JP2627521B2 - Automotive interior materials - Google Patents

Description

Description: BACKGROUND OF THE INVENTION The present invention relates to an automobile interior material, and more particularly to an improved automobile interior material used for interior parts such as an automobile ceiling material, a door trim, a rear package, and a trunk room. is there.

[Prior art] Conventionally, as this kind of automobile interior material, a laminated material of a textured polyvinyl chloride sheet and a polyurethane sponge,
Fiber knitted fabric or its raised fabric is used,
In recent years, in automotive interior applications, weight reduction, price reduction,
Increased fiber orientation, wear resistance and flame retardancy (Those that meet the automotive safety standards applied to automotive materials and the combustion standards for automotive interior materials (FMVSS 302) are considered flame-retardant materials.)
Non-woven fabric substrates satisfying the above requirements have come to be widely used.

For example, Japanese Patent Application Laid-Open No. 63-43337 discloses a polypropylene fiber or a polyester fiber alone or mixed with a fiber which does not melt or shrink upon burning (for example, cotton, sheep, rayon, hemp, aramid, phenol, ceramic, carbon, metal). (2) discloses an automotive interior material having a flame-retardant thermoplastic resin coating on one surface of a nonwoven fabric comprising at least one of the following.

[Problems to be solved by the invention]

However, non-woven fabrics have a flame-retardant thermoplastic resin coating on one side, and unfixed fibers are pulled out at the time of friction to improve abrasion resistance by fixing some of the fibers, It is difficult to obtain a high level of abrasion resistance, and in order to obtain a high level of abrasion resistance, a method of impregnating the thermoplastic resin can be considered. Is also hard,
There are problems such as not being able to obtain satisfactory appearance and feeling.

[Means for solving the problem]

The present invention provides a high-density needle-punched nonwoven fabric mat containing shrinkable polyester composite fibers by heat shrinkage treatment, and provides a coating layer of a fluorocarbon resin on the front surface and a resin binder containing a foaming agent on the back surface to provide abrasion resistance. An object of the present invention is to provide an automotive interior material excellent in installation property, antifouling property and light weight.

〔Example〕

 Hereinafter, the present invention will be described in detail based on examples.

As shown in FIG. 2, shrinkable polyester composite fiber 2.5d × 51 mm 97 previously dyed in a required color, for example, gray
% Were mixed with rayon 2d × 51mm3% stained in the same color, uniformly spread, subjected to needle punching of the laminated fiber total struck number than the upper and lower mat 500P / cm ^2, weight per unit area 150 g / m ²
To obtain a needle-punched nonwoven fabric mat (1). Next, the needle-punched nonwoven fabric mat was subjected to a heat shrinking process at 180 ° C. at an area shrinkage of 30% to obtain a nonwoven fabric mat (2) having a high density of 210 g / m ² . Further, as shown in FIG. 1, for example, 2 g / m ² of a fluororesin (3) is applied to the surface of the densified nonwoven fabric mat (2) subjected to the heat shrinking process, and foamed at 150 ° C. or more on the back surface. A resin binder containing 50% of a foaming agent to be coated is coated with a thickness of, for example, 1 mm, and dried at a temperature of 120 ° C. at which the foaming agent does not foam, and a coating layer (4) of the foaming agent-containing resin binder is formed. To obtain the desired automotive interior materials.

Here, the shrinkable polyester fiber may be either original cotton or dyed cotton, or may be dyed after needle punching.

Further, the foaming agent may be a drying condition of the binder, and it is preferable to use a foaming agent which foams at 150 ° C. or more. The coating layer of the resin binder containing the foaming agent may be used for automobile ceiling materials, door trims, By foaming into a predetermined shape such as a rear package at the time of heat molding, moldability is improved, and heat insulation and soundproofing are further improved.

(Comparative example)

Polyester fiber 3d × 51mm dyed in the same manner as in the example
97% and rayon 2d x 51mm3% of the same color are mixed and opened uniformly.
subjected to needle punching in m ^2, and to obtain a needle punched nonwoven substrate having a basis weight of 210g / m ^2.

Next, a binder 30 is applied to the back of the needle punched nonwoven fabric.
g / m ^{2 was} applied to obtain an automobile interior material.

The automobile interior material obtained by the above-described example has a high degree of frictional fastness due to the fact that the fibers are well entangled due to the high density after heat shrinkage of the shrinkable polyester composite fiber and the three-dimensional crimp, and the taper abrasion test is performed. It showed excellent results and was sufficiently resistant to use as automotive interior materials such as automotive ceiling materials, door trims, and rear packages.

The table below shows the results of the taper abrasion test of the above examples and comparative examples.

As described above, it was possible to obtain an automobile interior material having a higher level than that of the comparative example.

〔The invention's effect〕

As described above, the present invention relates to a foaming agent having a temperature condition that does not foam during the drying treatment on the back surface of a needle-punched nonwoven fabric that has been densified in a spring shape due to shrinkage of a high shrinkage polyester composite fiber that has developed a three-dimensional crimp. Is applied, the thermoforming process is performed at the temperature at which foaming starts during the subsequent thermoforming process, which enables stocking with a small winding diameter. It is possible to obtain an automotive interior material having excellent properties.

In addition, the surface is coated with a fluorine resin, which is excellent in antifouling properties, is resistant to friction, and is composed of a fiber mat mainly composed of a highly shrinkable three-dimensional crimp-expressing polyester composite fiber. Therefore, it is dense and bulky, and has various effects such as reduction in weight by weight reduction.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view of an automobile interior material showing one embodiment of the present invention, and FIG. (1) Needle-punched nonwoven fabric mat (2) High-density nonwoven fabric mat (3) Fluororesin (4) Foaming agent-containing resin binder coating layer

Claims (1)

(57) [Claims] 1. A needle-punched nonwoven fabric mat comprising heat-treated shrinkable polyester composite fibers exhibiting a three-dimensional crimp of at least 80% (by weight) and densified by shrinkage of the polyester composite fibers.
Fluorine resin on one side of the needle punched nonwoven mat,
An automotive interior material comprising a coating layer of a resin binder containing a foaming agent provided on another surface.