JP2023058148A - Skin material for interior - Google Patents

Abstract

To provide a skin material for interior having a nonwoven fabric as the base material, and capable of suppressing penetration of a foamable resin.SOLUTION: A skin material 101 for interior forms a floor carpet for car interior by including a resin foam layer F at a rear side by filling the rear side with a foamable resin in the inside of a molding die, and heating the product to foam the foamable resin. The skin material 101 for interior has a skin substrate 10 having as the base material, a needle punch nonwoven fabric 5 which is obtained by needle-punch processing a web formed of a synthetic resin fiber 1 of a thickness of 0.5-20 dtex, and having a basis weight of 100-300 g/m2, and a synthetic resin porous layer 60 provided at a lower side of the skin substrate 10 and having an application quantity of 20-100 g/m2 at a non-volatile component conversion. With this, the skin material 101 for interior can suppress penetration of the foamable resin even without using an oil repellent agent when the foamable resin is applied.SELECTED DRAWING: Figure 1

Description

TECHNICAL FIELD The present invention relates to an interior covering material having a nonwoven fabric as a base material.

2. Description of the Related Art Conventionally, there has been known a floor carpet that uses a non-woven fabric as an interior covering material and has a foamed resin layer on the back side (for example, Patent Documents 1 and 2).

JP-A-2000-177056 JP-A-2004-027466

The floor carpet, which has a foamed resin layer on the back side of the interior skin material, heats the non-woven fabric as the interior skin material and the foamable resin filled on the back side in a mold to melt the foamable resin. Formed by foaming. However, the upholstery material for interior is required to have air permeability in order to ensure sound absorption. For this reason, when conventional interior skin materials are heated after being filled with foaming resin in the mold, the foaming resin may permeate the non-woven fabric and reach the surface side. I had a problem.

The problem to be solved by the technique of the present specification was achieved in view of the above-mentioned points, and provides an interior covering material having a nonwoven fabric as a base material, which can suppress the permeation of foamable resin. for the purpose.

The interior skin material according to the embodiment of the present specification is a needle-punched web formed from synthetic resin fibers having a thickness of 0.5 to 20 dtex and having a basis weight of 100 to 300 g/m ^{2 .} A skin base material having a nonwoven fabric as a base material,
a synthetic resin porous layer having a coating amount of 20 to 100 g/m ² in terms of non-volatile matter provided on the underside of the skin base material;
characterized by having

According to the interior skin material according to the embodiment of the present specification, a web formed of synthetic resin fibers having a thickness of 0.5 to 20 dtex and having a basis weight of 100 to 300 g/m ² is needle-punched. A skin base material having a needle-punched nonwoven fabric as a base material and a synthetic resin porous layer having a non-volatile content of 20 to 100 g/m ² on the lower side are formed. As a result, since the porous layer of the synthetic resin is formed so as to fill the gaps between the nonwoven fabrics, the upholstery material for interior according to the embodiment is heated after the back side thereof is filled with the foamable resin in the mold. In this case, the permeation of the foamable resin can be suppressed.

Here, in the interior skin material, the synthetic resin porous layer may be impregnated in the skin base material.

According to this, since the synthetic resin porous layer is impregnated in the skin base material, when the foaming resin is filled on the back side of the skin base material in the mold and then heated, the interior skin The material can suppress the permeation of the foamable resin.

Further, in the interior covering material, the synthetic resin porous layer may be formed in the shape of foam rubber.

According to this, since a foam rubber-like synthetic resin porous layer is formed on the lower side of the skin base material, the back side of the skin base material is filled with a foamable resin in the mold and then heated. In this case, the interior skin material can suppress the permeation of the expandable resin.

In the interior skin material, the skin base material is provided with a permeation-preventing nonwoven fabric below the needle-punched nonwoven fabric, and the needle-punched nonwoven fabric and the permeation-preventing nonwoven fabric are needle-punched. can be done.

According to this, the permeation-preventing nonwoven fabric can suppress permeation of the foamable resin filled in the back side of the skin base material.

Moreover, in the above interior covering material, the permeation-preventing nonwoven fabric may be a spunbond nonwoven fabric, a meltblown nonwoven fabric, or a wet-laid nonwoven fabric.

According to this, the interior skin material can suitably suppress the permeation of the expandable resin.

Further, in the interior covering material, the synthetic resin forming the synthetic resin porous layer may be an acrylic resin.

According to this, the interior covering material can be made excellent in durability.

Further, in the above interior covering material, thermally expandable capsules may be mixed in the synthetic resin porous layer.

According to this, it is possible to suppress the ventilation amount of the interior covering material.

Here, the interior skin material according to the embodiment is an interior skin material in which an upper layer skin base material and a lower layer skin base material are needle-punched,
The upper skin base material is a nonwoven fabric formed by needle-punching a web formed of synthetic resin fibers having a thickness of 0.5 to 20 dtex and having a basis weight of 50 to 200 g/m ² ,
The lower layer skin base material is formed of synthetic resin fibers having a thickness of 0.5 to 20 dtex, and has a basis weight of 50 to 200 g/m ² . The web is needle-punched nonwoven fabric. .

According to this, the interior skin material according to the embodiment is formed of synthetic resin fibers with a thickness of 0.5 to 20 dtex, and a web having a basis weight of 50 to 200 g/m ² is needle-punched as an upper layer. A skin base material and a lower skin base material obtained by needle-punching a web formed of synthetic resin fibers having a thickness of 0.5 to 20 dtex and having a basis weight of 50 to 200 g/m ² are needle-punched. It is a thing. Since the two-layer needle-punched nonwoven fabric is needle-punched, the interior skin material according to the embodiment is filled with the foamable resin by the two-layer needle-punched nonwoven fabric and then heated. permeation can be suppressed.

Further, in the interior skin material, an intermediate film layer may be interposed between the upper skin base material and the lower skin base material.

According to this, the intermediate film layer can suppress permeation of the foamable resin.

According to the interior skin material of the embodiment, it is possible to suppress permeation of the foamable resin when heating after filling the back side of the foamable resin in the molding die.

It is an image sectional view of the skin material for interiors of 1st Embodiment. It is an image sectional view of the skin material for interiors of 2nd Embodiment. It is an enlarged photograph of the back surface of the skin material for interiors of Example 3 (1st Embodiment). It is an enlarged photograph of the back surface of the skin material for interiors of Example 4 (1st Embodiment). 4 is a graph of normal incident sound absorption coefficients of floor carpets using the interior covering materials of Examples 3 and 4. FIG.

(First embodiment)
Hereinafter, the interior skin material 101 according to the first embodiment of the present specification will be described based on the drawings. In addition, the scope of the present invention is not limited to the scope disclosed in the embodiments. The interior skin material 101 according to the first embodiment is heated in the mold together with the expandable resin filled on the back side thereof, and the expandable resin is expanded to form a foamed resin layer F on the back side. to form a floor carpet for automotive interior materials. As shown in FIG. 1, the interior skin material 101 according to the first embodiment is provided on the skin base material 10 whose base material is a needle-punched needle-punched nonwoven fabric 5, and on the underside of the skin base material 10. It also has a synthetic resin porous layer 60 with a coating amount of 20 to 100 g/m ² in terms of non-volatile matter. As a result, the interior skin material 101 according to the first embodiment, even without using an oil-repellent agent, has a foaming property when the foaming resin is filled on the back side thereof and then heated in the mold. Permeation of resin can be suppressed.

The needle-punched nonwoven fabric 5, which is the base material of the skin base material 10, is obtained by needle-punching a web made of synthetic resin fibers 1. As shown in FIG. The synthetic resin fiber 1 is a synthetic resin fiber 1 composed of a single resin structure, and a core-sheath type synthetic resin fiber that is a composite fiber having a core-sheath structure of a high-melting-point resin in the core and a low-melting-point resin in the sheath. 1 can be used. In addition, these synthetic resin fibers 1 can also be used in combination of multiple types.

As the all-melting type synthetic resin fiber 1 composed of a single resin structure, in the embodiment, polyester fiber, polyolefin fiber (PE (polyethylene), PP (polypropylene), etc.), PA (polyamide) fiber, acrylic resin fiber, polyvinyl Alcohol fibers and the like can be used. In another embodiment, polyester fiber having excellent strength and water resistance can be used as the all-melting type synthetic resin fiber 1. In still another embodiment, PET (polyethylene terephthalate) fiber of polyester fiber is used. be able to.

As the core-sheath type synthetic resin fiber 1 made of the core-sheath composite fiber, in the embodiment, the expressions of core/sheath include PET/low melting point PET, PET/PE, PET/PP, PET/PA, PP/PE, PA/PA or the like can be used. In another embodiment, the core-sheath type synthetic resin fiber 1 may be made of PET/low melting point PET, PET/PE, or PET/PP, which have excellent strength. PET can be used.

In the embodiment, the thickness of the synthetic resin fiber 1 can be 0.5 to 20 dtex in terms of fineness (dtex), which is the weight of 10,000 m of fiber. The needle-punched nonwoven fabric 5 formed from the synthetic resin fiber 1 can be easily formed, and the interior skin material 101 is formed, and the back side thereof is filled with the foamable resin in the mold and then heated. This is because the interior skin material 101 can suppress the permeation of the foamable resin when it is used. If the fineness of the synthetic resin fiber 1 is less than 0.5 dtex, the production efficiency may deteriorate due to the thinness. On the other hand, when the fineness of the synthetic resin fiber 1 exceeds 20 dtex, the interior skin material 101 is formed, filled with an expandable resin, and then heated. There is a possibility that the permeation of the resin cannot be suppressed. As another embodiment, the synthetic resin fiber 1 can have a fineness of 1 to 10 dtex, and as a further embodiment, the synthetic resin fiber 1 can have a fineness of 2 to 5 dtex.

The length of the synthetic resin fiber 1 can be 20-100 mm in the embodiment. This is because the needle-punched nonwoven fabric 5 can be easily formed. If the length of the synthetic resin fiber 1 is less than 20 mm, it may not be possible to form the needle-punched nonwoven fabric 5 because it is too short. On the other hand, if the length of the synthetic resin fiber 1 exceeds 100 mm, it may be difficult to form the needle-punched nonwoven fabric 5 due to the long length. In another embodiment, the length of the synthetic resin fiber 1 can be 25-90 mm, and in another embodiment 30-80 mm.

The basis weight of the web (the basis weight of the needle-punched nonwoven fabric 5) can be 100 to 300 g/m ² in the embodiment. The interior skin material 101 is formed from the needle-punched nonwoven fabric 5, and when the back side of the interior skin material 101 is filled with the foamable resin in the molding die and then heated, the interior skin material 101 suppresses the permeation of the foamable resin. because it can When the basis weight of the needle-punched nonwoven fabric 5 is less than 100 g/m ² , the interior skin material 101 is formed from the needle-punched nonwoven fabric 5, filled with an expandable resin, and then heated. The material 101 may not be able to suppress permeation of the foamable resin. On the other hand, when the basis weight of the needle-punched nonwoven fabric 5 exceeds 300 g/m ² , although the permeation of the expandable resin can be suppressed, the amount becomes excessive and may be uneconomical. As another embodiment, the basis weight of the needle-punched nonwoven fabric 5 can be 180-290 g/m ² , and as still another embodiment, 220-280 g/m ² .

The skin base material 10 used for the interior skin material 101 of the embodiment includes the permeation-preventing nonwoven fabric 20 below the needle-punched nonwoven fabric 5, and the needle-punched nonwoven fabric 5 and the permeation-preventing nonwoven fabric 20 are needle-punched. can be This is because the permeation-preventing nonwoven fabric 20 can further suppress permeation of the foamable resin into the interior skin material 101 when the back side of the foamable resin is filled in the molding die and then heated. . Non-woven fabrics such as spunbond non-woven fabrics, melt-blown non-woven fabrics, or wet-laid non-woven fabrics can be used as the permeation-preventing non-woven fabric 20 . As another embodiment, the permeation-preventing nonwoven fabric 20 can be a spunbond nonwoven fabric.

The interior skin material 101 of the embodiment includes a synthetic resin porous layer 60 on the lower side of the skin base material 10 . The synthetic resin porous layer 60 is formed from a synthetic resin emulsion, and depending on the coating method, either an impregnation layer 61 or a foam rubber layer 62 is formed. The impregnated layer 61 is impregnated as the synthetic resin porous layer 60 in which the interior skin material 101 is impregnated or semi-impregnated with the synthetic resin emulsion by applying the synthetic resin emulsion to the back surface of the skin base material 10 using a doctor knife. A layer 61 is formed. The foam rubber layer 62 is formed as the synthetic resin porous layer 60 by applying a foamed synthetic resin emulsion to the back surface of the skin base material 10 . The synthetic resin porous layer 60 is formed by either the impregnated layer 61 or the foam rubber layer 62. When the foam rubber layer 62 is formed, the synthetic resin emulsion is partially impregnated into the skin base material 10. It has layers.

The amount of the synthetic resin emulsion that forms the synthetic resin porous layer 60 can be 20 to 100 g/m ² in terms of non-volatile matter for either the impregnation layer 61 or the foam rubber layer 62 . This is because it is possible to suppress the permeation of the foamable resin, and to impart appropriate rigidity to the interior skin material 101 . If the applied amount of the synthetic resin emulsion (hereinafter, the applied amount is calculated as the non-volatile content) is less than 20 g/m ² , there is a possibility that the permeation of the foaming resin may not be suppressed. There is a possibility that appropriate rigidity cannot be imparted to the skin material 101 . On the other hand, if the coating amount of the synthetic resin emulsion exceeds 100 g/m ² , the amount may be excessive and uneconomical. In another embodiment, the coating weight of the synthetic resin emulsion can be from 30 to 80 g/m ² , and in still another embodiment from 40 to 60 g/m ² .

As the composition of the synthetic resin emulsion, acrylic resins, vinyl acetate resins, vinyl versatate resins, ethylene vinyl acetate copolymer resins, styrene butadiene resins, and the like can be used. As another embodiment, an acrylic resin emulsion having excellent weather resistance can be used.

An acrylic resin emulsion is, in other words, a copolymer emulsion containing a modified acrylic acid ester. (Meth)acrylic acid, di(meth)acrylic acid, 2-hydroxyethyl (meth)acrylate, methoxypolyethylene glycol (meth)acrylate, (meth)acrylic acid 2-aminoethyl, (meth)acrylamide, N-methylol (meth)acrylamide, N-(2-hydroxyethyl) (meth)acrylamide, (meth)acrylonitrile, and mixtures thereof and mixtures thereof with styrene can be used. As the resin to be modified, urethane modification, silicone modification, vinyl chloride modification, or the like can be used. Of course, non-modified acrylate copolymer emulsions can also be used. As another embodiment, an acrylic resin emulsion containing acrylonitrile as a structural unit to be a copolymer of acrylic acid ester can be used. As yet another embodiment, an acrylic resin emulsion containing acrylonitrile and styrene can be used as structural units that form an acrylic acid ester copolymer. For example, an acrylonitrile/styrene/acrylic acid ester copolymer emulsion can be used. , acrylonitrile-acrylate copolymer emulsions can be used.

The acrylic resin (modified acrylic acid ester copolymer) constituting the acrylic resin emulsion can have a glass transition temperature (Tg) of 0 to 50°C. This is because the interior skin material 101 can be imparted with appropriate rigidity. When the Tg of the acrylic resin is less than 0° C., the resin is soft, and there is a possibility that the interior skin material 101 cannot be imparted with appropriate rigidity. On the other hand, when the Tg of the acrylic resin exceeds 50° C., the film formation temperature (≈Tg) is high, and there is a possibility that the film formation of the acrylic resin becomes difficult. In another embodiment, the glass transition temperature (Tg) of the resin can be between 5 and 30°C, and in still another embodiment between 10 and 20°C.

The Tg of the acrylic resin can be adjusted by adjusting the type and amount of the monomers (structural units that form copolymers of acrylic acid esters) to be used. Tg can be obtained from the FOX calculation formula (formula (1) below). Wi indicates the mass fraction of the monomer i, Tgi indicates the Tg (° C.) of the monomer i, and the Tg of the monomer is a value such as those described in Polymer Handbook (John Willey & Sons). Known values can be used.

1/(273+Tg)=Σ(Wi/(273+Tgi)) (1)

For the acrylic resin emulsion, an aqueous solution containing a surfactant etc. is placed in a reactor where the polymerization reaction proceeds, and a pre-emulsified emulsion (monomer component, milk surfactant and water previously emulsified) and a polymerization initiator are added dropwise over about 2 hours to obtain a synthetic resin emulsion in which the monomer component is polymerized. By preparing two or more types of pre-emulsified emulsions and dropping them in order, an emulsion having a core-shell structure can be obtained.

Thermally expandable capsules 70 can be mixed in the synthetic resin porous layer 60 (impregnated layer 61, foam rubber layer 62). By mixing the heat-expandable capsules 70 into the synthetic resin porous layer 60, the interior skin material 101 has an air permeability (fabric test method for woven and knitted fabrics (JIS L 1096:2010) 8.26 air permeability A method (Fragile method) )) can be suppressed, and when the back side of the foaming resin is filled in the molding die and then heated, the penetration of the foaming resin into the interior skin material 101 can be suppressed. , the upholstery covering material 101 can be imparted with appropriate rigidity. The thermally expandable capsule 70 has a particle size of 10 to 50 μm before expansion, and expands to a particle size of 30 to 200 μm when heated. As another embodiment, the thermally expandable capsule 70 can have a particle size of 15 to 40 μm before expansion, and can be expanded to a particle size of 50 to 180 μm by heating.

As the thermally expandable capsule 70, a commercial product can be used as an embodiment. A cell (manufactured by Nippon Ferrite Co., Ltd.) or the like can be used.

Next, a method for manufacturing the interior skin material 101 according to the first embodiment of the present specification will be described. The manufacturing method of the interior skin material 101 according to the first embodiment includes a carding step of unraveling the synthetic resin fibers 1 used for the needle-punched nonwoven fabric 5 to form a web (fibrous sheet). a needle punching step of forming a needle-punched nonwoven fabric 5 by entangling and bonding fibers to each other in the formed web with minute projections of needles; A lamination step of forming the base material 10, a smoothing treatment step of smoothing the skin base material 10 using a heated roller, and a synthetic resin emulsion in which the heat-expandable capsules 70 are mixed in the skin base material 10. and a coating step of forming the synthetic resin porous layer 60 by coating. Note that the bonding process and the smoothing process are processes that are included as necessary and can be omitted.

In the carding process, the synthetic resin fibers 1, which are the raw materials of the needle-punched nonwoven fabric 5, are mixed at a specific ratio, and the mixed fibers are loosened and arranged into a sheet-like mass by a carding machine to form a web.

In the needle punching process, the web formed in the carding process is pressed with needles (countless needles on one side of a flat plate at approximately right angles) many times at high speed. The needle-punched nonwoven fabric 5 was formed by entangling and bonding them together. In embodiments, only one side of the web was needle punched.

In the laminating step, the skin base material 10 was formed by laminating the needle-punched nonwoven fabric 5 and the permeation-preventing nonwoven fabric 20 by needle punching. In the embodiment, needle punching was performed from the upper side (needle-punched nonwoven fabric 5 side). In addition, in an embodiment in which the permeation-preventing nonwoven fabric 20 is not provided, the bonding step is omitted, and the needle-punched nonwoven fabric 5 itself becomes the skin base material 10 .

In the smoothing process, a heated roller was pressed against the upper side of the skin base material 10 to heat and smooth the upper side of the skin base material 10 . At this time, the set temperature of the roller is adjusted to a temperature at which the synthetic resin fibers 1 forming the skin base material 10 (needle-punched nonwoven fabric 5) are softened and the synthetic resin fibers 1 are fused together. When the synthetic resin fiber 1 is PET/low melting point PET, the set temperature of the roller is 190 to 200.degree. Note that the smoothing process is a process that is incorporated as necessary and can be omitted.

In the coating step, a synthetic resin emulsion mixed with thermally expandable capsules 70 was coated on the back surface (lower side) of the skin base material 10 and dried by heating to form the synthetic resin porous layer 60 . There are two types of coating methods: a method in which the impregnation layer 61 is formed by applying a synthetic resin emulsion to the back surface of the skin base material 10 using a doctor knife; and a method in which the foam rubber layer 62 is formed by coating the back surface. In the coating step, either the method for forming the impregnation layer 61 or the method for forming the foam rubber layer 62 is performed. Note that the thermally expandable capsule 70 is blended as necessary, and can be omitted depending on the embodiment. Also, the thermally expandable capsule 70 is thermally expanded by heating and drying after applying the synthetic resin emulsion.

The interior skin material 101 manufactured in this manner is formed from synthetic resin fibers 1 having a thickness of 0.5 to 20 dtex, and has a needle-punched nonwoven fabric 5 having a basis weight of 100 to 300 g/m ² as a base material. It is composed of a skin substrate 10 and a synthetic resin porous layer 60 having a coating amount of 20 to 100 g/m ² in terms of non-volatile matter, which is formed on the lower side thereof. Since the interior skin material 101 has a synthetic resin porous layer (synthetic resin porous layer 60) formed so as to fill the gaps of the skin base material 10 (needle-punched nonwoven fabric 5), it does not contain an oil repellent. Even so, it is possible to suppress the permeation of the foamable resin when the back side of the mold is filled with the foamable resin and then heated.

In addition, the interior skin material 101 manufactured in this way can have an air permeability of 10 to 100 cc/cm ² /sec, thereby achieving both rigidity and resin exudation resistance. be able to. In another embodiment, the ventilation rate can be 20-80 cc/cm ² /sec, and in yet another embodiment, 25-55 cc/cm ² /sec.

(Second embodiment)
Hereinafter, the interior skin material 102 according to the second embodiment of the present specification will be described based on the drawings. In addition, in 2nd Embodiment, what has the same structure as 1st Embodiment uses the same code|symbol, and abbreviate|omits the description.

As shown in FIG. 2, the interior skin material 102 according to the second embodiment is obtained by joining an upper skin base material 10A and a lower skin base material 10B by needle punching. Since the two layers of needle-punched nonwoven fabrics are joined by needle-punching processing, the back side of the interior skin material 102 according to the embodiment is filled with foamable resin in the molding die by the two-layers of needle-punched nonwoven fabrics. Even if it does not have an oil-repellent agent, it is possible to suppress the permeation of the foamable resin when it is heated after it has been applied. In addition, in the interior skin material 102 according to the second embodiment, the intermediate film layer 30 made of a synthetic resin film that suppresses permeation of the expandable resin is interposed between the upper skin base material 10A and the lower skin base material 10B. can be made

The upper layer skin base material 10A is a non-woven fabric formed by needle-punching a web formed from synthetic resin fibers 1 having a thickness of 0.5 to 20 dtex and having a basis weight of 50 to 200 g/m ² , and a lower layer skin base material. 10B is a non-woven fabric obtained by needle-punching a web formed from synthetic resin fibers 1 having a thickness of 0.5 to 20 dtex and having a basis weight of 50 to 200 g/m ² . The synthetic resin fibers 1 used for the upper layer skin base material 10A and the lower layer skin base material 10B can be the same as the synthetic resin fibers 1 used for the needle-punched nonwoven fabric 5 of the first embodiment.

The intermediate film layer 30 is made of a synthetic resin film, and can be provided to further suppress permeation of the foamable resin when the back surface of the interior skin material 102 is filled with the foamable resin and then heated. is. As a material for the intermediate film layer 30, in the embodiment, polyester film, polyolefin film (PE (polyethylene), PP (polypropylene), etc.), PA (polyamide) film, acrylic resin film, polyvinyl alcohol film, etc. can be used. . Moreover, the intermediate film layer 30 can also use a multilayer film obtained by laminating these films, and can be used regardless of whether it is a stretched film or an unstretched film.

Next, a method for manufacturing the interior skin material 102 according to the second embodiment of the present specification will be described. The method for manufacturing the interior skin material 102 according to the second embodiment includes a carding step of forming a web from the synthetic resin fibers 1 used for the upper layer skin base material 10A (lower layer skin base material 10B), and an upper layer from the formed web. A needle punching process for forming the skin base material 10A (lower skin base material 10B), the upper skin base material 10A, the lower skin base material 10B, and the synthetic resin film (intermediate film layer 30) interposed therebetween. A bonding step of bonding by needle punching and a smoothing process of smoothing the surface of the bonded multilayer skin substrate 10C using a heated roller are carried out in this order. The synthetic resin film (intermediate film layer 30) is used as necessary and can be omitted.

The card process and needle punch process are the same as the card process and needle punch process of the first embodiment.

In the lamination step, the upper skin base material 10A, the lower skin base material 10B, and the synthetic resin film (intermediate film layer 30) interposed therebetween were laminated together by needle punching. It should be noted that in embodiments without an intermediate film layer 30, the intervention of the synthetic resin film is omitted.

In the smoothing process, a heated roller was pressed against the upper side, or the upper and lower sides of the laminated multilayer skin substrate 10C to heat and smooth the surface of the multilayer skin substrate 10C. 10 C of multilayer skin base materials become the skin material 102 for interiors by going through a smoothing process. The set temperature of the roller is the same as the set temperature of the roller in the first embodiment.

The interior skin material 102 manufactured in this manner is formed from a synthetic resin fiber 1 having a thickness of 0.5 to 20 dtex, and a web having a basis weight of 50 to 200 g/m ² is needle-punched as an upper layer. The skin base material 10A, a synthetic resin film (intermediate film layer 30) intervening as necessary, and a synthetic resin fiber 1 having a thickness of 0.5 to 20 dtex, and having a basis weight of 50 to 200 g/m ² The web is needle-punched, and the lower skin base material 10B is needle-punched. Since the two-layer needle-punched nonwoven fabric is needle-punched, even if the interior skin material according to the embodiment does not have an oil-repellent agent, the two-layer needle-punched nonwoven fabric allows the inner surface of the inner surface of the inner surface of the interior of the mold to be It is possible to suppress permeation of the foaming resin when heating is performed after the side is filled with the foaming resin.

The present invention will be described in more detail below with reference to examples. The characteristics of the synthetic resin fiber 1 used are shown in Table 1, the characteristics of the permeation-preventing nonwoven fabric 20 are shown in Table 2, the characteristics of the synthetic resin emulsion forming the synthetic resin porous layer 60 are shown in Table 3, and the characteristics of the thermally expandable capsules 70 are shown in Table 3. are listed in Table 4, and the properties of the intermediate film layer 30 are listed in Table 5, respectively. The synthetic resin emulsion N in Table 3 is a mixture of an acrylonitrile/styrene/acrylate copolymer emulsion and an acrylonitrile/acrylate copolymer emulsion.

The interior skin materials 101 and 102 of Examples were evaluated in terms of normal incident sound absorption coefficient, air permeability, rigidity, and resistance to resin exudation. These evaluation methods are described below.

(normal incidence sound absorption coefficient)
The normal incidence sound absorption coefficient was measured according to Measurement of sound absorption coefficient and impedance by acoustic tube-Part 2: transfer function method (JIS A 1405-2:2007 (ISO 10534-2:1998)). Then, the results were evaluated as ◯ when superior to the comparative example (Table 6), Δ when equivalent to the comparative example, and x when inferior to the comparative example.

(ventilation volume)
The air permeability was measured according to 8.26 Breathability A method (Fragile method) of woven and knitted fabric test methods (JIS L 1096:2010). The lower the ventilation rate, the better the result.

(rigidity)
Stiffness was evaluated by comparison with comparative examples (Table 6). Then, the results were evaluated as ◯ when superior to the comparative example (Table 6), Δ when equivalent to the comparative example, and x when inferior to the comparative example.

(resin exudation resistance)
The resistance to resin exudation is measured by filling the back side of the interior skin materials 101 and 102 with a foaming resin in a mold, heating it, and checking the degree of exudation to the surface side of the interior skin materials 101 and 102. checked and evaluated. Then, ◯ indicates that no oozing was observed, △ indicates that oozing was observed but did not impair the texture of the surface, and x indicates that oozing was confirmed but the texture of the surface was impaired. evaluated.

Table 6 describes formulations and physical property evaluations for examples and comparative examples of the first embodiment. A comparative example is a conventional interior covering material. Examples 3 and 4 are the best modes. FIG. 3 shows an enlarged photograph of the rear surface of the interior covering material 101 of Example 3, and FIG. 4 shows an enlarged photograph of the rear surface of the interior covering material 101 of Example 4. As shown in FIG. FIG. 5 shows a graph of normal incident sound absorption coefficients of the floor carpets of Examples 3 and 4 (having the foamed resin layer F on the back side of the interior covering material 101). The solid line is Example 3, and the dotted line is Example 4.

In Example 1, the basis weight of the needle-punched nonwoven fabric 5 was increased and the amount of the synthetic resin emulsion that forms the synthetic resin porous layer 60 was increased from the comparative example. In Example 1, the resistance to resin exudation was found to be such that, although exudation was confirmed, the texture of the surface was not impaired.

In Example 2, by blending the thermally expandable capsules 70 with the synthetic resin emulsion, even if the amount of the synthetic resin emulsion applied was reduced, the resistance to resin exudation was not confirmed. It is. It was also confirmed that the use of the heat-expandable capsules 70 has the effect of filling the spaces between the fibers of the spunbond nonwoven fabric (penetration-preventing nonwoven fabric 20) and lowering the air permeability.

In Example 3, it was confirmed that high rigidity can be obtained by changing the synthetic resin emulsion to an acrylic synthetic resin emulsion containing acrylonitrile and styrene. Moreover, it was confirmed that the resistance to resin exudation was improved by increasing the amount of the thermally expandable capsules 70 .

In Example 4, even if the heat-expandable capsules 70 were not blended, as shown in FIG. However, we were able to make sure that no exudation was confirmed.

In Example 5, the synthetic resin emulsion was changed from an acrylic synthetic resin emulsion containing acrylonitrile and styrene to an acrylic synthetic resin emulsion, and the foam rubber layer 62 was formed from the synthetic resin emulsion in the same manner as in Example 4. is. Although the resin exudation resistance was good, the acrylic synthetic resin emulsion was not sufficiently impregnated into the skin base material 10, resulting in poor rigidity.

In Example 6, the permeation-preventing nonwoven fabric 20 was changed to a wet-laid nonwoven fabric made of pulp and rayon. The interior covering material 101 with excellent performance was able to be obtained.

In Example 7, the permeation-preventing nonwoven fabric 20 was changed to a meltblown nonwoven fabric. The interior covering material 101 with excellent performance was able to be obtained.

Table 7 describes formulations and physical property evaluations of examples of the second embodiment.

In Example 8, the upper skin base material 10A and the lower skin base material 10B are needle-punched. Since both the front and back surfaces were smoothed by heated rollers, the interior skin material 102 of Example 8 was excellent in resistance to resin seepage and excellent in rigidity.

In Example 9, the PP (polypropylene) fibers of the synthetic resin fibers 1 of the lower skin base material 10B of Example 8 were changed to PET (polyester) fibers. In the smoothing treatment, the PET fiber has a high melting point and is not heat-sealed, resulting in poor resistance to resin exudation.

In Example 10, from Example 9, an intermediate film layer 30 (polyurethane single layer) was added between the upper skin base material 10A and the lower skin base material 10B. The intermediate film layer 30 improved the resistance to resin bleeding, but the intermediate film layer 30 made the sound absorption inferior. Moreover, in the lamination step of laminating by needle punching, a large amount of film pieces adhered to the barbs of the needle, resulting in poor work efficiency.

In Example 11, the polyurethane single layer of the intermediate film layer 30 was changed from Example 10 to a three-layer film. The results were the same as in Example 10, and although the intermediate film layer 30 improved the resistance to resin bleeding, the sound absorption was inferior. By changing the intermediate film layer 30 to a three-layer film, adhesion of the film pieces to the barbs of the needles is reduced in the laminating step of laminating by needle punching, making it practical.

REFERENCE SIGNS LIST 1 Synthetic resin fiber 5 Needle-punched nonwoven fabric 10 Skin base material 10A Upper skin base material 10B Lower skin base material 10C Multilayer skin base material 20 Anti-penetration nonwoven fabric 30 Intermediate film layer , 60... synthetic resin porous layer, 61... impregnation layer, 62... foam rubber layer, 70... thermally expandable capsule, 101... interior covering material, 102... interior covering material, F... foamed resin layer.

Claims (9)

A skin base material whose base material is a needle-punched nonwoven fabric obtained by needle-punching a web formed from synthetic resin fibers having a thickness of 0.5 to 20 dtex and having a basis weight of 100 to 300 g/m ² ;
a synthetic resin porous layer having a coating amount of 20 to 100 g/m ² in terms of non-volatile matter provided on the underside of the skin base material;
An interior skin material characterized by having 2. The interior skin material according to claim 1, wherein the synthetic resin porous layer is impregnated in the skin base material. 2. The interior covering material according to claim 1, wherein said synthetic resin porous layer is formed in the shape of foam rubber. 2. The skin base material according to claim 1, wherein the needle-punched nonwoven fabric is provided with a permeation-preventing nonwoven fabric below the needle-punched nonwoven fabric, and the needle-punched nonwoven fabric and the permeation-preventing nonwoven fabric are needle-punched. interior skin material. 5. The interior covering material according to claim 4, wherein the permeation-preventing nonwoven fabric is a spunbond nonwoven fabric, a meltblown nonwoven fabric, or a wet-laid nonwoven fabric. 2. The interior covering material according to claim 1, wherein the synthetic resin forming the synthetic resin porous layer is an acrylic resin. 2. The interior covering material according to claim 1, wherein said synthetic resin porous layer contains heat-expandable capsules. An interior skin material in which an upper layer skin base material and a lower layer skin base material are needle-punched,
The upper skin base material is a nonwoven fabric formed by needle-punching a web formed of synthetic resin fibers having a thickness of 0.5 to 20 dtex and having a basis weight of 50 to 200 g/m ² ,
The lower layer skin base material is formed of synthetic resin fibers having a thickness of 0.5 to 20 dtex, and has a basis weight of 50 to 200 g/m ² . The web is needle-punched nonwoven fabric. Skin material for interior. 9. The interior skin material according to claim 8, wherein an intermediate film layer is interposed between the upper skin base material and the lower skin base material.

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