JP2022086950A - Interior material for vehicle having embossment pattern - Google Patents

Abstract

To provide an interior material for a vehicle with design which has a variation in glossiness on a slant surface and is rich in expression of a fiber cloth layer as the present invention is rich in not only design of an embossment pattern, but also in variation in combination with the embossment pattern, the fiber cloth layer differs in glossiness between the slant surface and a bottom surface of the embossment pattern provided with the slant surface before the bottom surface, and glossiness of stretched yarn is emphasized.SOLUTION: An interior material 1 for a vehicle has an embossment pattern formed on a composite sheet having a fiber cloth layer 2 and a cushion layer 3 laminated in one piece, and is characterized in that: the fiber cloth layer 2 is cloth including stretched yarn (a) and false twisted yarn (b); the cushion layer 3 is flexible urethane foam; the embossment pattern is formed with a lithographic embossment pattern 4 or an embossment roll 6 having a slant surface between a recessed part and a projection part; the glossiness varies as well as the embossment pattern; and there is a variation in glossiness on the slant surface of the embossment pattern.SELECTED DRAWING: Figure 1

Description

The present invention relates to a method for manufacturing an interior material for a vehicle in which an embossed pattern is formed on a laminated sheet material mainly used for a seat or a door, and an interior material for a vehicle in which an embossed pattern is formed.

As an interior material for a vehicle, a material in which an embossed pattern is formed on the surface of a fiber cloth is widely known. For example, in Patent Document 1, a composite sheet in which an outer material made of a fiber fabric such as a woven fabric, a knitted fabric, or a non-woven fabric and a cushion layer made of a polyurethane foam material are laminated and integrated is heated in order to form an embossed pattern deeply and clearly. A method for manufacturing a skin material for a vehicle seat, which is embossed between an embossed roll and a heat roll heated in a temperature range of 100 ° C. to 250 ° C., is described.

By the way, in recent years, in addition to the embossed pattern, a more varied design is required. That is, there is an increasing demand for providing a slope between the concave portion and the convex portion to realize a design expression rich in variation such that the expression of the fiber cloth layer on the slope and the concave portion is different.

Japanese Unexamined Patent Publication No. 2007-276285

However, when embossing is performed between the embossed roll and the heat roll in which both the embossed roll and the heat roll are heated in the range of 100 ° C. to 250 ° C. as in the conventional case, an embossed pattern is deeply and clearly formed on the surface of the fiber cloth. However, it was not possible to realize a design expression rich in variation such that the expression of the fiber cloth layer on the slope and the recess was different.

On the other hand, even if the heating temperature is changed to solve this problem, the expression of the fiber cloth layer only changes uniformly, and the expression of the fiber cloth layer on the slope and the recess is different. Could not be realized.

The present invention has been made in view of such a technical background, and is rich in variation not only in the design of the embossed pattern but also in combination with the embossed pattern. Since the glossiness of the fabric layer is different and the glossiness of the drawn yarn is emphasized, the purpose is to provide a vehicle interior material with a design that has a change in the glossiness on the slope and is rich in the expression of the fiber fabric layer. And.

In order to achieve the above object, the present invention provides the following means.

[1] An interior material for a vehicle in which an embossed pattern is formed on a composite sheet in which a fiber cloth layer and a cushion layer are laminated and integrated.
The fiber fabric layer is a woven fabric containing drawn yarn and false twisted yarn.
The cushion layer is made of soft urethane foam.
The embossed pattern is formed by a lithographic embossed type or embossed roll having a slope between the concave portion and the convex portion.
An interior material for a vehicle, characterized in that the glossiness differs from that of the embossed pattern, and the glossiness on the slope of the embossed pattern also changes.

[2] The vehicle interior material according to item 1 above, wherein the drawn yarn is a modified cross-section yarn.

[3] The vehicle interior material according to item 1 or 2 above, wherein the drawn yarn is a bright yarn.

[4] The vehicle interior material according to any one of the preceding items 1 to 3, wherein the structure of the woven fabric is selected from the group consisting of twill weave, satin weave, and plain weave.

In the invention of [1], a flat plate having a slope between a concave portion and a convex portion on a composite sheet in which a fiber fabric layer composed of a woven fabric containing a drawn yarn and an embossed yarn and a cushion layer of a soft urethane foam are laminated and integrated. Since the embossed pattern is formed by embossing with an embossed type or an embossed roll, the interior material for a vehicle has a different glossy feeling from the embossed pattern and also has a change in the glossy feeling on the slope of the embossed pattern. That is, since the glossiness of the drawn yarn is emphasized on the surface of the fiber fabric layer including the slope and the bottom surface of the embossed pattern, the interior material for a vehicle having a design rich in expression expressing various glossiness. Can be.

In the invention of [2], since the drawn yarn is a deformed cross-sectional yarn, the glossiness of the fiber fabric layer in the embossed pattern is further conspicuous, and the fiber fabric layer can be made into a design rich in expression.

In the invention of [3], since the drawn yarn is a bright yarn, the glossiness of the fiber fabric layer in the embossed pattern is remarkably outstanding, and the fiber fabric layer can be made into a design rich in expression.

In the invention of [4], since the structure of the woven fabric is selected from the group consisting of twill weave, satin weave, and plain weave, the drawn yarn and the false twisted yarn are used when the glossiness of the embossed pattern surface of the fiber fabric layer 2 is changed. It can be arranged so as to stand up, and the fiber fabric layer can be made into an expressive design.

It is a schematic sectional drawing which shows one Embodiment of the interior material for a vehicle which concerns on this invention. It is a schematic explanatory view (plan view) of the vehicle interior material shown in FIG. It is a side explanatory view which shows an example of the planographic embossing type which has the slope between the concave part and the convex part which form embossed pattern. (Including composite sheet) It is explanatory drawing of the heat press by the planographic embossing type shown in FIG. (Composite sheet is a schematic cross-sectional view) It is explanatory drawing which shows an example of the roll embossing apparatus.

Next, an embodiment of the vehicle interior material according to the present invention will be described in detail with reference to the drawings.

As shown in FIGS. 1 to 6, the vehicle interior material 1 according to the present invention is a vehicle interior material in which an embossed pattern is formed on a composite sheet in which a fiber fabric layer 2 and a cushion layer 3 are laminated and integrated. The fiber fabric layer 2 is a woven fabric containing a drawn yarn a and a false twisted yarn b, the cushion layer 3 is a soft urethane foam, and the embossed pattern is a slope between the concave portion 4-1 and the convex portion 4-2. It is shaped by a flat plate embossed type 4 or embossed roll 6 having 4-3 (the convex portion is not shown in FIG. 5), and the glossiness is different from that of the embossed pattern, and the glossiness on the slope of the embossed pattern is obtained. It is characterized by changes.

By adopting such a configuration, the recess 4-1 is formed in the composite sheet in which the fiber cloth layer 2 made of a woven fabric containing the drawn yarn a and the false twisted yarn b and the cushion layer 3 of the soft urethane foam are laminated and integrated. Since the embossed pattern is formed by shaping with a flat plate embossed type 4 or an embossed roll 6 (the convex portion is not shown in FIG. 5) having a slope 4-3 between the convex portion 4-2 and the convex portion 4-2. The interior material 1 for a vehicle has a different glossiness from the embossed pattern and a change in the glossiness on the slopes 2-3 of the embossed pattern. That is, since the glossiness of the drawn yarn a is emphasized on the surface of the fiber fabric layer 2 including the slopes 2-3 and the bottom surface 2-2 of the embossed pattern, the design is rich in expression and expresses various glossiness. It is possible to provide an interior material 1 for a vehicle having the above.

Examples of the fiber cloth layer 2 of the present invention include woven fabrics. The fibers constituting the woven fabric may contain thermoplastic resin fibers on the side having the embossed pattern, and synthetic fibers such as polyester fibers, polyamide fibers and polyacrylonitrile fibers are preferably used as the thermoplastic resin fibers. can do. That is, the fiber fabric layer 2 is not only composed of thermoplastic resin fibers, but may also contain fibers such as cotton and rayon fibers in a composite manner with mixed fibers, blended fibers, twisted yarns, etc. It may be combined as appropriate, such as using a thread made of a thermoplastic resin fiber as a part.

The drawn yarn a of the present invention is a yarn that is continuously heat-stretched using a take-up roller, a preheating roller, and a drawing roller after spinning when a fiber is produced from a thermoplastic resin. It is preferable that the cross section of the drawn yarn a is a modified cross section because the change due to the difference in glossiness is remarkable, and it is preferable that the drawn yarn a is a bright yarn for the same reason.

The false twisted yarn b of the present invention is not particularly limited, and examples thereof include 110T / 144 / 1SD (semidal) yarn, 84T / 72 / 1SD (semidal) yarn, 84T / 36 / 2SD (semidal) yarn and the like. be able to.

An embossed pattern is formed by embossing with a flat plate embossing type or embossing roll having a slope between the concave portion and the convex portion, and at the same time, the drawn yarn a becomes more glossy and conspicuous than the false twisted yarn b. Therefore, the effect can be further enhanced by the structure of the woven fabric containing the drawn yarn a and the false twisted yarn b as warp and / or weft. That is, the structure of the woven fabric of the present invention is not particularly limited, but is preferably selected from the group consisting of twill weave, satin weave, and plain weave. By selecting from these structures, the drawn yarn a can be made to be the outermost surface of the fiber fabric layer 2 while combining the drawn yarn a and the false twisted yarn b, and the area thereof can be freely adjusted and drawn. The yarn a can be used as the warp so as to be the outermost surface, or the weft may be the outermost surface. Of course, the drawn yarn a is used for both the warp and the weft, and the drawn yarn a and the false twisted yarn are used. Since the fiber fabric layer 2 including b can be arranged so as to change the glossiness of the embossed pattern surface, the fiber fabric layer 2 can be made into a more expressive design. FIG. 2 is a schematic explanatory view (plan view) of the vehicle interior material shown in FIG. 1, and is an example of a woven fabric in which the weft yarn is omitted and the drawn yarn a and the false twisted yarn b are alternately used as the warp yarn. .. Further, the glossiness and the gradation are shown by the difference in shade, and a gap is provided between the drawn yarn a and the false twisted yarn b for explanation, but such a gap may be absent or present.

The cushion layer 3 of the present invention is a soft urethane foam, and the density of the soft urethane foam is high in order to make the embossed pattern stand out, change the glossiness on the slope, and make the design rich in the expression of the fiber cloth layer 2. The range of 0.015 g / cm ³ to 0.045 g / cm ³ and the thickness of 1 mm to 10 mm are preferable.

In the present invention, the composite sheet is formed by laminating and integrating the fiber cloth layer 2 and the cushion layer 3. The method of laminating and integrating is not particularly limited, but it may be carried out by using an adhesive or by a frame laminating method. Above all, it is preferable to use the frame laminating method.

The embossed pattern of the present invention is formed by a lithographic embossing type 4 or an embossed roll 6 having a slope between the concave portion and the convex portion. That is, a lithographic embossing type 4 or embossing having a slope 4-3 between the concave portion 4-1 and the convex portion 4-2 by using a conventionally known lithographic embossing type 4 embossing device or a roll embossing device of the embossing roll 6. It is obtained by shaping using roll 6. The angle of the slope 4-3 is preferably in the range of 10 to 30 degrees. By setting this range, it becomes easier to visually recognize the change in glossiness in the embossed pattern of the fiber cloth layer 2, so that the fiber cloth layer 2 can be made into a design rich in expression.

In the present invention, in order to form an embossed pattern on the composite sheet by using the embossing device of the lithographic embossing type 4, a convex portion 4-2 is projected on the lithographic embossing type 4, and the convex portion 4-2 and the convex portion 4-2. A composite sheet is formed between the flat plate embossed mold 4 in which the slope 4-3 is formed between the concave portion 4-1 and the lower mold 5 having a flat surface facing the flat plate embossed mold 4, and the surface of the fiber fabric layer 2 is formed. May be placed toward the planographic embossing mold 4 and hot pressed. The lower mold 5 may be provided with irregularities depending on the embossed pattern to be shaped.

The number of convex portions 4-2 projecting from the planographic embossed mold 4 or the embossed roll 6 may be large, and the height of the convex portions 4-2, the distance between the convex portions 4-2, and the convex portions 4-2. The size is not particularly limited, and although it depends on the embossed pattern to be shaped, the height of the convex portion 4-2 is preferable because a range of 3 mm to 7 mm can express a slope.

The planographic embossing mold 4 and the lower mold 5 are provided with heating means. The material of the planographic embossed mold 4 and the lower mold 5 is preferably made of metal because it expresses a slope and can emphasize the glossiness of the drawn yarn.

Further, when hot-pressing, it is preferable to perform hot-pressing for 20 to 150 seconds under the condition that the temperature of the flat plate embossed mold 4 is in the range of 150 to 220 ° C. and the pressure of the hot press is 2 to 60 kg / cm ² .

In the present invention, in order to form an embossed pattern on a composite sheet by using the roll embossing device of the embossed roll 6, the embossed roll 6 provided rotatably and the embossed roll 6 rotatably provided facing the embossed roll 6 are provided. The composite sheet may be passed between the backup roll 7 and the embossed roll 6 with the surface of the fiber cloth layer 2 facing the embossed roll 6.

Although the convex portion is not shown in FIG. 5, the embossed roll 6 may have a large number of convex portions, and the height of the convex portions, the distance between the convex portions, and the size of the convex portions are particularly large. Although not limited and depends on the embossed pattern to be shaped, the height of the convex portion is preferably in the range of 3 mm to 7 mm because the slope can be expressed.

The embossed roll 6 is provided with a heating means. The material of the embossed roll 6 is preferably metal because it can express a slope and enhance the glossiness of the drawn yarn.

The backup roll 7 includes a metal roll provided with a heating means and a roll having a rubber outer periphery. The surface of the backup roll 7 is substantially smooth.

When shaping with the embossed roll 6, the pressure between the embossed roll 6 and the backup roll 7 is 2 to 25 kg / cm ² in the temperature range of the embossed roll 6 of 150 to 220 ° C., and the composite sheet is passed through. The speed is preferably in the range of 0.5 to 3 m / min.

Further, when shaping the embossed pattern, the recesses of the planographic embossing type 4 or the embossed roll 6 do not have to come into contact with the fiber fabric layer 2, or may come into contact with them and heat-press. In the case of hot pressing in contact with each other, the non-pressing surface 2-1 portion of FIG. 1 becomes a pressing surface, and the glossiness can be further changed.

Next, specific examples of the present invention will be described, but the present invention is not limited to these examples. The evaluation results are shown in Table 2.

110T / 144 false twisted yarn, 33T / 12 SD (semi-dull) yarn, and 44T / 18 side-by-side elastic yarn are combined to improve followability, and 190T / 174/1 processed yarn is prepared. It was set to 1. Further, two drawn yarns of 84T / 144 deformed bright (deformed BR) and the above-mentioned 44T / 18 side-by-side elastic yarns were combined to prepare 210T / 306 drawn yarns, which were used as warp yarns 2. As the weft, a 167T / 48/1 SD (semi-dull) false twisted yarn is used as the weft 1, and a 330T / 72/2 SD (semi-dull) false twisted yarn is used as the weft 2, and the warp 1 is 14 by a known weaving machine. A raw machine was obtained by weaving a book and a warp 2 alternately with 6 threads each and a weft 1 and a weft 2 in a weft weft in which a large amount of warp appears on the surface of the fabric. The obtained raw machine was dyed with a disperse dye by a liquid flow dyeing machine and then dried at a temperature of 120 ° C. Next, an acrylic resin emulsion was applied to the back surface, dried at a temperature of 150 ° C., and cured to obtain a fabric having a warp density of 214 lines / inch and a weft density of 96 lines / inch. A soft urethane foam (specific gravity 20 g / m ³ ) having a thickness of 10 mm was laminated and integrated on the back surface of the fabric thus obtained by a frame laminating method to obtain a composite sheet. An interior material for a vehicle was obtained by heat-pressing the obtained composite sheet at a temperature of 180 ° C. for 60 seconds using a lithographic embossing type having a slope (20 degrees) between the concave portion and the convex portion of the embossed pattern. The vehicle interior materials thus obtained passed the evaluation results of glossiness and gradation of "5". That is, there was a change in the glossiness on the slope, and the fiber fabric layer had a richly expressive design.

<Examples 2 to 6, Comparative Examples 1 to 3>
Table 1 shows each example and each comparative example.

<Evaluation method>
Regarding the "glossiness" and "gradation (change in glossiness)" of the fiber fabric layer of the interior material for vehicles with an embossed pattern, place it on the desk with the embossed pattern facing up and diagonally 45 degrees from directly above the embossed pattern. It was visually observed from the direction of Comparative Example 1 in comparison with Comparative Example 1, and evaluated according to the following criteria. Judgment was "3" or higher as a pass.
"Glossiness"
"5": A considerably stronger glossiness is recognized as compared with the false twisted yarn.
"4": A strong difference in gloss is observed as compared with the false twisted yarn.
"3": A clear difference in gloss is observed as compared with the false twisted yarn.
"2": A slight difference in gloss is observed as compared with the false twisted yarn, but it is hardly noticeable.
"1": No glossiness is observed.
"Gradation (change in gloss)"
"5": Gradation is recognized quite strongly from the bottom surface to the slope.
"4": Gradation is strongly recognized.
"3": Gradation is clearly recognized.
"2": Gradation is recognized but hardly noticeable.
"1": No gradation is recognized.

As is clear from the evaluation results in Table 2, the vehicle interior materials of the present invention of Examples 1 to 6 have excellent glossiness and gradation, and have a richly expressive design expressing various glossiness. Had had.

On the other hand, in Comparative Example 1, no glossiness or gradation was observed, and in Comparative Examples 2 and 3, it was hard to say that the design had a uniform glossiness and was rich in expression.

The interior material for a vehicle according to the present invention has a design rich in expression of the fiber cloth layer, and is therefore suitable as a skin material or an interior material for a seat of a vehicle such as an automobile, a bus, or a train.

1 ... Vehicle interior material 2 ... Fiber fabric layer 2-1 ... Non-pressing surface 2-2 ... Bottom surface 2-3 ... Slope 3 ... Cushion layer 4 ... Flat plate embossing Mold 4-1 ... Concave 4-2 ... Convex 4-3 ... Slope 5 ... Lower mold 6 ... Embossed roll 7 ... Backup roll a ... Stretched yarn b ...・ False twisted yarn

Claims (4)

An interior material for vehicles in which an embossed pattern is formed on a composite sheet in which a fiber cloth layer and a cushion layer are laminated and integrated.
The fiber fabric layer is a woven fabric containing drawn yarn and false twisted yarn.
The cushion layer is made of soft urethane foam.
The embossed pattern is formed by a lithographic embossed type or embossed roll having a slope between the concave portion and the convex portion.
An interior material for a vehicle, characterized in that the glossiness differs from that of the embossed pattern, and the glossiness on the slope of the embossed pattern also changes. The vehicle interior material according to claim 1, wherein the drawn yarn is a modified cross-section yarn. The vehicle interior material according to claim 1 or 2, wherein the drawn yarn is a bright yarn. The vehicle interior material according to any one of claims 1 to 3, wherein the structure of the woven fabric is selected from the group consisting of twill weave, satin weave, and plain weave.

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