (10) contains a water repellent.

When the surface material (10) contains a binder, the basis weight thereof is appropriately selected. However, since it is easier to provide the surface material (10) having a smooth main surface as the amount of the binder increases, the basis weight of the binder is 0. It is preferably 5 g / m ² or more. On the other hand, if the amount of the binder is excessively large, the surface material (10) may have poor moldability. Therefore, the basis weight of the binder ^{is preferably 30 g / m 2} or less, and 20 g / m ² or less. Is preferable.

When each fiber layer constituting the surface material (10) is a woven fabric or knitted fabric, the woven fabric or knitted fabric can be prepared by weaving or knitting the fibers prepared as described above.

In addition to the fiber web, a non-woven fabric or a cloth such as a woven fabric or a knit may be used for the above-mentioned method of entwining and / or integrating the constituent fibers with each other.

The fineness of the constituent fibers of each fiber layer constituting the surface material (10) is not particularly limited, but the fineness can be 1 to 100 dtex, 3 to 50 dtex, and 5 to 10 dtex. be able to. The "fineness" in the present invention means a value obtained by the method A specified in JIS L1015: 2010, 8.5.1 (positive amount fineness). The fiber length can be 5 to 110 mm, 10 to 80 mm, and 20 to 60 mm.

The constituent fibers may be long fibers having a continuous length, but the constituent fibers are entangled with each other beyond the layers of the first fiber layer (1) and the second fiber layer (2) so that they can be easily laminated and integrated. , The constituent fibers such as flame-retardant fibers and low-hydrophilic fibers are preferably fibers having a predetermined length.

The various configurations of each fiber layer constituting the surface material (10), such as thickness and basis weight, are not particularly limited and are appropriately adjusted. The thickness of each fiber layer can be 0.5-5 mm, 1-3 mm, 1.1-1.9 mm. The basis weight of each fiber layer can be, for example, 50 to 500 g / m ² , 80 to 300 g / m ² , and 100 to 250 g / m ² . ^{In the present invention, the thickness refers to the length in the vertical direction when a compressive load of 20 g / cm 2} is applied in the direction perpendicular to the main surface, and the grain refers to the surface having the widest area of the object to be measured (main surface). ) Is the mass per ^{1 m 2.}

The surface material (10) may be provided with a print layer on the exposed main surface and a top coat layer on the print layer. The printed layer refers to a layer of resin that exists on at least one main surface of the surface material (10) and mainly plays a role of improving the design and / or tactile sensation of the surface material (10). The printed layer may contain the above-mentioned additives in addition to the resin. The surface material (10) may have only one type of print, or may have a plurality of types of prints having different formulations such as the type of resin constituting the print and the type or presence / absence of the pigment. .. The mode of existence thereof can also be adjusted as appropriate, and can be a mode in which it exists on the entire surface of the main surface or a mode in which it partially exists to form a handle.

The top coat layer refers to a layer of resin that exists on at least one main surface of the surface material (10) and mainly plays a role of protecting the main surface of the surface material (10). The top coat layer may contain the above-mentioned additives in addition to the resin. The surface material (10) may have only one type of topcoat, or may have a plurality of types of topcoats having different formulations such as the types of resins constituting the topcoat. The mode of existence can be adjusted as appropriate, and can be a mode existing on the entire main surface or a mode existing partially.

The type of resin constituting the print and the top coat layer can be appropriately selected, and the same resin as the above-mentioned binder can be adopted. In particular, it preferably contains an acrylic resin because it softens appropriately during thermoforming such as heat pressing using a mold and can provide a surface material that follows the mold and has excellent moldability.

The thickness of the surface material (10) is appropriately selected, but can be 2.5 mm or less, 2 mm or less, and 1.4 mm or less. On the other hand, the lower limit of the thickness is adjusted as appropriate, but it is realistic that it is 0.5 mm or more. The basis weight of the surface material (10) is appropriately selected, ^{but can be 300 g / m 2} or less and 250 g / m ² or less. On the other hand, the lower limit of the basis weight but is appropriately adjusted, a practical to be 10 g / ^{m 2} or more, preferably at 50 g / ^{m 2} or more, preferably at 100 g / ^{m 2} or more.

The surface material (10) of the present invention may include yet another member such as a porous body, a film, or a foam. These members may be provided by being laminated on the main surface of the surface material (10) on the side opposite to the main surface on the second fiber layer (2) side.
Further, the surface material (10) of the present invention may be subjected to a step of pressurizing to smooth the surface, such as a reliant press treatment. Further, it may be subjected to various secondary processing steps such as heat molding after punching a shape according to an application and a mode of use.

An interior material can be provided by laminating the surface material (10) according to the present invention with the base material (3). The interior material according to the present invention will be described mainly with reference to FIG. 2, which is a schematic cross-sectional view of the interior material provided with the surface material and the base material according to the present invention.

The type of the base material (3) can be appropriately selected depending on the aspect of the interior material (100) to be provided, such as a plate-shaped CFRP, a cloth, a resin plate, a film, etc., which is a mixture of fibers such as glass fibers and carbon fibers and a resin. Can be adopted.

The thickness of the base material (3) is appropriately selected, but can be 2.5 mm or less, 2 mm or less, and 1.4 mm or less. On the other hand, the lower limit of the thickness is adjusted as appropriate, but it is realistic that it is 0.5 mm or more. The basis weight of the base material (3) is appropriately selected, ^{but can be 2000 g / m 2} or less and 1500 g / m ² or less. On the other hand, the lower limit of the basis weight is adjusted as appropriate, but it is realistic that it is ^{250 g / m 2 or more, and it is preferable that it is 500 g / m 2} or more.

The laminating mode of the surface material (10) and the base material (3) can be appropriately selected, but the mode of simply overlapping, the mode of being adhesively integrated by a binder, the surface material (10) and / or the base material (3). A mode in which the constituent components are fused and adhered and integrated, and a mode in which the constituent fibers of the surface material (10) and the base material (3) are entangled and integrated when the base material (3) is a cloth. And so on.

The stacking order of the surface material (10) and the base material (3) can be appropriately selected, but the role of the second fiber layer (2) as a water-repellent layer is more effectively exhibited, and it is easy to absorb moisture and get wet. As shown in FIG. 2, the base material (3) is laminated on the main surface of the surface material (10) on the first fiber layer (1) side so that the interior material (100) in which the problem is unlikely to occur can be provided. It is preferable that the interior material (100) is made of.

The method for preparing the surface material (10) according to the present invention can be appropriately selected, and for example,
(I) A step of preparing a first fabric containing flame-retardant fibers and low-hydrophilic fibers,
(Ii) A step of preparing a second fabric containing low hydrophilic fibers in a mass ratio higher than that of the first fabric,
(Iii) A second fabric is laminated on one main surface of the first fabric, and fiber entanglement means is applied from the exposed main surface on the second fabric side to the other main surface. A step of preparing a non-woven fabric by entwining constituent fibers between adjacent main surfaces of one fabric and a second fabric.
(Iv) A step of applying a water repellent to the prepared nonwoven fabric,
It can be a method of manufacturing the surface material (10) provided with.
In the surface material (10) prepared in this manner, the first fiber layer (1) derived from the first cloth and the second fiber layer (2) derived from the second cloth extend over the layers to form the constituent fibers. It has a structure in which it is entangled and laminated and integrated.

Step (i) and step (ii) will be described.
As the cloth, for example, a fiber web or a non-woven fabric, or a woven fabric or a knitted fabric is prepared. As the fineness, fiber length, thickness and basis weight of the constituent fibers in the fabric, those having the above-mentioned numerical values can be adopted. The second fabric is a fabric composed of only low-hydrophilic fibers as constituent fibers so that the role of the second fiber layer (2) in the surface material (10) as a water-repellent layer can be more effectively exhibited. Is preferable.

The process (iii) will be described.
The type of fiber entanglement means can be appropriately selected, but fiber entanglement means using a needle or a water stream can be adopted. In particular, since the surface material (10) having more excellent flame retardancy can be easily provided by providing the thick first fiber layer (1), it is preferable to employ the fiber entanglement means using a needle.

The process (iv) will be described.
The method of applying the water repellent to the non-woven fabric can be appropriately selected, but a method of preparing a water repellent liquid obtained by dispersing the water repellent in a dispersion medium or dissolving it in a solvent and applying the water repellent liquid to the non-woven fabric is used. Can be adopted. The method of applying the water repellent can be appropriately selected, but a well-known method such as a method of impregnating the non-woven fabric in the water repellent liquid or a method of applying the water repellent liquid to the non-woven fabric by spraying or the like can be adopted.
The solvent and dispersion medium contained in the water repellent liquid can be removed by naturally drying the non-woven fabric to which the water repellent liquid is applied or by subjecting the non-woven fabric to a heat treatment. By subjecting to heat treatment, a part or all of the binder and the adhesive fiber may be melted, and the constituent fibers may be integrated by melt bonding. It is preferable that the upper limit of the heating temperature is adjusted so that the dispersion medium or the solvent can be removed and the constituent components such as the constituent fibers and the binder of the non-woven fabric are not unintentionally denatured.

Further, a printing liquid capable of forming a print and a top coating liquid capable of forming a top coat are prepared and applied to the main surface of the surface material (10) (preferably the main surface on the second fiber layer (2) side). The surface material (10) may be prepared. As the method for applying the printing liquid or topcoat liquid and the method for removing the dispersion medium or solvent contained in the printing liquid or topcoat liquid, the same method as described above can be adopted.

Further, the surface material (10) may be provided with yet another member such as a porous body, a film, or a foam. These members may be laminated on the main surface side of the surface material (10) different from the main surface on which the print or the top coat is present. Further, the surface material (10) of the present invention may be subjected to a step of pressurizing to smooth the surface, such as a reliant press treatment.
Further, it may be subjected to various secondary processing steps such as heat molding after punching a shape according to an application and a mode of use.

Then, the interior material (100) can be prepared by laminating a separately prepared base material (3) on the surface material (10) according to the present invention. Although the laminating method can be appropriately selected, the interior material (100), which is less likely to cause the problem that the second fiber layer (2) plays a more effective role as a water-repellent layer and easily absorbs moisture and becomes wet, is used. As shown in FIG. 2, the interior material (100) is prepared by laminating the base material (3) on the main surface of the surface material (10) on the first fiber layer (1) side so as to be provided. preferable.

The method for laminating and integrating the surface material (10) and the base material (3) can be appropriately selected, but the method mentioned as being able to laminate and integrate the first fiber layer (1) and the second fiber layer (2) is used. , Can be adopted as well.

Further, the interior material (100) may include yet another member such as a porous body, a film, or a foam. These members may be laminated on the main surface side of the interior material (100) different from the main surface on which the print or the top coat is present. Further, the interior material (100) provided with the surface material (10) of the present invention may be subjected to a step of pressurizing to smooth the surface, such as a reliant press treatment.
Further, it may be subjected to various secondary processing steps such as heat molding after punching a shape according to an application and a mode of use.

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

(Preparation of fiber)
The following fibers were prepared.
Flame-retardant fiber: Rayon fiber (fineness: 1.7 dtex, fiber length: 51 mm, composed only of resin having no melting point, LOI value: 17 to 19)
Low hydrophilic fiber: Polyethylene terephthalate fiber (fineness: 2.2 dtex, fiber length: 51 mm, composed only of resin having a melting point, LOI value: 22 or less, hereinafter may be referred to as PET fiber)

(Preparation of water repellent liquid)
A water repellent solution having the following composition was prepared.
-Anionic surfactant (solid content concentration: 20% by mass): 0.5 parts by mass-Sodium carboxymethyl cellulose (solid content concentration: 100% by mass): 0.1 parts by mass-Fluorine-based water repellent (solid content concentration) : 20% by mass): 6.0 parts by mass, water: 93.4 parts by mass

(Comparative Example 1)
^{The first fiber web (weight: 98 g / m 2} ) was prepared by applying 98.0 parts by mass of rayon fiber to a card machine.
^{Then, a needle punching non-woven fabric (grain: 98 g / m 2} ) was prepared by performing a needle punching treatment from one main surface of the fiber web to the other main surface.
Next, the water repellent liquid is impregnated with a needle punched non-woven fabric, and then the dispersion medium is removed by subjecting it to a heating device to satisfy the constitution of the present invention (grain: 100 g / m ² , derived from the water repellent liquid). The solid content of the above: 2 g / m ² , thickness: 1.3 mm) was produced.

(Comparative Example 2)
^{A fiber web (weight: 98 g / m 2} ) was prepared by mixing 24.5 parts by mass of rayon fiber and 73.5 parts by mass of PET fiber and feeding them to a card machine.
^{Then, a needle punching non-woven fabric (grain: 98 g / m 2} ) was prepared by performing a needle punching treatment from one main surface of the fiber web to the other main surface.
Next, the water repellent liquid is impregnated with a needle punched non-woven fabric, and then the dispersion medium is removed by applying it to a heating device to satisfy the constitution of the present invention (grain: 100 g / m ² , derived from the water repellent liquid). The solid content of the above: 2 g / m ² , thickness: 2.1 mm) was produced.
The mass ratio of rayon fiber and PET fiber to the constituent fibers of the surface material was rayon fiber: PET fiber = 25% by mass: 75% by mass.

(Example 1)
^{A first fiber web (first cloth, grain: 49 g / m 2} ) was prepared by mixing 24.5 parts by mass of rayon fiber and 24.5 parts by mass of PET fiber and feeding them to a card machine. Further, a second fiber web (second cloth, basis weight: 49 g / m ² ) was prepared by applying 49.0 parts by mass of PET fiber to a card machine.
Then, the first fiber web and the second fiber web are laminated and needle punched from the main surface on the second fiber web side to the main surface on the first fiber web side to perform needle punching non-woven fabric. (Grade: 98 g / m ² ) was prepared.
Next, the water repellent liquid is impregnated with a needle punched non-woven fabric, and then the dispersion medium is removed by subjecting it to a heating device to satisfy the constitution of the present invention (grain: 100 g / m ² , derived from the water repellent liquid). The solid content of the above: 2 g / m ² , thickness: 2.1 mm) was produced.
In the present surface material prepared in this manner, the first fiber layer derived from the first fiber web and the second fiber layer derived from the second fiber web are entangled with each other, and the constituent fibers between the adjacent main surfaces are entangled with each other. It was a surface material that was laminated and integrated. Further, the first fiber layer constituting the surface material contained rayon fibers and PET fibers, and the second fiber layer contained rayon fibers as constituent fibers in a higher mass ratio than the first fiber layer.
The mass ratio of rayon fiber and PET fiber to the constituent fibers of the surface material was rayon fiber: PET fiber = 25.0% by mass: 75.0% by mass.

(Comparative Example 3)
^{A fiber web (weight: 98 g / m 2} ) was prepared by mixing 9.8 parts by mass of rayon fiber and 88.2 parts by mass of PET fiber and feeding them to a card machine.
^{Then, a needle punching non-woven fabric (grain: 98 g / m 2} ) was prepared by performing a needle punching treatment from one main surface of the fiber web to the other main surface.
Next, the water repellent liquid is impregnated with a needle punched non-woven fabric, and then the dispersion medium is removed by applying it to a heating device to satisfy the constitution of the present invention (grain: 100 g / m ² , derived from the water repellent liquid). The solid content of the above: 2 g / m ² , thickness: 2.1 mm) was produced.
The mass ratio of rayon fiber and PET fiber to the constituent fibers of the surface material was rayon fiber: PET fiber = 10.0% by mass: 90.0% by mass.

(Example 2)
^{A first fiber web (first cloth, grain: 49 g / m 2} ) was prepared by mixing 9.8 parts by mass of rayon fiber and 39.2 parts by mass of PET fiber and feeding them to a card machine. Further, a second fiber web (second cloth, basis weight: 49 g / m ² ) was prepared by applying 49.0 parts by mass of PET fiber to a card machine.
Then, the first fiber web and the second fiber web are laminated and needle punched from the main surface on the second fiber web side to the main surface on the first fiber web side to perform needle punching non-woven fabric. (Grade: 98 g / m ² ) was prepared.
Next, the water repellent liquid is impregnated with a needle punched non-woven fabric, and then the dispersion medium is removed by subjecting it to a heating device to satisfy the constitution of the present invention (grain: 100 g / m ² , derived from the water repellent liquid). The solid content of the above: 2 g / m ² , thickness: 2.1 mm) was produced.
In the present surface material prepared in this manner, the first fiber layer derived from the first fiber web and the second fiber layer derived from the second fiber web are entangled with each other, and the constituent fibers between the adjacent main surfaces are entangled with each other. It was a surface material that was laminated and integrated. Further, the first fiber layer constituting the surface material contained rayon fibers and PET fibers, and the second fiber layer contained rayon fibers as constituent fibers in a higher mass ratio than the first fiber layer.
The mass ratio of rayon fiber and PET fiber to the constituent fibers of the surface material was rayon fiber: PET fiber = 10.0% by mass: 90.0% by mass.

(Example 3)
^{A first fiber web (first cloth, grain: 49 g / m 2} ) was prepared by mixing 4.9 parts by mass of rayon fiber and 44.1 parts by mass of PET fiber and feeding them to a card machine. Further, a second fiber web (second cloth, basis weight: 49 g / m ² ) was prepared by applying 49.0 parts by mass of PET fiber to a card machine.
Then, the first fiber web and the second fiber web are laminated and needle punched from the main surface on the second fiber web side to the main surface on the first fiber web side to perform needle punching non-woven fabric. (Grade: 98 g / m ² ) was prepared.
Next, the water repellent liquid is impregnated with a needle punched non-woven fabric, and then the dispersion medium is removed by applying it to a heating device to satisfy the constitution of the present invention (grain: 100 g / m ² , derived from the water repellent liquid). The solid content of the above: 2 g / m ² , thickness: 2.3 mm) was produced.
In the present surface material prepared in this manner, the first fiber layer derived from the first fiber web and the second fiber layer derived from the second fiber web are entangled with each other, and the constituent fibers between the adjacent main surfaces are entangled with each other. It was a surface material that was laminated and integrated. Further, the first fiber layer constituting the surface material contained rayon fibers and PET fibers, and the second fiber layer contained rayon fibers as constituent fibers in a higher mass ratio than the first fiber layer.
The mass ratio of rayon fiber and PET fiber to the constituent fibers of the surface material was rayon fiber: PET fiber = 5.0% by mass: 95.0% by mass.

(Comparative Example 4)
^{A fiber web (weight: 98 g / m 2} ) was prepared by applying 98.0 parts by mass of PET fiber to a card machine.
^{Then, a needle punching non-woven fabric (grain: 98 g / m 2} ) was prepared by performing a needle punching treatment from one main surface of the fiber web to the other main surface.
Next, the water repellent liquid is impregnated with a needle punched non-woven fabric, and then the dispersion medium is removed by subjecting it to a heating device to satisfy the constitution of the present invention (grain: 100 g / m ² , derived from the water repellent liquid). The solid content of the above: 2 g / m ² , thickness: 2.3 mm) was produced.

The physical characteristics of each surface material produced as described above are summarized in Table 1. For configurations that do not have, "-" is shown in the table. In addition, the results of evaluation using the following measurements are described in the columns of "flame retardant performance" and "water absorption performance" in the table.

(Evaluation method of flame retardant performance)
The test piece collected from the surface material to be measured was subjected to FMVSS No. The flame retardant performance was evaluated by subjecting it to the 302 flammability test. Then, the evaluation results are described in the table based on the measurement. The test piece was placed and measured so that the main surface of the surface material on the needle punched side (which is the main surface on the second fiber layer side in the embodiment) faces the flame side. rice field.
Based on the measurement results of the surface materials prepared in Comparative Example 1, the surface materials having the same flame retardancy were evaluated as "○". In addition, a surface material whose flame retardancy is inferior to that of a surface material evaluated to have a flame retardancy of "○" was evaluated as "x".

(Evaluation method of water absorption performance)
The water absorption performance was evaluated by subjecting the test piece collected from the surface material to be measured to the JIS L1092: 2009: 7.3 rain test (shower method) A method. Then, the measured series are listed in the table. The test piece is installed so that the main surface of the surface material on the needle punched side (which is the main surface on the second fiber layer side in the embodiment) faces the water droplet generating nozzle of the test apparatus. The measurement was performed.
A surface material having a high series has abundant properties such as water repellency, which makes it difficult to absorb moisture and makes it difficult to get wet.

The surface material of the example was superior in flame retardancy to the surface material of the comparative example, and was a surface material that was difficult to absorb moisture and was difficult to get wet. In particular, from the results of comparing Comparative Example 2 and Example 1 and Comparative Example 3 and Example 2, even if the fiber composition of the surface material is the same, by satisfying the configuration of the present invention, flame retardancy is achieved. It has been found that it is possible to provide a surface material that is not only excellent but also less likely to absorb moisture and to be wetted.
The surface material prepared in the examples has a fiber layer, and both the first fiber layer and the second fiber layer contain the same fibers (low hydrophilic fibers) as constituent fibers, so that the first fiber The fiber entanglement between the layer and the second fiber layer was efficiently performed and laminated and integrated, and the surface material was excellent in moldability and flame retardancy.

Further, the surface material according to the present invention can provide an interior material which is excellent in flame retardancy and moldability and is less likely to cause a problem of easily absorbing moisture and getting wet.

The present invention can be used as a surface material for various interior materials, particularly as a surface material for interior materials for vehicles such as floor interior materials, ceilings, doorsides, pillar garnishes, and rear packages.

10 ... Surface material 1 ... First fiber layer 2 ... Second fiber layer 3 ... Base material 100 ... Interior material

Claims (1)

An epidermis material in which the first fiber layer and the second fiber layer are laminated and integrated.
The first fiber layer contains flame-retardant fibers and low-hydrophilic fibers having lower hydrophilicity than the flame-retardant fibers as constituent fibers.
The second fiber layer contains the low hydrophilic fiber as a constituent fiber in a higher mass ratio than the first fiber layer.
Epidermis material.

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