JP4197280B2 - Interior skin material with excellent design and texture - Google Patents
Interior skin material with excellent design and texture Download PDFInfo
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- JP4197280B2 JP4197280B2 JP2003284601A JP2003284601A JP4197280B2 JP 4197280 B2 JP4197280 B2 JP 4197280B2 JP 2003284601 A JP2003284601 A JP 2003284601A JP 2003284601 A JP2003284601 A JP 2003284601A JP 4197280 B2 JP4197280 B2 JP 4197280B2
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Description
本発明は模様付けされ意匠性に優れた内装表皮材ならびにその製造方法に係り、例えば天井材，ドアトリム材，リヤーパッケージ材など、自動車内装材に用いて好適な内装表皮材ならびにその製造方法に関する。
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior skin material that is patterned and has excellent design properties, and a method for producing the interior skin material, and more particularly to an interior skin material that is suitable for use in automobile interior materials such as ceiling materials, door trim materials, and rear package materials.
従来、自動車内装用の表皮材には不織布が広く使用され、なかでもソフトな風合いを有するものとして、ニードルパンチ不織布の表や裏面に樹脂によるスプレーやディッピングを施した表皮材と基材とを接着したものが用いられている。
Conventionally, non-woven fabrics have been widely used for automotive interior skin materials. In particular, the surface and back surfaces of needle punched non-woven fabrics are bonded to a base material that has been sprayed or dipped with resin. Is used.
そして、このような不織布表面にエンボス模様を形成した車両用内装表皮材や各種用途に使用される不織布も知られている。（例えば特許文献１，２参照）
And the interior skin material for vehicles which formed the embossed pattern in such a nonwoven fabric surface, and the nonwoven fabric used for various uses are also known. (For example, see Patent Documents 1 and 2)
ところが上述した従来の車両用内装表皮材に使用する不織布は目付が低いため、成型時や表面の繊維間の接着を十分にするための樹脂を使用せざるを得なく、そのために表皮材としては充分にソフトさを満足するものではない。
However, since the nonwoven fabric used for the above-described conventional vehicle interior skin material has a low basis weight, it is necessary to use a resin for sufficient adhesion between the fibers on the surface and molding, and as a skin material for that purpose. Not enough softness.
本発明は上記従来の技術に鑑み、その問題を解消すべく、特に表皮材として成型性が優れ、表面をソフトにするために樹脂を使用することなく、繊維間の接着が良く、しかも表面が模様付けされ意匠性に優れた内装表皮材および内装表皮材の製造方法を提供することを目的とするものである。
In view of the above-described conventional technology, the present invention is excellent in moldability as a skin material, in particular, without using a resin to make the surface soft, and has good adhesion between fibers, and the surface is excellent. An object of the present invention is to provide an interior skin material that is patterned and has excellent design properties, and a method for producing the interior skin material.
本発明は上記の目的を達成するために高融点繊維と熱融着性繊維の短繊維からなる繊維層を基材とし、繊維間の交絡をニードル加工によって行い、かつ繊維層の繊維間を熱融着性繊維の溶融によって互いに接着させると共に、更にエンボスローラによる模様付け処理を行うことによって不織布の表裏少なくとも一面の一部を熱圧着せしめ、１００ｇ／ｍ２当たりの織圧縮弾性率を０．６ｇ／ｍｍ３〜１．２ｇ／ｍｍ３，剛軟度を２０ｍｍ〜２００ｍｍの範囲となした不織布である。
In order to achieve the above object, the present invention uses a fiber layer composed of high-melting point fibers and short fibers of heat-fusible fibers as a base material, entangles the fibers by needle processing, and heats the fibers of the fiber layer between the fibers. By fusing the fusible fibers, they are bonded to each other and further subjected to a patterning treatment with an embossing roller, so that at least part of the front and back surfaces of the nonwoven fabric is thermocompression bonded, and the woven compression elastic modulus per 100 g / m 2 is 0.6 g. / Mm 3 to 1.2 g / mm 3 , and a nonwoven fabric having a bending resistance of 20 mm to 200 mm.
ここで高融点繊維としては、例えばポリエステル系繊維，ポリエチレン系繊維，ポリプロピレン系繊維，ポリアミド系繊維などの熱可塑性繊維やレーヨン繊維，綿，麻，芳香族ポリアミド繊維などの熱不溶融性繊維などが挙げられるが、なかでもポリエステル系繊維，ポリエチレン系繊維，ポリプロピレン系繊維，ポリアミド系繊維は好適である。
Examples of the high melting point fiber include thermoplastic fibers such as polyester fibers, polyethylene fibers, polypropylene fibers, and polyamide fibers, and heat infusible fibers such as rayon fibers, cotton, hemp, and aromatic polyamide fibers. Among them, polyester fiber, polyethylene fiber, polypropylene fiber, and polyamide fiber are preferable.
また、熱融着性繊維としては、例えばポリエステル系樹脂，ポリエチレン系樹脂，ポリプロピレン系樹脂，ポリアミド系樹脂の何れかの熱可塑性樹脂の高融点成分と低融点成分からなる芯鞘型，サイドバイサイド型の何れかの複合繊維である。
代表例として、ポリエステル繊維（融点２５０℃〜２７０℃程度）と低融点ポリエステル繊維（融点１００℃から２００℃程度）の複合繊維，エステル／ナイロン複合繊維，ポリエステル／ポリエチレン複合繊維，ポリプロピレン／ポリエチレン複合繊維などが挙げられる。
そして、これら高融点繊維と熱融着性繊維からなる繊維層の混繊比率は高融点繊維／熱融着性繊維で７０／３０〜９５／５の範囲が好適である。
In addition, as the heat-fusible fiber, for example, a core-sheath type or a side-by-side type composed of a high melting point component and a low melting point component of a thermoplastic resin of any one of a polyester resin, a polyethylene resin, a polypropylene resin, and a polyamide resin. Any composite fiber.
Representative examples include composite fibers of polyester fibers (melting point: 250 ° C. to 270 ° C.) and low melting point polyester fibers (melting point: 100 ° C. to 200 ° C.), ester / nylon composite fibers, polyester / polyethylene composite fibers, polypropylene / polyethylene composite fibers. Etc.
And the fiber mixing ratio of the fiber layer which consists of these high melting point fibers and heat-fusible fiber has the suitable range of 70 / 30-95 / 5 with high melting point fiber / heat-fusible fiber.
また、本発明の第２の特徴は、上記内装表皮材の製造方法として、繊維層が高融点繊維と熱融着性繊維の短繊維からなり、熱融着性繊維を５〜３０質量％含有する繊維層にニードル加工を施し、次いでホットエアースルー法により熱風処理して繊維層中の熱融着性繊維を溶融して高融点繊維を互いに接着させ、不織布とした後、ローラーで繊維層内の厚さと繊維間の接着を調整して巻き取り、該巻き取った不織布をエンボスローラーに通しエンボスカレンダーによる処理により一部が熱圧着された不織布とするか、前記ニードル加工を施した不織布を加熱されたエンボスローラーに通し、エンボスカレンダーによる処理により繊維層中の熱融着性繊維を融着し、互いに接着すると共に一部が熱圧着された不織布とし、かつ、１００ｇ／ｍ２当たりの圧縮弾性率を０．６ｇ／ｍｍ３〜１．２ｇ／ｍｍ３，剛軟度が２０ｍｍ〜２００ｍｍの範囲となるように加工することである。
The second feature of the present invention is that, as a method for producing the interior skin material, the fiber layer is composed of short fibers of high melting point fibers and heat fusible fibers, and contains 5 to 30% by mass of heat fusible fibers. The fiber layer is subjected to needle processing, then hot air treated by a hot air-through method to melt the heat-fusible fibers in the fiber layer to bond the high melting point fibers to each other to form a nonwoven fabric, and then in the fiber layer with a roller The thickness and the adhesion between the fibers are adjusted and wound, and the wound nonwoven fabric is passed through an embossing roller to make a nonwoven fabric partly thermocompression bonded by treatment with an embossing calendar, or the needle processed nonwoven fabric is heated. The heat-fusible fibers in the fiber layer are melted by passing through the embossed roller and processed with an embossing calendar to form a non-woven fabric that is bonded to each other and partially heat-bonded, and is 100 g / m 2 The compressive modulus 0.6g / mm 3 ~1.2g / mm 3 of or bending resistance is be processed to be in the range of 20Mm～200mm.
上述した本発明内装表皮材は、成型性が良好であると共に、従来、問題となっていた模様状態も鮮明で、特に接着剤を用いないためソフトさを有し、しかも模様付けされたエンボスカレンダー処理により意匠性に優れ、天井材，ドアトリム材，リアパッケージ材などの内装表皮材に使用して極めて好適である。
The above-described interior skin material of the present invention has a good moldability and has a clear pattern which has been a problem in the past, and has a softness because no adhesive is used. It has excellent design properties due to its treatment, and is extremely suitable for use in interior skin materials such as ceiling materials, door trim materials, and rear package materials.
本発明は前述のように、先ず、基本的に高融点繊維と、熱融着性繊維の混繊からなる繊維層からなり、その高融点繊維／熱融着性繊維の比率が７０／３０〜９５／５の範囲のものが用いられる。
即ち、成型性の面より熱融着性繊維を５．０質量％以上、とりわけ１０．０質量％以上を含ませることが好ましく、また、製品の硬さや表面のソフトさのために３０質量％以下、好ましくは２５質量％以下、含有せしめるものである。
５質量％以下では成型性に難があり、３０質量％以上では製品が硬くなり、外観的に好ましくない。
そして、上記混繊された繊維層は、ニードル加工して一度巻き取り、また好ましくは熱風処理によって含有されている熱融着性繊維の低融点成分を溶融し、混繊されている高融点繊維と融着し、一体となって表皮材の基礎となる不織布を形成する。
As described above, the present invention is basically composed of a fiber layer composed of a mixed fiber of a high melting point fiber and a heat fusible fiber, and the ratio of the high melting point fiber / the heat fusible fiber is 70/30 to The thing of the range of 95/5 is used.
That is, it is preferable that the heat-fusible fiber is contained in an amount of 5.0% by mass or more, particularly 10.0% by mass or more in terms of moldability, and 30% by mass due to the hardness of the product and the softness of the surface. The content is preferably 25% by mass or less.
If it is 5% by mass or less, moldability is difficult, and if it is 30% by mass or more, the product becomes hard, which is not preferable in appearance.
Then, the mixed fiber layer is needle-processed and wound up once, and preferably melted the low-melting-point component of the heat-fusible fiber contained by hot air treatment, and the mixed high-melting fiber Are fused together to form a non-woven fabric that forms the basis of the skin material.
ニードルパンチ不織布の目付は、成型的にスケや破れが生じにくいようにするためには、５０ｇ／ｍ２以上、就中、８０ｇ／ｍ２以上とすることが好ましく、また軽量化の点からは３００ｇ／ｍ２、就中、２００ｇ／ｍ２が好ましい。
なお、ニードルパンチによる繊維の交絡処理は表面に起毛を起こし易いので、出来るだけ両面を均一にパンチすることが必要である。
The basis weight of the needle punched nonwoven fabric is preferably 50 g / m 2 or more, and more preferably 80 g / m 2 or more in order to prevent the occurrence of scaling and tearing, and from the viewpoint of weight reduction. 300 g / m 2 , especially 200 g / m 2 is preferred.
In addition, since the fiber entanglement process by the needle punch tends to raise the surface, it is necessary to punch both surfaces as uniformly as possible.
そして、ニードルパンチ処理された繊維層に対し熱風処理をする場合は、熱風が繊維層の厚さ方向に貫通するホットエアースルー方式（熱風貫通処理）がよく、熱風並行流のピンテンター方式では繊維層の内部とのむらを起こし易いので好ましくない。
ホットエアースルー方式は繊維層の表面と内層の温度差が少なく、高融点繊維と熱融着性繊維が立体的に接着するのに効果的である。
処理温度としては、熱融着性繊維の低融点の融点温度の５０℃以上の温度が好ましい。
When hot air treatment is performed on the needle punched fiber layer, the hot air through method (hot air penetration treatment) in which the hot air penetrates in the thickness direction of the fiber layer is good, and in the hot air parallel flow pin tenter method, the fiber layer It is not preferable because it is likely to cause unevenness with the inside of the.
The hot air through method has a small temperature difference between the surface of the fiber layer and the inner layer, and is effective for three-dimensionally bonding the high melting point fiber and the heat-fusible fiber.
The treatment temperature is preferably a temperature of 50 ° C. or higher, which is the low melting point temperature of the heat-fusible fiber.
なお、上記熱風処理された繊維層はその後、直ちにローラーにより厚さと繊維間の接着のコントロールをする。この場合、ローラーの温度とローラー間の間隔が重要である。
ローラーの温度範囲は熱風処理温度に対して９０℃から１５０℃以下の範囲が好ましい。熱風処理温度とローラーの温度の温度差が少ないと表面が硬くなり、全体に厚さが薄くなる。
逆に温度差が大きいと厚さのコントロールが出来ず、繊維間の接着が不十分となり、好ましくない。従って、通常、熱風処理温度に対して９０℃〜５０℃以下の温度範囲とすることが好適である。
The fiber layer treated with hot air is then immediately controlled for thickness and adhesion between fibers by a roller. In this case, the temperature of the roller and the distance between the rollers are important.
The temperature range of the roller is preferably in the range of 90 to 150 ° C. with respect to the hot air treatment temperature. When the temperature difference between the hot air treatment temperature and the roller temperature is small, the surface becomes hard and the thickness becomes thin as a whole.
On the other hand, if the temperature difference is large, the thickness cannot be controlled and adhesion between fibers becomes insufficient, which is not preferable. Therefore, it is usually preferable to set the temperature range to 90 ° C. to 50 ° C. or less with respect to the hot air treatment temperature.
次に上記所望の厚さと繊維間の交絡処理を行ったもの、あるいは更に繊維間の接着を行って得た不織布に対し、種々の凹凸を有する模様のエンボスロールに通すことにより模様付けされ意匠性を有する均一で成型性に優れた不織布とする。
エンボスローラーの模様は要望に応じて適宜、選択すればよく、模様付けは該模様付けローラーの間を通すことにより繊維間の熱圧着で達成される。従って、エンボスローラーの処理速度，処理温度，ローラー間の間隔が適切に選定されることが肝要である。
しかし、必ずしも慣用されるエンボスローラーに限るものではなく、加熱ローラ外周に金網の如き網状物を巻着し、網模様を不織布表面に圧着せしめることも可能であり、本願発明の含むところである。
Next, the non-woven fabric obtained by entanglement treatment between the desired thickness and fibers, or by further bonding between the fibers, is patterned by passing it through an embossing roll having various irregularities, and is designed. A non-woven fabric having a uniform and excellent moldability.
The pattern of the embossing roller may be appropriately selected according to demand, and the patterning is achieved by thermocompression between fibers by passing between the patterning rollers. Accordingly, it is important that the processing speed of the embossing roller, the processing temperature, and the interval between the rollers are appropriately selected.
However, the present invention is not necessarily limited to a commonly used embossing roller, and a net-like material such as a wire mesh can be wound around the outer periphery of the heating roller, and the net pattern can be pressure-bonded to the surface of the nonwoven fabric.
エンボスローラーの処理速度は処理温度との兼ね合いがあるが、生産能力の関係から１．０ｍ／ｍｉｎ〜１０．０ｍ／ｍｉｎの範囲がよく、処理温度は厚さと繊維間の接着を行ったローラーの温度と同等かあるいは熱融着性繊維の低融点の温度の１０℃〜５０℃以上の範囲が好適である。
また、エンボスローラー間の間隔は熱圧着による繊維層の単繊維が破壊されない程度に調節することが必要である。
Although the processing speed of the embossing roller has a balance with the processing temperature, the range of 1.0 m / min to 10.0 m / min is good from the relationship of the production capacity, and the processing temperature is that of the roller that has adhered between the thickness and the fiber. A temperature range of 10 ° C. to 50 ° C. or higher, which is equal to the temperature or the low melting point temperature of the heat-fusible fiber, is suitable.
Moreover, it is necessary to adjust the space | interval between embossing rollers so that the single fiber of the fiber layer by thermocompression may not be destroyed.
かくして以上の工程によって得られた不織布はその特性として、カンチレバーによる剛軟度が２０ｍｍ〜２００ｍｍの範囲で、１００ｇ／ｍ２当たりの圧縮弾性率を０．６ｇ／ｍｍ３〜１．２ｇ／ｍｍ３の範囲とすることにより不織布の成型性に優れた模様付けされて意匠性を備えたものとなる。
不織布の１００ｇ／ｍ２当たりの圧縮弾性率を０．６ｇ／ｍｍ３未満で、カンチレバーの剛軟度が２０ｍｍ未満では成型性が悪く、破れ引けを生じ易い。また、１００ｇ／ｍ２当たりの圧縮弾性率を１．２ｇ／ｍｍ３を超えて、カンチレバーの剛軟度が２００ｍｍを超えると不織布が硬く、プラスチックライクになり、成型性にはさほど問題にはならないが薄いものしか得られない。
As nonwoven its characteristics obtained thus by the above process, in the range stiffness due cantilever is 20Mm～200mm, the compression modulus per 100g / m 2 0.6g / mm 3 ~1.2g / mm 3 By setting it as the range, the pattern which was excellent in the moldability of a nonwoven fabric was provided, and the design property was provided.
If the compressive elastic modulus per 100 g / m 2 of the nonwoven fabric is less than 0.6 g / mm 3 and the bending resistance of the cantilever is less than 20 mm, the moldability is poor and tearing tends to occur. Further, when the compressive elastic modulus per 100 g / m 2 exceeds 1.2 g / mm 3 and the bending resistance of the cantilever exceeds 200 mm, the nonwoven fabric is hard, becomes plastic-like, and the moldability is not a problem. Can only get thin.
以下、本発明の実施例および比較例により、本発明をより具体的に説明するが、本発明はこれに限定されるものではない。
なお、以下の実施例及び比較例における目付量，厚さ，圧縮弾性率，剛軟度の評価又は測定は、下記の方法に従って行った。
Hereinafter, the present invention will be described in more detail by way of examples and comparative examples of the present invention, but the present invention is not limited thereto.
In the following examples and comparative examples, the basis weight, thickness, compression modulus, and bending resistance were evaluated or measured according to the following methods.
（１）目付質量
ＪＩＳ Ｌ１０９６の８．４．２に記載の方法に準拠して求めた。
（２）厚さ
ＪＩＳ Ｌ１０９６の８．５．１に記載の方法に従って荷重２ＫＰａで測定した。
（３）剛軟度
ＪＩＳ Ｌ１０９６の８．１９．１に記載の４５℃カンチレバー法で測定した。
但し、試料長は３０ｃｍを用いた。
（４）圧縮弾性率
圧縮試験は東洋ボールドイン社製１トンテンシロンを用い、圧縮面積１０ｃｍφで圧縮速度２ｍｍ／ｍｉｎで試料を圧縮し、初荷重０．１５ｇ／ｍｍ２として荷重０．８ｇ／ｍｍ２下での変形距離（ｍｍ）を求め、その距離を荷重０．８ｇ／ｍｍ２に除して、更に試料の目付で除して、１００倍して得た。
単位は１００ｇ目付当たりｇ／ｍｍ３である。
(1) Weight per unit area
It calculated | required based on the method as described in 8.4.2 of JISL1096.
(2) Thickness
It was measured at a load of 2 KPa according to the method described in JIS L1096, 8.5.1.
(3) Bending softness
It measured by the 45 degreeC cantilever method as described in 8.19.1 of JISL1096.
However, the sample length was 30 cm.
(4) Compression modulus
Compression tests by Toyo bold in KK 1 Tontenshiron, compressing the sample at a compression rate of 2 mm / min in compression area 10Cmfai, deformation distance in load 0.8 g / mm 2 under the initial load of 0.15 g / mm 2 (Mm) was obtained, and the distance was divided by a load of 0.8 g / mm 2 and further divided by the basis weight of the sample to obtain 100 times.
The unit is g / mm 3 per 100 g basis weight.
繊度３．３デシテックス（ｄｔｅｘ）、繊維長５１ｍｍのベージュ原着ポリエステル繊維（融点：２６０℃）９０質量％と、繊度４．４デシテックス、繊維長５１ｍｍのベージュ原着ポリエステル／低融点ポリエステル複合繊維（低融点ポリエステルの融点：１１０℃）１０質量％を均一混合し、次いで、カーディングして目付質量約１８０ｇ／ｍ２の繊維層（平均繊度：３．４デシテックス）とし、引き続き、表面に深さ８ｍｍ，打ち込み本数６０本／ｃｍ２、裏面に同様に深さ４．５ｍｍ，打ち込み本数１７０本／ｃｍ２、更に表面に深さ４．５ｍｍ，打ち込み本数１９０本／ｃｍ２、引き続き裏面に深さ５．０ｍｍ，打ち込み本数１５０本／ｃｍ２と表面に深さ５．０ｍｍ，打ち込み本数１９０本／ｃｍ２のニードルパンチ処理を施し、引き続きエンボスカレンダー加工装置に供給して模様付けした。
エンボスカレンダー条件として処理速度５．５ｍ／ｍｉｎ，エンボスローラー上ロール（模様付けされたロール）温度１４０℃，下ロール（鉄ロール）温度１２０℃，ローラー圧力２０ｋｇ／ｃｍで処理し、ワインダーに巻取り、本発明の模様付けされ意匠性に優れた内装表皮材の製品を得た。
90% by mass beige original polyester fiber (melting point: 260 ° C.) having a fineness of 3.3 dtex and a fiber length of 51 mm, and a beige original polyester / low-melting polyester composite fiber having a fineness of 4.4 decitex and a fiber length of 51 mm ( 10% by mass of a low-melting polyester (melting point: 110 ° C.) is uniformly mixed, and then carded to obtain a fiber layer (average fineness: 3.4 dtex) having a weight per unit area of about 180 g / m 2. 8mm, number of implantations 60 / cm 2 , depth 4.5mm, number of implantations 170 / cm 2 , depth 4.5mm, number of implantations 190 / cm 2 , depth on the back 5.0mm, end counts 150 present / cm 2 and a depth 5.0mm on the surface, the needle punching of the thread count 190 present / cm 2 Applied, was put pattern continues to supply the embossed calendering apparatus.
The embossing calendar is processed at a processing speed of 5.5 m / min, an embossing roller upper roll (patterned roll) temperature of 140 ° C., a lower roll (iron roll) temperature of 120 ° C., and a roller pressure of 20 kg / cm, and wound on a winder. Thus, a product of an interior skin material having a design and excellent design properties according to the present invention was obtained.
実施例１と同じ条件でニードルパンチ処理を施し、引き続きエンボスカレンダー加工装置に供給して模様付けした。
エンボスカレンダー条件は処理速度５．０ｍ／ｍｉｎ，エンボスローラー上ロール（模様付けされたロール）温度２００℃，下ロール（ゴムロール）温度３０℃、ローラー圧力３０ｋｇ／ｃｍで、処理後、ワインダーに巻取り本発明の模様付けされ意匠性に優れた内装表皮材の製品を得た。
Needle punching was performed under the same conditions as in Example 1, and the pattern was then fed to an embossing calendar processing apparatus.
The embossing calendering conditions were: processing speed 5.0 m / min, embossing roller upper roll (patterned roll) temperature 200 ° C, lower roll (rubber roll) temperature 30 ° C, roller pressure 30 kg / cm. The product of the interior skin material which was patterned and excellent in designability of the present invention was obtained.
繊度３．３デシテックス（ｄｔｅｘ）、繊維長５１ｍｍのグレー原着ポリエステル繊維（融点：２６０℃）８０質量％と、繊度４．４デシテックス、繊維長５１ｍｍのグレー原着ポリエステル／低融点ポリエステル複合繊維（低融点ポリエステルの融点：１１０℃）２０質量％を均一混合し、次いでカーディングして目付質量約１３０ｇ／ｍ２の繊維層（平均繊度：３．５デシテックス）とし、引き続き表面に深さ８ｍｍ，打ち込み本数６３本／ｃｍ２，裏面に同様に深さ１０．０ｍｍ，打ち込み本数９０本／ｃｍ２、更に、表面に深さ７．０ｍｍ，打ち込み本数９０本／ｃｍ２のニードルパンチ処理を施し、連続して熱処理機（ホットエアースルー方式）で、処理温度１８０℃で９０秒間の滞留時間で熱処理した。
そして、次に処理された繊維層を連続して熱ロール（ロール温度７０℃，ロール間隙間巾０．４ｍｍ）で繊維間の接着と厚み調整をしてワインダーに巻き取った。この巻き取った不織布を引き続きエンボスカレンダー加工装置の供給部に装着して模様付けした。
エンボスカレンダー条件は、処理速度５．０ｍ／ｍｉｎ，エンボスローラー上ロール（模様付けされたロール）温度１８０℃、下ロール（ゴムロール）温度３０℃、ローラー圧力３０ｋｇ／ｃｍで、処理後、ワインダーに巻き取り本発明の意匠性に優れた内装表皮材の製品を得た。
（比較例１）
80% by mass of a gray original polyester fiber (melting point: 260 ° C.) having a fineness of 3.3 dtex and a fiber length of 51 mm, and a gray original polyester / low-melting polyester composite fiber having a fineness of 4.4 dtex and a fiber length of 51 mm 20% by mass of low-melting polyester (melting point: 110 ° C.) is uniformly mixed, and then carded to obtain a fiber layer (average fineness: 3.5 dtex) having a weight per unit area of about 130 g / m 2 . end counts 63 present / cm 2, similarly depth 10.0mm on the back, end counts 90 present / cm 2, further depth in the surface of 7.0 mm, a needle punching process thread count 90 present / cm 2 applied, It heat-processed by the heat processing machine (hot air through system) continuously with the processing temperature of 180 degreeC for 90 second residence time.
Then, the treated fiber layer was continuously wound around a winder by adjusting the thickness and adjusting the thickness between the fibers with a hot roll (roll temperature: 70 ° C., gap width between rolls: 0.4 mm). The wound non-woven fabric was subsequently attached to the supply section of the embossing calendar processing apparatus and patterned.
Embossing calendar conditions are: processing speed is 5.0 m / min, embossing roller upper roll (patterned roll) temperature is 180 ° C, lower roll (rubber roll) temperature is 30 ° C, roller pressure is 30 kg / cm. The product of the interior skin material excellent in the designability of the present invention was obtained.
(Comparative Example 1)
実施例３と同様の構成でカーディング加工，ニードル加工の条件は同じとして連続して熱処理機（ホットエアースルー方式）で処理温度１８０℃，６０秒間の滞留時間で熱処理し、更に、処理された繊維層を連続して熱ロール（ロール温度９０℃，ロール間隙間巾０．２ｍｍ）で繊維間の厚み調整をしてワインダーに巻き取った。
引き続き、この巻き取った不織布をエンボスカレンダー加工装置の供給部に装着し、エンボスカレンダー条件として処理速度５．０ ｍ／ｍｉｎ，エンボスローラー上ロール（模様付けされたロール）温度２００℃、下ロール（ゴムロール）温度３０℃，ローラ圧力３０Ｋｇ／ｃｍで処理し、ワインダーに巻き取り、比較内装表皮材を得た。
（比較例２）
With the same configuration as in Example 3, the carding and needle processing conditions were the same, and the heat treatment was continuously performed with a heat treatment machine (hot air through method) at a treatment temperature of 180 ° C. for a residence time of 60 seconds, and further processed. The fiber layer was continuously wound around a winder after adjusting the thickness between fibers with a hot roll (roll temperature: 90 ° C., gap width between rolls: 0.2 mm).
Subsequently, the wound nonwoven fabric is mounted on a supply unit of an embossing calendering device. As embossing calendering conditions, a processing speed of 5.0 m / min, an embossing roller upper roll (patterned roll) temperature of 200 ° C., a lower roll ( Rubber roll) Treated at a temperature of 30 ° C. and a roller pressure of 30 kg / cm, wound on a winder to obtain a comparative interior skin material.
(Comparative Example 2)
繊度３．３デシテックス（ｄｔｅｘ）、繊維長５１ｍｍのポリエステル繊維（融点：２６０℃）をカーディングして目付量約１８０ｇ／ｍ２の繊維層とし、引き続き表面に深さ８ｍｍ，打ち込み本数６３本／ｃｍ２、裏面に深さ５ｍｍ，打ち込み本数３６０本／ｃｍ２、更に表面に深さ５ｍｍ，打ち込み本数３４５本／ｃｍ２のニードルパンチ処理を施した、得られた不織布の表面にスプレー法でアクリル樹脂を１０ｇ／ｍ２になるように、更に裏面に５０ｇ／ｍ２になるようにアクリル樹脂をコーティングし、引き続き熱処理機で乾燥し、トータル目付量約２４０ｇ／ｍ２の不織布を得た。
この不織布を次にエンボスカレンダー加工装置の供給部に装着し、エンボスカレンダー条件として処理速度５．０ｍ／ｍｉｎ，エンボスローラー上ロール（模様付けされたロール）温度２００℃，下ロール（ゴムロール）温度３０℃，ローラ圧力３０ｋｇ／ｃｍで処理し、処理後、ワインダーに巻き取り比較内装材を得た。
A polyester layer (melting point: 260 ° C.) having a fineness of 3.3 dtex and a fiber length of 51 mm is carded to form a fiber layer having a basis weight of about 180 g / m 2 , and subsequently has a depth of 8 mm and a number of driven wires of 63 / The surface of the resulting non-woven fabric, which has been subjected to a needle punching treatment with a depth of 5 mm and a depth of 360 mm / cm 2 on the back surface, a depth of 360 mm / cm 2 on the back surface, and a depth of 5 mm and a depth of 345 lines / cm 2 on the surface, is acrylic by spraying. Acrylic resin was coated so that the resin was 10 g / m 2 and the back surface was 50 g / m 2 , and subsequently dried with a heat treatment machine to obtain a nonwoven fabric having a total basis weight of about 240 g / m 2 .
This non-woven fabric is then mounted on the supply section of the embossing calendering apparatus. The embossing calendering conditions include a processing speed of 5.0 m / min, an embossing roller upper roll (patterned roll) temperature of 200 ° C., and a lower roll (rubber roll) temperature of 30. The sample was treated at a temperature of 30 ° C. and a roller pressure of 30 kg / cm.
以上の実施例，比較例により得られた各内装表皮材について前述したカンチレバーによる剛軟度及び圧縮弾性率の評価を行った。
そして、その結果及び５名のパネラーによる不織布表面の模様の状態，硬さの評価を実施した結果を表１に示す。
なお、評価分類は模様の状態と硬さが良好を○，やや良を△，模様が不十分で硬くてゴワゴワ感を×に分けて行った。
また、得られた表皮材について成型加工を施し、その加工性と表面状態を評価し、その結果を表１に併せて示す。
Each interior skin material obtained in the above examples and comparative examples was evaluated for the bending resistance and the compressive modulus by the cantilever described above.
And the result and the result of having implemented the state of the pattern of the nonwoven fabric surface by five panelists, and hardness evaluation are shown in Table 1.
The evaluation classification was performed by dividing the state and hardness of the pattern into good (circle), slightly good (triangle), and the pattern being inadequate and hard, with a sense of hardness.
Further, the obtained skin material is subjected to molding processing, its workability and surface condition are evaluated, and the results are also shown in Table 1.
以上の表１に示された結果から、実施例１〜３で得られた内装表皮材は、何れも表面の模様が鮮明で、意匠性に優れ、成型性も良好であることが判る。
それに対して比較例においては、比較例１は表面状態が硬く、意匠性はよいが、成型性に乏しいことが判る。
また、比較例２は表面状態，意匠性共に稍、不充分であると共に、成型性にも劣ることが判る。
From the results shown in Table 1 above, it can be seen that the interior skin materials obtained in Examples 1 to 3 each have a clear surface pattern, excellent design properties, and good moldability.
In Comparative Example contrast ratio Comparative Examples 1 hard surface condition, design property is good, it is understood that poor moldability.
In addition, it can be seen that Comparative Example 2 is poor and inferior in moldability as well as being inferior and insufficient in both surface state and design.
以上のように、本発明の内装表皮材は成型性に優れ、得られた製品の表面の模様が鮮明で、意匠性に優れており、従来問題となっていた表面の模様状態及び成型性を改善し、天井材，ドアトリム材，リアパッケージ材などの内装表皮材にに使用して極めて好適なものである。
As described above, the interior skin material of the present invention is excellent in moldability, the surface pattern of the obtained product is clear, excellent in design, and has the surface pattern state and moldability that have been problematic in the past. It is improved and is extremely suitable for use in interior skin materials such as ceiling materials, door trim materials, and rear package materials.
Claims (6)
高融点繊維と熱融着性繊維の短繊維からなる繊維層であって、繊維間の交絡がニードル加工によって行われており、かつ該繊維層の繊維間が熱融着性繊維で接着されていると共に、一部が模様付けされたエンボスローラーにより熱圧着された不織布よりなり、該不織布の１００ｇ／ｍ２当たりの初期圧縮弾性率が０．６ｇ／ｍｍ３〜１．２ｇ／ｍｍ３の範囲であり、剛軟度が２０ｍｍ〜２００ｍｍの範囲であることを特徴とする模様付けされ意匠性に優れた内装表皮材。
A fiber layer comprising short fibers of a high melting point fiber and a heat-fusible fiber, wherein the fibers are entangled by needle processing, and the fibers of the fiber layer are bonded with a heat-fusible fiber. range with, a part made of thermally crimped nonwoven fabric textured embossing rollers, the initial compressive modulus of 100 g / m 2 per the nonwoven fabric is 0.6g / mm 3 ~1.2g / mm 3 are An interior skin material that is patterned and is excellent in design, characterized in that the bending resistance is in the range of 20 mm to 200 mm.
高融点繊維と熱融着性繊維からなる繊維層の混繊比率が高融点繊維／熱融着性繊維で７０／３０〜９５／５の範囲である請求項１記載の模様付けされ意匠性に優れた内装表皮材。
2. The patterned and designed design according to claim 1, wherein the fiber layer ratio of the fiber layer composed of the high melting point fiber and the heat fusible fiber is in the range of 70/30 to 95/5 for the high melting point fiber / the heat fusible fiber. Excellent interior skin material.
高融点繊維がポリエステル系繊維，ポリプロピレン系繊維，ナイロン系繊維から選ばれた少なくとも１種である請求項１または２記載の模様付けされ意匠性に優れた内装表皮材。
The interior skin material with a patterned and excellent design property according to claim 1 or 2, wherein the high melting point fiber is at least one selected from polyester fibers, polypropylene fibers, and nylon fibers.
熱融着性繊維が熱可塑性樹脂の高融点成分と低融点成分からなる芯鞘型，サイドバイサイド型の何れかの複合繊維である請求項１または２に記載の模様付けされ意匠性に優れた内装表皮材。
The interior of the patterned and excellent design property according to claim 1 or 2, wherein the heat-fusible fiber is a core-sheath type or side-by-side type composite fiber composed of a high melting point component and a low melting point component of a thermoplastic resin. Skin material.
高融点繊維と熱融着性繊維の短繊維からなり、熱融着性繊維を５〜３０質量％含有する繊維層を、繊維間の交絡をニードル加工で行うと共に、そのまま不織布として巻取り、次いで巻き取った不織布に模様付けされた加熱エンボスローラー装置により模様付け処理を行って、不織布の繊維間を熱融着性繊維の溶融により互いに接着すると共に、一部が熱圧着された不織布とし、かつその不織布の１００ｇ／ｍ２当たりの圧縮弾性率を０．６ｇ／ｍｍ３〜１．２ｇ／ｍｍ３、剛軟度を２０ｍｍ〜２００ｍｍの範囲とすることを特徴とする模様付けされ意匠性に優れた内装表皮材の製造方法。
It consists of short fibers of high melting point fibers and heat-fusible fibers, and a fiber layer containing 5-30% by mass of heat-fusible fibers is entangled between the fibers by needle processing, and then wound as a nonwoven fabric as it is, A patterning process is performed by a heated embossing roller device patterned on the wound nonwoven fabric, the nonwoven fabric fibers are bonded to each other by melting of the heat-fusible fibers, and a part of the nonwoven fabric is thermocompression bonded, and the compressive modulus of 100 g / m 2 per the nonwoven 0.6g / mm 3 ~1.2g / mm 3 , is textured, characterized in that the range of the bending resistance 20mm~200mm excellent design A method for manufacturing an interior skin material.
高融点繊維と熱融着性繊維の短繊維からなり、熱融着性繊維を５〜３０質量％含有する繊維層を、繊維間の交絡をニードル加工で行うと共に、該繊維層の繊維間をホットエアースルー法により熱風処理して繊維層中の熱融着性繊維を溶融することにより、互いに接着させて不織布を形成した後、該不織布をローラーで繊維層内の厚さと繊維間の接着を調整して巻取り、次いで巻き取った不織布に模様付けされたエンボスローラー装置により模様付け処理を行って、一部を熱圧着せしめ、かつその不織布の１００ｇ／ｍ２当たりの圧縮弾性率を０．６ｇ／ｍｍ３〜１．２ｇ／ｍｍ３、剛軟度を２０ｍｍ〜２００ｍｍの範囲とすることを特徴とする模様付けされ意匠性に優れた内装表皮材の製造方法。
A fiber layer composed of high melting point fibers and short fibers of heat-fusible fibers, containing 5-30% by mass of heat-fusible fibers, interlaced between the fibers by needle processing, and between the fibers of the fiber layer After hot air treatment by hot air-through method to melt the heat-fusible fibers in the fiber layer, they are bonded to each other to form a nonwoven fabric. Adjustment and winding, and then patterning with an embossing roller device patterned on the wound nonwoven fabric, a part of the nonwoven fabric is thermocompression-bonded, and the compression elastic modulus per 100 g / m 2 of the nonwoven fabric is 0.00. 6g / mm 3 ~1.2g / mm 3 , textured by excellent manufacturing method of the interior skin material design properties, characterized in that the range of the bending resistance 20Mm～200mm.
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| JP2003284601A JP4197280B2 (en) | 2003-08-01 | 2003-08-01 | Interior skin material with excellent design and texture |
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| JP2003284601A JP4197280B2 (en) | 2003-08-01 | 2003-08-01 | Interior skin material with excellent design and texture |
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| JP6807204B2 (en) * | 2016-10-04 | 2021-01-06 | 呉羽テック株式会社 | Skin material for interior |
| KR102219310B1 (en) | 2017-03-31 | 2021-02-22 | 코오롱인더스트리 주식회사 | Nonwoven with improved strength and sound absorption, manufacturing method thereof and vehicle under cover composed of nonwoven with improved strength and sound absorption |
| EP4008823B1 (en) * | 2020-12-04 | 2023-10-25 | Carl Freudenberg KG | Embossed nonwoven fabric for vehicle interior |
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