JP2741683B2 - Interior material and method of manufacturing the interior material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior material used for, for example, an automobile and a method for producing the same.

[0002]

BACKGROUND OF THE INVENTION For example, cardboard is used as a base material for interior materials such as ceiling materials and door trims in automobiles and the like.
The corrugated cardboard (1) comprises a corrugated core material (2) and a surface material (3) attached to the core material (2) as shown in FIG. The surface material (3) is made of paper. However, cardboard made of paper (1)
Is poor in formability due to the low stretchability of the paper, causing wrinkles and cracks in the deep draw forming part, the car body panel and cardboard rubbing during car running and producing low-grade sound,
There are problems such as poor soundproofing and heavy weight.

[0003]

2. Description of the Related Art Conventionally, as a means for solving the problems of the cardboard made of paper, a cardboard made of paper and having a surface material made of non-woven fabric on both sides of a core material (Japanese Patent Laid-Open Publication No. H10-163,873). No. 61-29532), surface material and / or
Alternatively, a cardboard using a cork sheet as a core material (Japanese Utility Model Laid-Open No. 4-83742), a cardboard using a laminated material of a nonwoven fabric and a cork sheet as a surface material (Japanese Utility Model Application No. 4-72933), and the like are provided. I have.

[0004]

SUMMARY OF THE INVENTION However, Japanese Unexamined Patent Publication No.
In the case of the corrugated cardboard of No. 1-29532, the surface material is made of non-woven fabric, but since the core material is made of paper, the formability cannot be said to be sufficient, and there is also a problem in soundproofing. In the corrugated cardboard disclosed in Japanese Utility Model Application No. 4-72933, the stretchability of the cork sheet is not sufficient, good moldability cannot be obtained, and low-grade sound may be generated by rubbing with the vehicle body panel. There is a problem that it is not enough.

[0005]

According to the present invention, as a means for solving the above-mentioned conventional problems, a corrugated core (12) made of a nonwoven fabric (10) and two or one surfaces of the core (12) are provided. Corrugated cardboard comprising a surface material (13) made of a nonwoven fabric (10) to be adhered, and at least the low-melting fiber is contained in the nonwoven fabric (10) of the core material (12) in a ratio of 10 to 70% by weight. (1
The present invention provides an interior material (11A) made of 1) and formed into a predetermined shape, and further comprises 10 to 70% by weight of a low melting point fiber.
Non-woven fabric (10) contained at a rate of not less than the softening point of the low-melting fiber is heated and formed into a corrugated core material (12), and the non-woven fabric (10) is formed on both sides or one surface of the core material (12). The present invention provides a method for producing an interior material (11A) in which a corrugated cardboard (11) having a surface material (13) made of the same is formed into a predetermined shape.

The non-woven fabric used as the material of the cardboard of the present invention includes organic fibers such as polyester fiber, polyamide fiber, acrylic fiber, acetate fiber, cotton fiber, wood fiber, bamboo fiber, glass fiber, ceramic fiber, carbon fiber and the like. It is a nonwoven fabric using one or more kinds of fibers such as inorganic fibers, and the nonwoven fabric of at least the core material preferably has a melting point of 100 to 100, such as low-melting polyester fiber, low-melting polyamide fiber, polyethylene fiber, or polypropylene fiber. The low-melting fiber in the range of 150 ° C. is contained in the range of 10 to 70% by weight, preferably 30 to 60% by weight.
When the content of the low melting point fiber is less than 10% by weight, thermoformability is not sufficient, and when it exceeds 70% by weight, heat resistance becomes a problem. The above-mentioned nonwoven fabric binds the above-mentioned fibers with a synthetic resin binder, or is entangled by needle punching or the like,
Alternatively, when the low melting point fiber is contained, it is produced by heating to a temperature higher than the softening point of the low melting point fiber to soften the low melting point fiber and to bind the fiber. In the present invention, the nonwoven fabric is usually 100 g / m ^{2 to} 2000 g.
/ M ² , but the thickness can be partially changed as desired. Acrylic resin, vinyl acetate resin, styrene resin, urethane resin, melamine resin, urea resin, synthetic resin such as phenol resin,
Alternatively, a precursor such as a monomer, prepolymer, or oligomer of the synthetic resin may be impregnated, or a plastic film such as a polyethylene film, a polypropylene film, or a polyester film may be laminated. Further, the nonwoven fabric may be colored or embossed, and if such a nonwoven fabric is used as a surface material, a surface layer material becomes unnecessary.

In order to manufacture a cardboard using the above nonwoven fabric, the low melting fiber containing the nonwoven fabric as a core material is heated to a temperature higher than the softening point thereof to soften the low melting fiber and then cold-formed into a corrugated shape. Alternatively, hot forming is performed in a corrugated shape at a temperature not lower than the above temperature.

It is not always necessary to mix low-melting fibers in the nonwoven fabric used as the surface material. However, if desired, a nonwoven fabric containing low-melting fibers as in the case of the core material may be used.

The core material and the surface material are adhered by using a normal adhesive, a hot melt adhesive or the like. When using a synthetic resin or a non-woven fabric impregnated with a synthetic resin precursor, the synthetic resin or the non-woven fabric is used. Since the precursor functions as an adhesive, no adhesive is required.

[0010]

The cardboard (11) of the present invention uses a non-woven fabric for both the core material (12) and the surface material (13). As a result, the cardboard (11) has excellent stretchability and thermoformability as a whole, and the nonwoven fabric contains a large amount of air and has excellent soundproofing and heat insulating properties and cushioning properties. No low-pitched sound is generated due to rubbing, and it is extremely lightweight and highly breathable.

[0011]

EXAMPLE A high melting point fiber having a melting point exceeding 150 ° C. (eg, a polyester fiber having a melting point of 180 ° C.) is added
30% by weight of a low-melting fiber having the following melting point (for example, a polyester fiber having a melting point of 130 ° C.) is mixed and entangled by needle punching, and then a range of not less than the softening point of the low-melting fiber and not more than the softening point of the high-melting fiber. Temperature, for example, 160 ° C.
Then, the high melting point fiber was bound by heating to soften the low melting point fiber to produce a nonwoven fabric having a weight of 150 g / m ² .

As shown in FIG. 1, the nonwoven fabric (10) is heated in a heating furnace (1).
4) heating to a temperature in the above range, for example, 160 ° C. to soften the low melting point fiber of the non-woven fabric (10), cold-formed by a tooth roll press (15), and a corrugated core material
(12) is manufactured. Alternatively, the nonwoven fabric (10) may be formed into a corrugated core material (12) by being hot-formed by a toothed roll press heated to a temperature in the above range without being heated in a heating furnace.

A roll coater (16) is provided on both sides of the core material (12).
Acrylic adhesive is applied, and the core material (1
A surface material (13) made of a non-woven fabric (10) is pressed onto both surfaces of 2) to produce a cardboard (11) as shown in FIG. The weight of the cardboard (11) used as a ceiling material is 500 to
600 g / m ² and the weight of conventional cardboard is 800
~900g / m ^2, it is extremely light in comparison to the resin board 1.45 kg / m ^2. In the present invention, the surface material (13) may be adhered to only one surface of the core material (12).

The corrugated cardboard (11) is heated to a temperature in the above range, for example, 160 ° C. to soften the low melting point fiber and then cold pressed, or is formed by a hot press heated to a temperature in the above range. As a result, for example, as shown in FIG.
Used as (11A).

[0015]

Accordingly, the present invention provides an excellent interior material which is lightweight, has extremely good moldability, has excellent soundproofing and heat insulating properties, and does not generate low-pitched sound even when rubbed with a vehicle body.

[Brief description of the drawings]

 1 to 3 show one embodiment of the present invention.

FIG. 1 is a cardboard manufacturing process diagram

FIG. 2 is a partial sectional view

FIG. 3 is a perspective view of an automobile ceiling material.

FIG. 4 is a partial sectional view of a conventional example.

[Explanation of symbols]

 10 Nonwoven fabric 11 Corrugated cardboard 12 Corrugated core 13 Surface material 11A Interior material

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Tadao Asano 1511 Tsuya, Minano-cho, Kaizu-gun, Gifu Prefecture

Claims (2)

(57) [Claims] 1. A corrugated core made of a non-woven fabric and a surface material made of a non-woven fabric adhered to both sides or one surface of the core. An interior material characterized by being formed of a corrugated cardboard contained in a percentage by weight and having a predetermined shape. 2. A nonwoven fabric containing low-melting fibers in a proportion of 10 to 70% by weight is formed by heating at a temperature not lower than the softening point of the low-melting fibers to form a corrugated core. A method of manufacturing an interior material, comprising forming a corrugated cardboard having a surface material made of a nonwoven fabric adhered to one surface into a predetermined shape.