JP3096206B2 - Automotive interior surface materials - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a surface material for a vehicle interior such as a door trim, a ceiling trim, and a seat cover of a vehicle.

[0002]

2. Description of the Related Art As this kind of surface material for automobile interior, as shown in Japanese Utility Model Laid-Open No. 1-103400, a fabric surface such as a knitted fabric or a woven fabric is formed on the surface of a polyurethane foam excellent in volume and cushioning properties. Laminated skin materials have been used in many cases.However, in this type of laminated skin material, polyurethane foam has insufficient strength. As a result, this increases the cost, and the polyurethane foam has problems in terms of waste pollution and recycling.

[0003] In order to solve such problems, recently, a fiber web is used as a wadding material instead of polyurethane foam which has problems in terms of waste pollution or recycling and also has a problem in strength, and a skin material is used as a wadding material. Adhesive-integrated surface materials for automobile interiors have also been proposed in Japanese Utility Model Laid-Open Publication No. Hei 5-15899 and Japanese Patent Laid-Open Publication No. Hei 4-332590, but those in which a skin material is adhesively integrated with a fiber web require a small amount of adhesive. If the skin material is to be adhered to the surface, there is a problem that the adhesive strength required for automobiles cannot be obtained due to the fluffing of the surface of the fibrous web, and the use of a large amount of adhesive impairs the feeling due to this adhesive. Also, even when the skin material is bonded and integrated with the fiber web, the low-density fiber web does not have sufficient strength. You can use the skin material, which becomes the cause of the high cost backing is required. Furthermore, the surface material for automobile interiors needs to be subjected to a flame retardant treatment as a fire prevention measure. However, there is also a problem that the flame retardant treatment for a fiber web having a considerable thickness increases costs.

Therefore, the present applicant has solved the above-mentioned problems by first bonding and integrating a skin material to a laminated wadding material in which a low-density fiber web and a high-density nonwoven fabric are entangled and integrated. However, if the skin material is bonded and integrated with the laminated wadding material by a normal bonding method, the laminated wadding material and the skin material are completely bonded, and therefore, depending on the type of the skin material, the skin material may have It has been found that the elastic properties and texture are impaired by adhesion, the types of skin materials are limited, and there are many problems in practical use from the viewpoint of cost.

[0005]

An object of the present invention is to solve all of the above-mentioned problems, and to solve the problem of waste pollution or recycling, and the problem of polyurethane having a problem in strength. Uses a fiber-based wadding material without using foam, has the necessary adhesive strength to the skin material required for automobiles, and has a strength problem such as a low-weight fabric skin material as the skin material. The aim is to provide an inexpensive surface material for automobile interiors that has sufficient strength as a whole, even if a skin material with a coating is used, and that does not impair the properties of various skin materials due to adhesion. is there.

[0006]

The automobile interior surface material of the present invention which has solved the above-mentioned problems has a low-density nonwoven fabric structure.
The base layer and the surface layer of the high-density nonwoven fabric are entangled by needle sticking.
The surface of the low-density nonwoven fabric base layer
Part of the filament is innumerably smaller than the surface layer of the high-density nonwoven fabric.
Front side of fiber-based laminated wadding material protruding as a bump
Then, a skin material is bonded with the top of the small ridge as a point-like bonding portion.
It is characterized by being embodied.

[0007]

When used as a surface material for a vehicle interior such as a door trim or a ceiling trim of a vehicle interior or a seat cover, the appearance of the vehicle interior material is the same as that of a conventional vehicle interior material. Although it is not different from the surface material for the fabric, the fiber-based laminated wadding material used in place of polyurethane foam as a pressure material has a low density nonwoven structure base layer and a high density nonwoven structure surface layer It is entangled and integrated, and the low-density nonwoven fabric base layer exhibits a volume feeling and cushioning property comparable to those using a polyurethane foam. Moreover, the adhesion of the skin material to the laminated wadding material is not surface adhesion to the low-density nonwoven fabric base layer having a lot of fluff, but to the high density nonwoven fabric structure layer having little fluff which is entangled and integrated with the low density nonwoven structure base layer. Both are bonded and integrated with sufficient adhesive strength because they are point-bonded, and the point-bonding at countless point-like bonded parts makes it possible to expand and contract the skin regardless of the type of skin used. The properties and texture are not impaired by adhesion.

In particular, in the present invention, a fibrous laminated wadding material is used in which a number of small ridges are formed on the surface of the surface layer of the high-density nonwoven fabric structure, in which countless small ridges from which a part of the fiber filaments of the low-density nonwoven structure base are drawn out. this because a fiber based laminate wadding material and surface material are integrally bonded to the top of the small ridge as point-like bonding portion, the skin material for a part of the small ridge low density nonwoven fabric base layer is peeled off When a tensile force is applied in the direction in which the low density nonwoven fabric structure base layer is applied, the peeling force applied to the skin material is increased when the skin material is bonded to the high density nonwoven fabric structure surface layer. In addition to being attenuated, the fiber filaments constituting the small ridges expand and contract, thereby exhibiting excellent adhesive strength and increasing the degree of expansion and contraction of the skin material.

[0009]

Next, an automobile seat cover using the present invention will be described in detail as an embodiment. Reference numeral 1 denotes a fibrous laminated wadding material in which a low-density nonwoven fabric base layer 2 and a high-density nonwoven fabric surface layer 3 are entangled and integrated by needle sticking, and 6 is a skin material bonded and integrated to the surface thereof. In Examples, polypropylene-based fibers are used as the low-density nonwoven fabric base layer 2,
Polyester fibers, polyamide fibers and other fibers are mixed and entangled in a web shape.
1000 g / m ^2, preferably about 3-7 mm thick, with a basis weight of 150
Using a fiber web ~200g / m ^2. The fiber used as the material of the low-density nonwoven fabric base layer 2 is such that a hollow fiber is mixed with a regular fiber when a sense of volume is particularly required. It may be selected and used according to the purpose, such as a composite type heat-fusible fiber composed of a melting point component. In the case where rebound resilience is particularly required, 3 to 20 fibers / inch without entanglement of the composite fiber The crimping may be performed to the degree. On the other hand, as the high-density nonwoven fabric surface layer 3, a thickness of 0.3 to 2 mm made of polypropylene fiber, polyester fiber, polyamide fiber, etc. having good abrasion resistance and commercially available, which is called spunbond, has a basis weight of 5 to 5 mm.
200 g / m ² and preferably about a thickness 0.5 to 1.5 mm, but to use a basis weight 10 to 100 g / m ² approximately nonwoven fabric sheet is generally, take the like configured by Haritoge machining It is not limited to such a material as long as it can be made.

The low-density nonwoven fabric base layer 2
And the high-density nonwoven fabric surface layer 3 are such that the number of penetrations is 30 to 200 and the driving depth is 5 to 1 from the front side of the high density nonwoven structure surface layer 3.
A part of the fiber filaments of the low-density nonwoven fabric base layer 2 enters the high-density nonwoven fabric surface layer 3 by needle-piercing under the condition of about 5 mm, and a part of the fiber filaments of the high-density nonwoven structure surface layer 3 becomes low-density nonwoven fabric base. At the same time as being entangled and integrated into the layer 2, a part of the fiber filaments of the low-density nonwoven fabric base layer 2 protrude from the surface thereof through the high-density nonwoven structure surface layer 3 as countless small ridges 2 a to form a high-density nonwoven structure. The surface of the surface layer 3 is formed as an uneven surface.

In the embodiment, the low-density nonwoven fabric base layer 2 is not subjected to the flame-retardant treatment but only the high-density non-woven structure surface layer 3 is subjected to the flame-retardant treatment. When viewed, the surface side is flame-retarded, and the low-density nonwoven fabric base layer 2 is subjected to odor prevention and other necessary treatments as necessary. Further, when the surface of the low-density nonwoven fabric structure layer 3 is attached to the surface of the low-density nonwoven fabric structure base layer 2 and entangled and integrated by needle sticking, as shown in the figure,
It is preferable that the backing material 4 is also attached to the back surface to integrate the two together, since the durability and strength of the fibrous laminated wadding material 1 are further improved. When the low-density nonwoven fabric base layer 2 and the high-density nonwoven fabric surface layer 3 are entangled and integrated by needle sticking, the backing material 4 is also integrated at the same time when the nonwoven fabric sheet is used. . In addition, at the time of the above-described needle piercing, a reinforcing material such as a metal fiber made of vegetable fiber or a synthetic resin net is interposed between the low-density nonwoven fabric base layer 2 and the high-density nonwoven fabric surface layer 3 to reinforce, The interposition of a material for adjusting the strength in the lateral and bias directions may be arbitrarily performed.

On the other hand, the skin material 6 bonded and integrated to the surface of the fibrous laminated wadding material 1 does not have any problem in terms of waste pollution in fabrics such as knitted fabrics, woven fabrics and nonwoven fabrics, and is required as a skin material. Any type may be used as long as it has a certain degree of abrasion resistance.
Even if a low-weight fabric skin material of about 60 g / m ² is used, the vertical high
Since the required strength is obtained in both the lateral and bias directions, such a low-weight fabric skin material can be used in view of cost.

The adhesive for bonding the laminated wadding material 1 and the skin material 6 is to bond the high density nonwoven fabric surface layer 3 forming the surface layer of the laminated wadding material 1 and the skin material 6 with sufficient adhesive strength. If so, the type is not particularly limited, but it is preferable to use a water-soluble adhesive such as an emulsion of an acryl-vinyl acetate copolymer in consideration of the work environment. Then, the laminated wadding material 1 and the skin material 6 are bonded and integrated at the innumerable point-like bonding portions 5 using this adhesive, and the amount of use thereof may be 300 g / m ² or less because the entire surface is not bonded. As described in the above embodiment, the low density nonwoven fabric base layer 2 and the high density nonwoven fabric surface layer 3 are used as the fiber-based laminated wadding material 1 so that a part of the fiber filaments of the low density nonwoven fabric base layer 2 has a high density. When using a surface having an uneven surface formed by entanglement by needle sticking so as to protrude from the surface of the nonwoven fabric structure surface 3 as countless small protrusions 2a, water is applied to the top of each small protrusion 2a. The top of each small ridge 2a is adhered and integrated as a point-like adhesive portion 5 by applying a hydrophilic adhesive, superimposing the high-density nonwoven fabric surface layer 3 and pressing with a pressing roll. In this way, when the tops of the small ridges 2a are bonded and integrated as the point-like bonding portions 5, extremely flexible bonding can be obtained by the expansion and contraction of the small ridges 2a.

[0014] In the same manner as a conventional surface material for an automobile interior, this structure is cut into an arbitrary size by a known means and then sewn to form a seat cover, which is used as a pad material. When coated, the appearance is not different from the conventional surface material for automobile interiors, but the fiber-based laminated wadding material 1 used in place of polyurethane foam as a pressure-resisting material has a low-density nonwoven fabric structure. The base layer 2 and the high-density nonwoven fabric surface layer 3 are entangled and integrated by needle piercing, and the low-density nonwoven fabric base layer 2 is not inferior to that using a polyurethane foam. It will exhibit a sense of volume and cushioning.

Moreover, the bonding of the skin material 6 to the laminated wadding material 1 is not surface bonding to the low-density nonwoven fabric base 2 having a large amount of fluff, but is less entangled and integrated with the low density nonwoven structure base layer 2. Since the adhesive is applied to the high-density nonwoven fabric surface layer 3, both are bonded and integrated with sufficient adhesive strength, and the insufficient strength of the skin material 6 lined with the high-density nonwoven structure surface layer 3 is eliminated. Moreover, the high-density nonwoven fabric surface layer 3
The bonding portion between the skin material 6 and the skin material 6 is not the entire surface but a point bonding at an infinite number of point-like bonding portions 5. Therefore, the skin material 6 is integrated with the laminated wadding material 1 while maintaining a certain degree of freedom. Therefore, no matter what kind of the skin material 6 is used, the elasticity and texture of the skin material 6 are not impaired by the adhesion.

Further, as in the embodiment, a number of small ridges 2a, from which a part of the fiber filaments of the low-density nonwoven fabric layer 2 are drawn out, are formed on the surface of the surface layer 3 of the high density nonwoven fabric structure. When the fibrous laminated wadding material 1 and the skin material 6 are bonded and integrated by using the material 1 and the tops of the small ridges 2 a as the point-like adhesive portions 5, the force in the direction of peeling off from the skin material 6 is obtained. Is added and small ridge 2a
Since the subsequent fiber filaments are part of the low-density nonwoven fabric structure layer 2, the low-density nonwoven fabric structure layer 2 itself is pulled up together with the skin material 6, so that the skin material 6 is directly bonded to the high-density nonwoven fabric surface layer 3. It is much harder to peel off than in the case, and a sufficient adhesive strength can be obtained in combination with flexibility due to expansion and contraction of a part of the fiber filament constituting the small ridge 2a, and at the same time, the degree of freedom of expansion and contraction of the skin material 6 is increased. There is a feature that can be.

[0017]

As apparent from the above description, the present invention provides a fiber-based laminated wadding material and a skin material in which a low-density nonwoven structure base layer and a high-density nonwoven structure surface layer are entangled and integrated by needle sticking. It is bonded and integrated at a myriad of point-like adhesive parts, and because it does not use polyurethane foam, there is no problem on disposal pollution and recycling is possible, and as a skin material, a low-weight fabric skin material etc. Even if an inexpensive skin material with a problem in strength is used, it has sufficient strength as a whole, and furthermore, the characteristics of various skin materials are not impaired by adhesion. Has various advantages that cannot be seen. Accordingly, the present invention has solved the problems of the conventional surface materials for automobile interiors, and there is an extremely large one that contributes to the development of the industry together with the advantage that the cost can be significantly reduced.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an embodiment of the present invention.

FIG. 2 is a cross-sectional view showing an embodiment of a laminated wadding material according to the present invention.

FIG. 3 is a cross-sectional view showing another embodiment of the laminated wadding material according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Laminated wadding material 2a Small ridge 2 Low-density nonwoven fabric base layer 3 High-density nonwoven fabric surface layer 5 Point bonding part 6 Skin material

────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Yoichi Fujiyama 3867 Kuroishi, Shimada, Tenpaku-cho, Tenpaku-ku, Nagoya-shi, Aichi (56) References JP-A-61-135614 (JP, A) (58) Fields investigated (Int.Cl. ⁷ , DB name) B68G 5/00 B68G 11/02

Claims (1)

(57) [Claims] 1. A low-density nonwoven fabric base layer (2) and a high-density nonwoven fabric base layer (2)
Entangled and integrated with the nonwoven fabric surface layer (3) by needlestick
One of the fiber filaments of the low-density nonwoven fabric base layer (2)
Countless small protrusions from the surface of the high-density nonwoven fabric surface layer (3)
(2a) of fiber-based laminated wadding material (1)
The skin material (6) is placed on the front side, and the top of the small ridge (2a) is point-like bonded.
(5) An automobile characterized by being integrated by bonding
Interior surface materials.