JP3188149B2 - Manufacturing method of surface material for automobile interior - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

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

[0002]

2. Description of the Related Art Conventionally, as a surface material for an automobile interior, a laminated skin material obtained by laminating a fabric skin material such as a knitted fabric or a woven fabric on the surface of a polyurethane foam having excellent volume and cushioning properties has been widely used. However, polyurethane foam has problems in terms of waste pollution and recycling, as well as cost increases,
Recently, various surface materials in which a fiber web is used as a wadding material instead of a polyurethane foam and a skin material is adhered and integrated with the wadding material have been proposed (for example, Japanese Utility Model Laid-Open No. 5-1589).
9 and JP-A-4-332590). Such a surface material is manufactured by bonding and integrating the wadding material and the skin material with a hot melt adhesive as seen in Japanese Patent Publication No. 6-98728 and Japanese Patent Application Laid-Open No. 3-87242. Is common.

However, since the hot melt adhesive is a solid at room temperature, a separate melting device is required to use the hot melt adhesive, and the production equipment becomes complicated and expensive. Gravure roll, if you try to apply adhesive in dot form to give flexibility
A special roll such as a screen roll is required, so that there is a problem that the roll manufacturing cost is increased, the versatility is low, and the number of the rolls owned by each coating pattern is increased. Furthermore,
If an attempt is made to mix an additional function imparting agent such as a flame retardant, it is necessary to change the molecular design of the hot melt adhesive, which is also troublesome.

[0004]

SUMMARY OF THE INVENTION The present invention solves the above-mentioned conventional problems and makes it possible to easily and inexpensively produce a surface material for an automobile interior without using a special device such as a melting device. The present invention has been completed for the purpose of providing a method for manufacturing a surface material for an automobile interior, which can easily provide an additional function such as a flame retardant.

[0005]

Method for producing automotive interior surface material of the present invention the above object, according to an aspect of has been made to solve the the fiber filaments between the front and back surfaces by Haritoge processing Fi
The entanglement is integrated so that the bundle of
The tip of the filament bundle protrudes from the surface as countless small bumps.
The surface of this wadding material
Roll coater with low viscosity water-based hot melt adhesive
The top of the small ridge is made into a dot-shaped adhesive part by a
And then apply heat to dissolve the aqueous hot melt adhesive.
Melt and disperse the water to give the adhesive
The present invention is characterized in that a skin material is bonded and integrated through a fitting portion .

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Although the kind of wadding material in the present invention is not particularly limited, a particularly preferred embodiment is such that a filament bundle is erected between a front surface and a back surface by needle piercing. The tip portion of the filament bundle is entangled and integrated, and a wadding material is projected from the surface as countless small protrusions. A low-viscosity water-based hot melt adhesive is applied to the surface of the wadding material by a roll coater coating machine. The tops of the ridges are applied as dots in the form of point-like adhesives, then the aqueous hot-melt adhesive is melted by heating and dispersed with water to give an adhesive ability, and then the skin material is integrally bonded through the point-like adhesives. Shall be In this case, the fiber filament used as the material of the wadding material may be either a low-melting fiber filament, a high-melting fiber filament, or a fiber filament obtained by mixing them in a web form. ~ 20mm, basis weight 50
About 1000 g / m ² .

In addition, the wadding material is entangled and integrated by a needle sticking process so that a filament bundle is erected between the front and back surfaces, and the leading end of the filament bundle forms an infinite number of loops from the surface. It is configured so as to protrude as a small ridge, and the skin material is bonded and integrated with the top of the small ridge as a point-like adhesive portion.
The filament bundle is erected between the front and back surfaces of the wadding material to sufficiently reinforce the wadding material, thereby properly preventing the sag from occurring and acting to ensure excellent cushioning properties. The shape-bonded portion acts to ensure excellent adhesive strength and excellent air permeability and texture.

In the present invention, it is particularly important to bond the wadding material and the skin material with an aqueous hot melt adhesive, and it is preferable to apply the aqueous hot melt adhesive in a dot form. That is, by using a water-dispersible aqueous hot-melt adhesive made of, for example, a saturated copolymerized polyester resin that can be dissolved and dispersed in an aqueous solvent, it is possible to eliminate a melting device that is indispensable in the case of a conventional hot-melt adhesive. Becomes possible. Also, as described above, by applying the tops of the small ridges of the wadding material in a dot-like manner as a point-like adhesive portion, application using a general roll coater coating machine without using a special gravure roll or the like as in the related art. In addition, it is possible to ensure excellent air permeability and texture and to reduce the amount of adhesive used.

Such a water-based hot-melt adhesive is applied to a wadding material, and then subjected to a heat treatment using a far-infrared ray method or a hot air method to disperse water and melt the hot-melt adhesive, thereby producing an adhesive ability. In this state, the skin material is bonded and bonded and integrated, and thus complete bonding can be achieved. In addition, since this water-based hot melt adhesive has a low viscosity, an organic halogen compound is preliminarily mixed as a flame retardant in an amount of about 30% by weight, and a water repellent, an antifouling agent, an antistatic agent, a deodorant, One or more additional function imparting agents such as an antibacterial agent and a fogging agent can be mixed, and various additional functions such as flame retardancy can be added. In addition, if the viscosity of the aqueous hot melt adhesive is set to about 2000 to 7000 cps, it is possible to apply the film efficiently by a roll coater coating machine.

A high-density nonwoven fabric surface layer may be laminated on the front side of the wadding material. In this case, the fiber filaments are entangled by a needle stick process so that a filament bundle is erected between the front and back surfaces. When integrated, the surface of the high-density nonwoven fabric structure layer is superimposed on the surface, and the tip of the filament bundle protruding from the surface is protruded from the surface of the high-density nonwoven structure surface as innumerable small protrusions by needle sticking,
In this case, the strength of the wadding material is further improved and the entanglement with the filament bundle is further strengthened, which is preferable. As such a high-density nonwoven fabric surface layer, 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
Generally, a nonwoven fabric sheet of about g / m ² is used, but the material is not limited to such a material as long as it can have the above-described configuration by needle sticking.

On the other hand, as a skin material that is bonded and integrated to the surface of a fiber-based laminated wadding material, there is no problem in terms of disposal and pollution, as well as a fabric skin material such as a knitted fabric, a woven fabric, or a non-woven fabric. Those having a certain degree of wear resistance are preferred. When the surface layer of the high-density nonwoven fabric is laminated as a reinforcing sheet, a mass that is conventionally rarely used alone is 23 for strength reasons.
Even if a low-weight fabric skin material of about 0 to 360 g / m ² is used, the required strength can be obtained in the vertical, horizontal, and bias directions. Use is also possible.

[0012]

Next, an embodiment of the present invention will be described with reference to FIG. A low-viscosity aqueous hot-melt adhesive obtained by mixing an additional function imparting agent such as a flame retardant with a roll coater coating machine 11 on the surface of the wadding material 1 supplied from the wadding material unwinding device 10 (manufactured by Toa Gosei Chemical Industry Co., Ltd.) (1155A30) of the saturated copolymerized polyester resin Aronmelt PES series is applied in the form of dots and then heated by a heating device 12 to disperse the aqueous hot melt adhesive in water and to melt the hot melt adhesive. State. Then, under this state, the skin material unwinding device 13
After the skin material 2 is further supplied and bonded to the wadding material 1, the product is pressed by a pressing device 14 and the two are bonded and integrated, and the product is wound by a winding device 15 to obtain a product. In the present invention, in the above-mentioned adhesive application step, as shown in FIG.
When the water-based hot melt adhesive is applied by the roll coater coating machine 11 because the filament bundles 3 are entangled and integrated so as to stand, and the tip end of the filament bundle 3 protrudes from the surface as countless small bumps 4. The tops of the small ridges 4 are applied in a dot-like manner as a point-like bonding portion 5, and the bonding between them is integrated through the point-like bonding portion 5.

[0013] The car interior surface material produced as described above is, for example, cut to an arbitrary size by a known means and then sewn to form a seat cover in the same manner as a conventional car interior surface material. When this is coated on a pad material, the appearance is the same as the conventional method of manufacturing this kind of interior surface material for automobile interiors, but the fiber-based material used in place of polyurethane foam as a pressure material The wadding material 1 is entangled and integrated so that the filament bundle 3 is erected between the front and back surfaces by needle piercing, and has a volume comparable to that using polyurethane foam as the base layer. In addition, even when the wadding material 1 having a large thickness is used, excellent cushioning can be achieved without sagging.

Moreover, the bonding of the skin material 2 to the wadding material 1 is not surface bonding, but is point bonding with the small ridge 4 at the tip of the filament bundle 3 protruding to the front side of the wadding material 1, so that both are sufficient. In addition to being bonded and integrated with bonding strength, the point bonding at the countless point-like bonding portions 5 impairs the elasticity and texture of the skin material regardless of what kind of skin material is used. Nothing. In addition, the skin material 2 is integrated with the wading material 1 while maintaining a certain degree of freedom, and therefore, whatever type of the skin material 2 is used, There is no loss of the elastic properties and texture of the adhesive. Furthermore, since the bonding between them is countless dot-shaped point bonding, sufficient air permeability as a seat cover can be secured. In particular, when the high-density nonwoven fabric surface layer 6 is laminated on the surface side of the wadding material 1, the strength of the wadding material 1 is further improved, and the entanglement with the filament bundle 3 is further strengthened, which is preferable.

[0015]

As is clear from the above description, according to the present invention, when the skin material is bonded and integrated on the surface of the wadding material, it is easily applied by a roll coater coating machine because it has a low viscosity as an adhesive. In addition, water-based hot-melt adhesive is used, which disperses and melts water by heating after coating and exhibits excellent adhesion. It can be produced easily and inexpensively without using it, and it can also be easily provided with additional functions such as a flame retardant. Use a fiber-based wadding material that is entangled and integrated so that the tip of the filament bundle protrudes from the surface as countless small protrusions, and protrudes from the surface of the wadding material. When the above-mentioned water-based hot melt adhesive is applied in the form of dots with the tops of the small ridges as point-like adhesive portions, and the skin material is adhered and integrated with the adhesive by imparting the adhesive ability, it is necessary to avoid waste pollution or recycling. Surface materials for automotive interiors that have no problems of strength and strength, and that have sufficient adhesive strength with the skin material required for automobiles, and also have excellent air permeability and flexibility. There is an effect that it can be easily and inexpensively produced. Therefore, the present invention has an extremely large contribution to industrial development as a method for producing a surface material for automobile interiors that has eliminated the conventional problems.

[Brief description of the drawings]

FIG. 1 is a front view showing the entire production equipment of the present invention.

FIG. 2 is a front view of a main part in FIG.

FIG. 3 is a sectional view showing a surface material for an automobile interior produced according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Wadding material 2 Skin material 3 Filament bundle 4 Small ridge 5 Point bonding part 6 High density nonwoven fabric surface layer

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-3-87242 (JP, A) JP-A-54-101978 (JP, A) JP-A-2-17960 (JP, A) Nikkei Technical Books Co., Ltd. Issued "Adhesion Application Technology" Published April 1, 1991, 1st edition P 157-159 (58) Fields investigated (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 B60R 13/00- 13/08

Claims (4)

(57) [Claims] 1. A front and back side of a fiber filament by a needle piercing process.
Entangling and unifying so that the filament bundle stands between the surfaces
In each case, the tip of the filament bundle is innumerably smaller than the surface.
The wadding material that protrudes as a starting material
Roll a low-viscosity aqueous hot-melt adhesive on the surface of
Using a coater coating machine, the top of the small ridge is used as a point-like adhesive part.
Water-based hot melt by applying
Melt the adhesive and disperse the water to give the adhesive ability
Bonding and integrating the skin material through this point-like bonding part
A method for producing a surface material for automobile interiors. 2. The aqueous hot melt adhesive is mixed with at least one additional function imparting agent such as a flame retardant, a water repellent, an antifouling agent, an antistatic agent, a deodorant, an antibacterial agent, and a fogging agent. The method for producing a surface material for an automobile interior according to item 1 . 3. The water-based hot melt adhesive has a viscosity of 200.
3. The method for producing a surface material for an automobile interior according to claim 1, wherein the surface material is 0 to 7000 cps. 4. When a fiber filament is entangled and integrated by needle piercing so that a filament bundle is erected between the front and back surfaces, a filament protruding from the surface by needle piercing with a high-density nonwoven fabric surface layer superimposed on the surface. claim to bond and integrate the skin material to the top of the nub of the bundle as a point-like bonding portion 1 or
4. The method for producing a surface material for an automobile interior according to 2 or 3 .