JP2872896B2 - Thermoformable core material, production method thereof and interior material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

This invention relates to thermoformed composites,
In particular, the present invention relates to a thermoformable core material used for a ceiling base material of a vehicle such as an automobile and an interior base material of a door, a method for producing the core material, and an interior material.

[0002]

2. Description of the Related Art Conventionally, thermoformable core materials used for interior materials of vehicles such as automobiles, in particular, base materials for thermoformed ceilings are lightweight,
It is required to have excellent properties such as rigidity, heat resistance, heat shaping, and air permeability. Such materials include, for example,
JP-A-1-56562 and JP-A-2-53948 disclose that the core material itself is completely heated and shaped without impairing the lightness, heat resistance, heat shaping property, sound absorbing property and the like. A thermoformable core material having ventilation blocking properties and a method for producing the same are disclosed.

[0003]

However, when such a thermoformable core material or the like is used as a base material of a molded ceiling of an automobile, for example, a surface material such as a skin material is formed on the surface of the thermoformable core material. After laminating a thermoformable core material to laminate a knit skin, a knit urethane skin, a nonwoven fabric skin, etc., the adhesive resin was dissolved in an organic solvent or dispersed in water on the surface on which the skin material was to be laminated. A step of applying and drying the adhesive must be provided, and then the skin material must be laminated to the thermoformable core material. Thus, the conventional method requires a coating and drying process of the adhesive,
In addition, there is a disadvantage that the working environment is soiled.

An object of the present invention is to provide an adhesive application and drying process for laminating a skin material without impairing the lightness, heat resistance, heat shaping, sound absorption and air-permeability, in view of the above drawbacks. It is an object of the present invention to provide a thermoformable core material capable of laminating a skin material without providing the same, a production method thereof, and an interior material.

[0005]

According to the first aspect of the present invention, a heat-resistant stiffness having a higher melting temperature than that of the thermoplastic resin fiber is provided on at least one outer side of a mat-like material formed mainly of inorganic fibers and thermoplastic resin fibers. It is a thermoformable core material in which a resin layer and a thermoactive resin layer are laminated in this order.

[0006] In the present invention 1, the mat-like material is composed mainly of inorganic fibers and thermoplastic resin fibers. Examples of the inorganic fibers include glass fibers and rock wool. From the viewpoint of the moldability of the base layer, the length of the inorganic fiber is preferably 5 to 250 mm, more preferably 50 to 250 mm.
Those having a size of about 150 mm have a distribution of 70% by weight or more. In addition, the thickness of the inorganic fiber is preferably from 5 to 20 μm, more preferably from 7 to 13 μm, from the viewpoint of the bending strength and the thickness recovery of the obtained thermoformable core material.

The thermoplastic resin fiber is preferably a resin which is easily melted and binds to the inorganic fiber. Examples of such thermoplastic resin fibers include fibers made of a resin such as polyethylene, polypropylene, and polystyrene.
The length and thickness of the thermoplastic resin fibers are preferably such that the base layer can be easily formed by mixing the inorganic fibers with the dispersant with good dispersibility.
Specifically, the length is preferably 5 to 200 mm, more preferably 20 to 100 mm. The thickness is 5 to 70 μm
And more preferably 15 to 40 μm.

The mat-like material may contain a thermoplastic resin as required. It is preferable that the thermoplastic resin is easily impregnated between the inorganic fibers in a molten state and easily bonded to the inorganic fibers. Examples of such a thermoplastic resin include thermoplastic resins such as polyethylene, polypropylene, polystyrene, ethylene-vinyl acetate copolymer, saturated polyester, and modified products thereof (for example, maleic anhydride-modified polyethylene).

In the thermoformable core material of the present invention 1, a heat-resistant rigid resin layer having a higher melting temperature than the thermoplastic resin fiber and a thermoactive resin layer are laminated in this order on at least one outer side of the mat-like material. ing.

The heat-resistant rigid resin has a higher melting temperature than the thermoplastic resin fiber and the thermoplastic resin contained as required, and is 30 ° C. or more higher than the melting temperature of the thermoplastic resin contained as necessary. , Preferably 50 ° C. or higher. This makes it possible to heat the entire layer to be laminated on the mat-like material to melt the resin other than the heat-resistant rigid resin. Examples of such a heat-resistant rigid resin include heat-resistant rigid resins such as polybutylene terephthalate, polyethylene terephthalate, polycarbonate, polyamide, and modified products thereof.

In order to obtain good thermoformability, the heat-resistant rigid resin has a thermoforming draw ratio (the thermoform draw ratio is a diameter D and a height when a plate-like material is drawn into a cylindrical shape by a vacuum forming machine). H ratio H /
Specified by D. ) Is preferably 0.5 or more.
When the thermoforming draw ratio is 0.5 or less, thermoforming performance of the core material,
That is, a problem occurs in the shapeability.

[0012] The thermoactive resin has a thermal activity manifestation temperature preferably lower than the melting temperature of the heat-resistant rigid resin by 20 ° C. or more, and is preferably about the same as the melting temperature of the thermoplastic resin and the thermoplastic resin fiber. . Thereby, it is possible to heat and heat-activate the heat-activated resin on the surface by heating the entire laminated sheet, without impairing the permeability blocking performance by the heat-resistant rigid resin layer, and without providing the adhesive application drying step. The skin material can be bonded to the thermoformable core material (in the prior application, Japanese Patent Application Laid-Open No. 5-93352, an adhesive application and drying step was required).

The melt flow rate (MFR) as a measure of the fluidity of the thermoactive resin is preferably 0.5 to 2
0, more preferably 2 to 15. MFR is 2
If it exceeds 0, the thermoactive resin impregnates all inside the skin material and no adhesive strength is obtained. Conversely, if it is less than 0.5, the heat active resin does not impregnate inside the skin material and anchor effect is obtained. Can not be obtained. Examples of such heat-active resins include polyethylene, polypropylene, ethylene-vinyl acetate copolymer, maleic anhydride-modified polyethylene, saturated polyester-modified polyethylene, and copolymerized polyamide.

The thermoformable core material of the present invention 1 is expanded in the thickness direction. The degree of expansion is such that the porosity of the base layer is
A range that becomes 9% is preferable. Thereby, in the base layer, the inorganic fibers are bonded by the thermoplastic resin fiber and the melt of the thermoplastic resin at the intersections thereof, and
It has large voids throughout.

A second aspect of the present invention is the thermoformable core material according to the first aspect, wherein a sheet-like material is formed from the heat-resistant rigid resin layer and the heat-active resin layer, and the sheet-like material has fine through holes. It is.

[0016] The size and density of the fine through-holes are not less than the extent that the surface of the obtained thermoformable core material cannot be depressed,
In addition, it is necessary that the air-permeable property of the obtained thermoformable core material is not more than the extent to be maintained, and specifically, the diameter of the fine through-hole is preferably in the range of 0.02 to 1 mm, and the density thereof is , 5,000 to 1,000,000 pieces / m ² .

More preferably, the porosity defined by the following formula: porosity (%) = (average pore area per fine through-hole × density of fine through-holes) × 100 is 0.
The range is from 01 to 10%. The method of drilling the fine through-hole may be any method such as a needle hole or a punch hole,
The mechanical needle hole method is preferably used because a fine through hole having an arbitrary hole diameter can be stably formed by heating the needle and the thickness of the needle.

A third aspect of the present invention is an interior material in which a skin material is laminated on the surface of the thermoactive resin layer of the thermoformable core material of the first or second aspect of the present invention and is shaped.

In the present invention 3, as the skin material, for example, a non-woven fabric having a feeling, flexibility, and design properties made of natural fibers such as cotton, wool, and hemp, and synthetic fibers such as polyester, polyamide, and polyurethane is used. Can be

As a method of laminating and shaping the skin material on the surface of the heat-active resin layer, for example, a heat-active resin comprising a polyamide-based copolymer, a polyester-based copolymer, an acid-modified polyolefin, etc. A method of laminating a skin material via a resin film or a synthetic fiber such as polyethylene, polypropylene, polyurethane or the like, and press-molding the skin material in a heated state can be adopted.

The present invention 4 is a process for obtaining a laminate by laminating a thermoplastic resin film on at least one outer side of a mat-like material formed mainly of inorganic fibers and thermoplastic resin fibers, A multilayer material comprising a thermoplastic resin layer (a), a heat-resistant rigid resin layer (b) having a higher melting temperature than the thermoplastic resin fiber and the thermoplastic resin film, and a thermoactive resin layer (c) at least outwardly. [(A) / (b) /
(C)] to obtain a laminated sheet by laminating the thermoactive resin layer (c) to the outside, and heating the laminated sheet at a temperature equal to or lower than the melting temperature of the heat-resistant rigid resin to form a thermoplastic resin fiber. Melt and compress the thermoplastic resin, and impregnate the thermoplastic resin into the mat-shaped material without impregnating the heat-resistant rigid resin and the mat-shaped material with the non-contact thermoactive resin. Thermoforming core comprising a step of bonding inorganic fibers to each other with a thermoplastic resin fiber and a thermoplastic resin in a state, then expanding in a thickness direction, and curing the thermoplastic resin fiber and the thermoplastic resin in a molten state. It is a method of manufacturing a material.

The present invention 4 includes a step of obtaining a laminate. In the step of obtaining a laminate, a mat-like material mainly composed of inorganic fibers and thermoplastic resin fibers is used. The mixing ratio of the inorganic fiber and the thermoplastic resin fiber of the mat-like material is
When the proportion of the inorganic fibers is small, the heat resistance of the obtained thermoformable core material is reduced, and when the proportion is large, the bonding strength between the inorganic fibers is reduced and the mechanical strength, that is, the rigidity is reduced. Is preferably set in the range of 5: 1 to 1: 5 in terms of weight ratio with respect to.

As a method for producing the mat-like material, any method may be adopted. In general, an inorganic fiber and a thermoplastic resin fiber are supplied to a card machine, and these are defibrated and subjected to a needle punch. A mat is manufactured. The needle punch is preferably punched at ^{2 to} 100 points, more preferably at 10 to 50 points per 1 cm ^{2 in} order to improve the mechanical strength of the mat-like material and the obtained thermoformable core material.

The density of the mat-like material is preferably 0.01 to 0.2 g / cm ³ because the larger the density, the heavier the mat-like material, and the lower the density, the lower the mechanical strength of the mat-like material. The weight of the mat is 2 to obtain mechanical strength.
00 to 1500 g / m ² is preferable, and 3 is more preferable.
It is 00 to 800 g / m ² .

As the inorganic fibers and the thermoplastic resin fibers used for the mat-like material, the same ones as those of the first invention are used. A laminate is obtained by laminating a thermoplastic resin film on at least one outer side of the mat-like material. In addition, it is preferable to form a sandwich laminate by laminating a thermoplastic resin film on both outer sides of the mat-like material. When the thermoplastic resin film is heated by forming a sandwich laminate in this manner, a part of the thermoplastic resin film remains on both outer sides of the mat-like material without being impregnated into the mat-like material, so that the thermoformable core material Therefore, it is preferable because the strength can be increased.

The thermoplastic resin film according to the present invention 1
A film made of the same thermoplastic resin as described above is used.
The thickness of the film is preferably 50 to 500 μm because the mechanical strength decreases as the film becomes thinner and becomes heavier as the film becomes thicker.
More preferably, it is 70 to 300 μm.

The present invention 4 has a step of obtaining a laminated sheet. A thermoplastic resin film is laminated on at least one outer side of the mat-like material, and a thermoplastic resin layer (a) and a heat-resistant rigid resin layer (b) are laminated on at least one outer side of the obtained laminate.
And a multi-layered material comprising a thermoactive resin layer (c) [(a) /
(B) / (c)] so that the thermally active resin layer (c) is on the outside to obtain a laminated sheet. As the multilayer material, a material further provided with an adhesive layer between [(a) / (b)] and [(b) / (c)] may be used.

In the present invention 4, the method for producing a multilayer material is not particularly limited, and a coextrusion method, an extrusion lamination method, a dry lamination method, or the like is applied. A preferred method is a co-extrusion method, that is, a method of simultaneously extruding a thermoplastic resin and a heat-resistant stiff resin through an adhesive resin, and producing a laminated sheet by a conventional method such as a T-die. It is a target.

The present invention 4 includes a step of heating and compressing the laminated sheet, expanding the sheet in the thickness direction, and curing the thermoplastic resin fiber and the thermoplastic resin in a molten state. The laminated sheet obtained by the above method is heated at a temperature not higher than the melting temperature of the heat-resistant rigid resin and not lower than the melting temperature of the thermoplastic resin forming the thermoplastic resin film and the thermoplastic resin layer (a). Compress while maintaining the temperature.
The compression pressure is ^{2 to 20} kg / cm ² and the compression time is 2 to
A range of 10 seconds is preferred.

After this compression, the entire laminated sheet (mat and multilayer material) is expanded in the thickness direction. Spreading in the thickness direction may be recovered by the elasticity of the inorganic fibers, but in order to make it easier to release the multilayer material outside the laminated sheet at room temperature, for example, sandwich it with a Teflon-coated steel plate or glass cloth sheet. Vacuum suction of both surfaces may be performed forcibly.

In the heating and compression step, the thermoplastic resin forming the thermoplastic resin film and the thermoplastic resin layer (a) is melted and impregnated into the mat-like material, and the inorganic fiber is melted together with the melted thermoplastic resin fiber. Bind each other. On the other hand, the heat-resistant rigid resin does not melt and does not impregnate into the mat-like material. Further, the thermoactive resin (c) outside the heat-resistant rigid resin is melted, but is not impregnated in the mat-like material.

The curing of the thermoplastic resin fiber, thermoplastic resin and thermoactive resin in the molten state may be performed by natural cooling, forced cooling, or curing while expanding. Alternatively, it may be cured after spreading.

The present invention 5 is a process for obtaining a sandwich laminate by laminating a thermoplastic resin film on both sides of a mat-like material formed mainly of inorganic fibers and thermoplastic resin fibers, A multilayer material [(b) / (c)] comprising a heat-resistant stiff resin layer (b) having a higher melting temperature than the thermoplastic resin fiber and the thermoplastic resin, and a thermoactive resin layer (c) at least on the outside. To obtain a laminated sheet by laminating the thermoactive resin layer (c) to the outside, and heating the laminated sheet at a temperature equal to or lower than the melting temperature of the heat-resistant rigid resin to form a thermoplastic resin fiber and a thermoplastic resin. The thermoplastic resin in the molten state is melted and compressed, and the thermoplastic resin in the molten state is impregnated with the thermoplastic resin without impregnating the heat-resistant rigid resin and the thermo-active resin in a non-contact state with the mat-like substance. Resin fiber and After binding the inorganic fibers each other in the thermoplastic resin, and expanded in the thickness direction, a manufacturing method of a thermoformable core material comprising the step of curing the thermoplastic resin fibers and a thermoplastic resin in a molten state.

In the present invention 5, the step of obtaining a laminated sheet differs from that of the method of the present invention 4 in that a multilayer material having no thermoplastic resin layer (a) is used. There is no problem because the thermoplastic resin film is laminated on the outside.

The present invention 6 relates to a multilayer material [(a) / (b) /
(C)] A method for producing a thermoformable core material according to the fourth aspect of the present invention, wherein a fine through-hole is provided.

The present invention 6 differs from the method of the present invention 4 in that a multilayer material provided with fine through holes is used. The diameter and density of the fine through holes provided in the multilayer film are the same as those described in the second embodiment.

According to the sixth aspect of the present invention, since the multilayer film is provided with fine through holes, when the laminated sheet is sandwiched between a Teflon-coated steel plate or a glass cloth sheet, the laminated sheet and the Teflon-coated The air collected between the laminated steel sheet or glass cloth sheet is expelled toward the mat-like object through the fine through holes by the compression pressure at the time of compression, and the space between the laminated sheet and the Teflon-coated steel sheet or glass cloth sheet is completely Adhere to

At the same time, since the outermost layer of the multilayer sheet in contact with the Teflon-coated steel sheet or glass cloth sheet, that is, the thermoactive resin (c) is in a molten state and is in a fluid state, the fine through-holes have been melted. Filled with thermoactive resin (c).

When the laminated sheet is spread in the thickness direction, the laminated sheet and the Teflon-coated steel sheet or glass cloth sheet are in close contact with each other, and air cannot be trapped. In addition, no depression is formed in the obtained thermoformable core material.

[0040]

According to the first aspect of the present invention, the thermoformable core material has a heat-resistant stiffness having a higher melting temperature than the thermoplastic resin fiber at least one outside of a mat-like material formed mainly of inorganic fibers and thermoplastic resin fibers. By laminating the resin layer and the thermo-active resin layer in this order, it is possible to apply the adhesive for laminating the skin material without impairing the light weight, heat resistance, heat shaping property and ventilation blocking property. The skin material can be laminated without providing a drying step, and when the skin material is bonded to the thermoformable core material, the skin material can be brought into direct contact with the surface of the thermoactive resin layer. By activating the melt, the skin material can be laminated with excellent adhesiveness.

The thermoformable core material according to the second aspect of the present invention has a sheet-like material formed from the heat-resistant stiff resin layer and the heat-active resin layer according to the first aspect of the present invention, and the sheet-like material has fine through holes. Because of this, without impairing the lightness, heat resistance, heat shaping property and ventilation blocking property, there is no air pocket between the pressure plate and the laminated sheet in the compression process, so there is no dent on the surface and lamination of the skin material It is possible to laminate the skin material without providing an adhesive application drying step for the purpose, and when the skin material is bonded to the thermoformable core material, the skin material can be brought into direct contact with the surface of the thermoactive resin layer. Therefore, it is possible to laminate the skin material in a state of excellent adhesiveness by activating the heat-active resin by melting.

The interior material according to the third aspect of the present invention has a light-weight, heat-resistant property because the skin material is laminated and shaped on the surface of the thermoactive resin layer of the thermoformable core material according to the first or second aspect of the invention. The skin material is provided on the surface in a state of excellent adhesive strength without impairing the heat shaping property and the ventilation blocking property.

The method for producing a thermoformable core material according to the fourth aspect of the present invention is a method of laminating a thermoplastic resin film on at least one outer side of a mat-like material formed mainly of inorganic fibers and thermoplastic resin fibers. Obtaining a product, at least one outer side of the laminate, a thermoplastic resin layer (a), a heat-resistant rigid resin layer (b) having a higher melting temperature than the thermoplastic resin fiber and the thermoplastic resin film, and A step of obtaining a laminated sheet by laminating a multilayer material [(a) / (b) / (c)] composed of a resin layer (c) such that the thermoactive resin layer (c) is on the outside; The thermoplastic resin fibers and thermoplastic resin are melted and compressed by heating at a temperature not higher than the melting temperature of the heat-resistant rigid resin, and the heat-resistant resin that is not in contact with the heat-resistant rigid resin and the mat-like material is placed in the mat-like material. Without impregnation, the thermoplastic resin After impregnating the inside of the material, binding the inorganic fibers with each other with the thermoplastic resin fiber and the thermoplastic resin in the molten state, then expanding in the thickness direction to cure the thermoplastic resin fiber and the thermoplastic resin in the molten state By including the step of squeezing, the above-mentioned thermoformable core material can be manufactured with good workability.

The method for producing a thermoformable core material according to the fifth aspect of the present invention uses a multilayer material having no thermoplastic resin layer (a). Towards,
A thermoplastic core material can be manufactured with good workability.

The method for producing a thermoformable core material according to the sixth aspect of the present invention is characterized in that the multilayer material [(a) / (b) / (c)] according to the fourth aspect of the invention is provided with fine through-holes, When sandwiched between a Teflon-coated steel plate or glass cloth sheet and compressed, air accumulated between the laminated sheet and the Teflon-coated steel plate or glass cloth sheet causes fine through-holes due to the compression pressure at the time of compression. When the laminated sheet is expelled to the mat side and spreads out in the thickness direction, the laminated sheet and the Teflon-coated steel sheet or glass cloth sheet are in close contact with each other and air cannot be trapped. The thermoforming core material having no depression on the surface can be manufactured with good workability.

[0046]

EXAMPLES The present invention will be described below in detail with reference to examples, but the present invention is not limited to these examples.

Example 1 Glass fiber having a length of 40 to 75 mm and a diameter of 9 μm, and 6 denier (thickness of about 30 μm)
m), 50 mm cut high density polyethylene fiber,
The mixture was blended at a weight ratio of 2: 1 and supplied to a card machine, which was defibrated and mixed to obtain a floc. Next, a needle punch was performed on the cotton-like material at a density of 20 places / cm ² ,
A mat having a basis weight of about 500 g / m ² was obtained.

Next, as shown in FIG. 1, on both sides of the obtained mat-like material 11, a thickness made of a high-density polyethylene resin [melting point 135 ° C., MFR 7.0] is about 100 μm.
Thermoplastic resin films 12 and 12 were laminated. Furthermore,
A thermoplastic resin layer 131 made of a high-density polyethylene resin (melting point 135 ° C., MFR 2.0) containing a maleic anhydride-modified polyethylene resin (MFR 0.91) and a nylon # 6 resin (melting point) 230 ° C.) and a heat-active resin layer 133 made of a copolymerized nylon resin (melting point: 80 to 115 ° C.)
The multilayer film 13 obtained by co-extrusion with a layer thickness of 30 μm / 20 μm / 30 μm is laminated so that the thermoactive resin layer 133 is on the outside, and is about 7 mm thick and about 800 g / weight.
A laminated sheet of m ² was produced.

The laminated sheet thus produced was sandwiched from both outer sides by a glass cloth sheet coated with Teflon,
After being supplied to a hot air heating furnace at 0 ° C. and left for 5 minutes, it was transferred to a flat plate press heated to 200 ° C. while being sandwiched by glass cloth sheets, and compressed so that the thickness of the laminated sheet became 0.9 mm. For 5 seconds. Next, the flat sheet press is spread so as to have an interval of about 7 mm, and the laminated sheet is transferred to a flat-plate vacuum expanding device while sandwiching the glass sheet with the glass cloth sheet. The suction was performed at a speed, the suction plate was widened to a distance of 6 mm to release the suction, taken out, and air-cooled for 3 minutes. Next, the glass cloth sheet was peeled off, the thickness was about 5.5 mm, and the weight was about 800 g /
An m ² flat thermoformable core material was obtained.

The surface of the obtained flat thermoformable core material on which the thermally active resin layer was laminated was heated to a surface temperature of 1 with an infrared heater.
After heating to 15 ° C., a urethane skin material is laminated on the surface of the thermally active resin layer, transferred to a flat plate press having a predetermined shape, compressed so that the interval becomes 4.0 mm, and held for 10 seconds to be heated. At the same time as the moldable core material was shaped, a skin material was attached. Next, the laminate was taken out from the flat plate press to obtain a thermoformable core material to which a skin material was bonded.

When the adhesive strength of the skin material of the obtained thermoformed core material with the skin material was measured, it was confirmed that the skin material was broken and sufficient adhesive strength was obtained. When the air permeability of the obtained thermoformed core material with a skin material was measured, 0.3 cc was obtained.
/ Cm ² · sec or less, indicating that sufficient ventilation blocking properties were obtained. Example 2 As shown in FIG. 2, a high-density polyethylene resin containing maleic anhydride-modified polyethylene resin (MFR 0.91) (melting point: 135 ° C., outside of the mat-like material 21 obtained in Example 1) MFR 12.0) thickness 13
A 0 μm thermoplastic resin film 22 was laminated. Furthermore,
A thermoplastic resin layer 231 made of a high-density polyethylene resin (melting point 135 ° C., MFR 12.0) containing a maleic anhydride-modified polyethylene resin (MFR 0.91) and a nylon # 6 resin (melting point) 230 ° C.) and a heat-active resin layer 233 made of a maleic anhydride-modified polyethylene resin (melting point: 130 ° C., MFR 10.0) with a layer thickness of 100 μm / 10
Multi-layer film 2 obtained by co-extrusion at μm / 100 μm
3 are laminated so that the thermoactive resin layer 233 is on the outside,
As in Example 1, the thickness is about 6.9 mm, and the weight is about 700 g.
/ M ² .

In the same manner as in Example 1, a flat thermoformed core material having a thickness of about 5.5 mm and a weight of about 700 g / m ² was obtained from the produced laminated sheet. After heating the surface of the obtained flat thermoformable core material on which the thermoactive resin layer is laminated to a surface temperature of 160 ° C. with an infrared heater, a skin material made of a nonwoven fabric made of polyester fiber is applied to the thermoactive resin layer surface. Laminated, transferred to a flat plate press die having a predetermined shape, compressed so that the interval becomes 4.0 mm, and held for 10 seconds to form a thermoformable core material and to attach a skin material at the same time. Was. Next, the laminate was taken out from the flat plate pressing mold to obtain a thermoformable core material to which a skin material was bonded.

When the adhesive strength of the skin material of the obtained thermoformed core material with the skin material was measured, it was confirmed that the skin material was broken and sufficient adhesive strength was obtained. When the air permeability of the obtained thermoformed core material with a skin material was measured, 0.3 cc was obtained.
/ Cm ² · sec or less, indicating that sufficient ventilation blocking properties were obtained.

Example 3 As shown in FIG. 3, a high-density polyethylene resin containing a maleic anhydride-modified polyethylene resin (MFR 0.91) (melting point) was provided on both sides of the mat-like material 31 obtained in Example 1. 135 ° C., MFR 12.0) and a thermoplastic resin film 32 having a thickness of 130 μm
Were laminated to obtain a laminate. Further, outside the laminate, a heat-resistant rigid resin layer 332 made of nylon # 6 resin (melting point 230 ° C.) and a heat-active resin layer made of maleic anhydride-modified polyethylene resin (melting point 130 ° C., MFR 10.0) 333 and a multilayer film 33 obtained by co-extrusion with a layer thickness of 10 μm / 100 μm.
Was laminated on the outside, and a laminated sheet having a thickness of about 7 mm and a weight of about 800 g / m ² was produced in the same manner as in Example 1.

In the same manner as in Example 1, a flat thermoformed core material having a thickness of about 5.5 mm and a weight of about 800 g / m ² was obtained from the produced laminated sheet. After heating the surface of the obtained flat thermoformable core material on which the thermoactive resin layer is laminated to a surface temperature of 160 ° C. with an infrared heater, a skin material made of a nonwoven fabric made of polyester fiber is applied to the thermoactive resin layer surface. Laminated, transferred to a flat plate press die having a predetermined shape, compressed so that the interval becomes 4.0 mm, and held for 10 seconds to form a thermoformable core material and to attach a skin material at the same time. Was. Next, the laminate was taken out from the flat plate pressing mold to obtain a thermoformable core material to which a skin material was bonded.

When the adhesive strength of the skin material of the thermoformed core material with the skin material was measured, it was confirmed that the skin material was broken and sufficient adhesive strength was obtained. When the air permeability of the obtained thermoformed core material with a skin material was measured, 0.3 cc was obtained.
/ Cm ² · sec or less, indicating that sufficient ventilation blocking properties were obtained.

[Example 4] As shown in FIG. 4, one side of the mat-like material 41 obtained in Example 1 has a thickness 130 made of high-density polyethylene (melting point 135 ° C, MFR 7.0).
A μm thermoplastic resin film 42 was laminated. Further, a thermoplastic resin layer 431 made of a high-density polyethylene resin (melting point 135 ° C., MFR 2.0) containing a maleic anhydride-modified polyethylene resin (MFR 0.91) and a nylon # 6 resin are provided outside the laminate. (A melting point of 230 ° C.) and a heat-active resin layer 433 of a maleic acid-modified linear low-density polyethylene (melting point of 125 ° C., MFR 10.0) having a layer thickness of 130 μm / 20.
μm / 60 μm co-extruded multilayer film 43
Having a fine through-hole having a hole diameter of 0.2 mm and a hole density of 55,555 / m ² were laminated so that the thermoactive resin layer 433 was on the outside, and the thickness was approximately the same as in Example 1. 7mm,
A laminated sheet having a weight of 800 g / m ² was prepared.

The laminated sheet was sandwiched from both sides with a glass cloth sheet coated with Teflon,
℃ hot air heating furnace, and left for 5 minutes, then transferred to a flat plate press heated to 200 ° C. while being sandwiched by glass cloth sheets, and compressed so that the thickness of the laminated sheet becomes 0.9 mm, Hold for 5 seconds. Next, the flat sheet press is spread so as to have an interval of about 7 mm, and while the laminated sheet is sandwiched between the glass cloth sheets, the sheet is transferred to a flat-plate vacuum expanding device, and the glass cloth sheet is moved from both sides at a speed of 0.5 mm / sec. , And the suction plate was widened to 6 mm to release the suction, removed, and air-cooled for 3 minutes. Next, the glass cloth sheet was peeled off, the thickness was about 5.5 mm, and the weight was about 800 g.
/ M ² of a flat thermoformable core material. The obtained thermoformable core material had a uniform thickness without any depression on the surface.

The surface of the obtained flat thermoformable core material on which the thermally active resin layer was laminated was heated to a surface temperature of 1 with an infrared heater.
After heating to 15 ° C., a urethane skin material is laminated on the surface of the thermally active resin layer, transferred to a flat plate press having a predetermined shape, compressed so that the interval becomes 4.0 mm, and held for 10 seconds to be heated. At the same time as the moldable core material was shaped, a skin material was attached. Next, the laminate was taken out from the flat plate press to obtain a thermoformable core material to which a skin material was bonded.

When the adhesive strength of the skin material of the obtained thermoformable core material with the skin material was measured, it was confirmed that the skin material was broken and sufficient adhesive strength was obtained. When the air permeability of the obtained thermoformed core material with a skin material was measured, 0.3 cc was obtained.
/ Cm ² · sec or less, indicating that sufficient ventilation blocking properties were obtained.

COMPARATIVE EXAMPLE 1 As shown in FIG. 5, a thermoplastic material comprising the same high-density polyethylene film as used in Example 1 was provided on both outer sides of the same mat-like material 51 as used in Example 1. The resin films 52 were laminated, and a laminated sheet having a thickness of about 6.9 mm and a weight of about 700 g / m ² was produced in the same manner as in Example 1. Example 1 from the prepared laminated sheet
Approximately 5.5mm in thickness and 700g / m in weight
To obtain a ² of a flat thermoformable core material.

After heating one surface of the obtained flat thermoformable core material to a surface temperature of 160 ° C. with an infrared heater, a skin material made of a nonwoven fabric made of polyester fiber is laminated on the surface, and the surface is formed into a predetermined shape. It was then transferred to a flat plate press die, compressed so that the interval became 4.0 mm, and held for 10 seconds to shape the thermoformable core material and to attach the skin material at the same time. Next, the laminate was taken out from the flat plate pressing mold to obtain a thermoformable core material to which a skin material was bonded.

Air permeability of the thermoformed core material with a skin material obtained
0.3cc / cm ^Two・ Second and ventilation cutoff
Performance was confirmed, but the adhesive strength of the skin material was measured.
Of course, the skin material peels off easily and does not provide sufficient adhesive strength
won.

[0064]

As described above, the thermoformable core material of the present invention 1 has the above-mentioned structure, so that a thermoformable core material having excellent ventilation blocking properties can be obtained as described above. A thermoformable core material to which a skin material can be bonded without providing a step is obtained.

As described above, the thermoformable core material of the present invention 2 has no depression on the surface and is excellent in air-blocking properties, and can be bonded without providing an adhesive application drying step. The skin material can be laminated with excellent properties.

The interior material according to the third aspect of the present invention has the above-mentioned structure, so that the skin material has an adhesive strength on the surface without impairing the lightness, heat resistance, heat shaping property and air permeability. It is provided in an excellent condition.

Since the methods for producing thermoformable core materials of the present inventions 4 and 5 are respectively configured as described above, thermoformable core materials having the above-described effects can be produced with good workability. .

The method for producing a thermoformable core material according to the sixth aspect of the present invention is configured as described above, so that the thermoformable core material having the above-mentioned effects and having no depression on the surface can be obtained with good workability. Can be manufactured.

[0069]

[Brief description of the drawings]

FIG. 1 is a cross-sectional view illustrating a laminating step of a laminated sheet in one embodiment of a method for producing a thermoformable core material of the present invention.

FIG. 2 is a cross-sectional view illustrating a step of laminating a laminated sheet in another embodiment of the method for producing a thermoformable core material of the present invention.

FIG. 3 is a cross-sectional view illustrating a step of laminating a laminated sheet in still another embodiment of the method for producing a thermoformable core material according to the present invention.

FIG. 4 is a cross-sectional view illustrating a step of laminating a laminated sheet in still another embodiment of the method for producing a thermoformable core material according to the present invention.

FIG. 5 is a cross-sectional view illustrating a laminating step of a laminated sheet in a conventional method for producing a thermoformable core material.

[Brief description of reference numerals]

 11, 21, 31, 41 Mat-like material 12, 22, 32, 42 Thermoplastic resin film 13, 23, 33, 43 Multilayer film 131, 231, 331, 431 Thermoplastic resin layer 132, 232, 332, 432 Heat resistance Resin layer 133, 233, 333, 433 Thermally active resin layer

──────────────────────────────────────────────────続 き Continued on the front page (58) Fields surveyed (Int.Cl. ⁶ , DB name) B32B 5/08 B32B 17/02 B32B 27/12 B60R 13/02 D04H 1/58

Claims (6)

(57) [Claims] 1. A heat-resistant stiff resin layer having a higher melting temperature than the thermoplastic resin fiber, a heat-active resin layer, and at least one outer side of a mat-like material formed mainly of inorganic fibers and thermoplastic resin fibers. Are laminated in this order. 2. The thermoformability according to claim 1, wherein a sheet-like material is formed from the heat-resistant rigid resin layer and the heat-active resin layer, and the sheet-like material has fine through holes. Core material. 3. An interior material characterized in that a skin material is laminated and shaped on the surface of the thermoactive resin layer of the thermoformable core material according to claim 1 or 2. 4. A step of laminating a thermoplastic resin film on at least one outer side of a mat-like material formed mainly of inorganic fibers and thermoplastic resin fibers to obtain a laminate, wherein at least one outer side of the laminate is obtained. On the other hand, a multilayer material comprising a thermoplastic resin layer (a), a heat-resistant rigid resin layer (b) having a higher melting temperature than the thermoplastic resin fiber and the thermoplastic resin film, and a thermoactive resin layer (c) [(a ) / (B) / (c)]
To obtain a laminated sheet by laminating the thermoactive resin layer (c) to the outside, and heating the laminated sheet at a temperature equal to or lower than the melting temperature of the heat-resistant rigid resin to form a thermoplastic resin fiber and a thermoplastic resin. Is melted and compressed, and the thermoplastic resin is impregnated into the mat-like material without impregnating the heat-resistant rigid resin and the mat-like material with the non-contact thermo-active resin. After binding inorganic fibers to each other with resin fiber and thermoplastic resin, expand in the thickness direction,
A method for producing a thermoformable core material, comprising a step of curing a thermoplastic resin fiber and a thermoplastic resin in a molten state. 5. A step of laminating a thermoplastic resin film on both sides of a mat-like material formed mainly of inorganic fibers and thermoplastic resin fibers to obtain a sandwich laminate, wherein at least one of the sandwich laminates is used. On the outside, a multilayer material [(b) / (c)] composed of a heat-resistant rigid resin layer (b) having a higher melting temperature than the thermoplastic resin fiber and the thermoplastic resin film, and a thermoactive resin layer (c), The thermoactive resin layer (c)
The laminated sheet to obtain a laminated sheet, the laminated sheet is heated at a temperature equal to or lower than the melting temperature of the heat-resistant rigid resin to melt the thermoplastic resin fibers and the thermoplastic resin and to compress the laminated sheet. The thermoplastic resin is impregnated in the mat-shaped material without impregnating the resin and the mat-shaped material with the thermo-active resin without impregnating the mat-shaped material. A method for producing a thermoformable core material, comprising a step of bonding together, expanding in a thickness direction, and curing a thermoplastic resin fiber and a thermoplastic resin in a molten state. 6. The multilayer material [(a) / (b) / (c)] is provided with fine through holes.
3. The method for producing a thermoformable core material according to item 1.