JP4366816B2 - Interior material for vehicle and method for manufacturing the same - Google Patents
Interior material for vehicle and method for manufacturing the same Download PDFInfo
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- JP4366816B2 JP4366816B2 JP2000067505A JP2000067505A JP4366816B2 JP 4366816 B2 JP4366816 B2 JP 4366816B2 JP 2000067505 A JP2000067505 A JP 2000067505A JP 2000067505 A JP2000067505 A JP 2000067505A JP 4366816 B2 JP4366816 B2 JP 4366816B2
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- binder
- interior material
- urethane chip
- vehicle interior
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- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
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Description
【0001】
【発明の属する技術分野】
本発明は車両用内装材及びその製造方法に係り、特に、自動車のフロアーインシュレーター材としての遮音、吸音性能に優れ、軽量で踏み心地の良い車両用内装材とこの車両用内装材を製造する方法に関する。
【0002】
【従来の技術】
従来、車両用内装材としては、ウレタンチップをウレタン系接着剤よりなるバインダーと混合し、これを金型内に投入してプレス成形して製造されたウレタンチップ成形品よりなるものが提供されている。ウレタンチップ成形品は遮音、吸音性能に優れ、しかも、ウレタンフォームの製造の際に排出されるフォーム切断片やウレタンフォームの廃品をチップ状に切断したウレタンチップを主原料とするものであるため、リサイクルによる廃棄物の減量化、コストダウン等の面でも有益であるといった利点がある。
【0003】
このような車両用内装材には、車室内の騒音低減の目的で遮音、吸音性能に優れることが要求され、特に自動車のフロアーインシュレーター材にあっては、更に、車体を軽量化して燃費を低減するために、軽量であること;踏み込んだときの沈み込みが少なく、踏み心地に優れること;が要求される。なお、踏み込んだときの沈み込みを防止して踏み心地を良くするためには、ある程度の硬度が必要である。
【0004】
【発明が解決しようとする課題】
しかしながら、ウレタンチップ成形品は、密度と硬度とが比例関係にあり、硬度を上げて踏み心地を良くしようとすると重量の増大を招き、軽量化が図れないという欠点がある。また、ウレタンチップ成形品は比較的遮音、吸音性能に優れるものであるが、車両用内装材としての用途の面から、遮音、吸音性能のより一層の向上が望まれている。
【0005】
しかも、ウレタン系接着剤をバインダーとする従来のウレタンチップ成形品では、製造時の作業環境が悪いという欠点もある。
【0006】
本発明は上記従来の問題点を解決し、自動車のフロアーインシュレーター材として、遮音、吸音性能に優れ、軽量で踏み心地の良い車両用内装材とこの車両用内装材を製造する方法を提供することを目的とする。
【0007】
【課題を解決するための手段】
本発明の車両用内装材は、ウレタンチップをバインダーを用いて成形してなるウレタンチップ成形層の表面に、軟化して接着性を示すバインダー繊維の表面層が一体成形されてなる車両用内装材において、該ウレタンチップ成形層の密度が、0.05〜0.12g/cm3で、該表面層の目付が100〜500g/m2であり、該バインダー繊維が、長さ38〜76mmで4〜65デニールであり、該バインダー繊維の軟化温度が、80〜140℃であり、該ウレタンチップ成形層のバインダーが、軟化して接着性を示すバインダー繊維であり、該ウレタンチップ成形層のバインダーと、該表面層を構成するバインダー繊維とが同一のものであることを特徴とする。
【0008】
本発明に従って、ウレタンチップ成形層の表面に軟化して接着性を示す繊維(以下「バインダー繊維」と称す場合がある。)の表面層を設けることにより、バインダー繊維の表面層で硬度を高めることができ、これにより、ウレタンチップ成形層の密度を下げて車両用内装材全体としての軽量化を図ることができる。また、遮音、吸音性能についても、バインダー繊維の表面層とウレタンチップ成形層との積層体とすることで著しく優れた遮音、吸音性能が得られる。
【0009】
本発明においては、ウレタンチップ成形層のバインダーとしてもこのバインダー繊維を用いているため、バインダーとしてウレタン系接着剤を用いる従来品に比べて、製造時の作業環境を改善することができる。
【0010】
また、表面層を構成するバインダー繊維、或いは更にウレタンチップ成形層のバインダーとしてのバインダー繊維は、軟化温度が80〜140℃であり、このようなバインダー繊維は開繊機で単繊維状に開繊して用いることが、繊維のからみ合いによる結合強度の向上効果の面で好ましい。
【0011】
また、ウレタンチップ成形層に用いるウレタンチップは粒径が5〜30mm、特に5〜15mmであることが好ましい。
【0012】
本発明の車両用内装材は、ウレタンチップ成形層の密度が0.05〜0.12g/cm3で、表面層の目付が100〜500g/m2であるため、より一層の高硬度、軽量化を図ることができる。
【0013】
このような本発明の車両用内装材は、バインダー繊維を型内に吹き込んで加熱加圧成形した後、更にウレタンチップとバインダーとの混合物を型内に吹き込んで加熱加圧成形する本発明の車両用内装材の製造方法により容易かつ効率的に製造することができる。
【0014】
【発明の実施の形態】
以下に図面を参照して本発明の実施の形態を詳細に説明する。
【0015】
図1は本発明の車両用内装材の実施の形態を示す断面図である。
【0016】
図示の如く、本発明の車両用内装材は、ウレタンチップをバインダーを用いて成形してなるウレタンチップ成形層1の表面に、バインダー繊維の表面層2が一体成形されてなるものである。
【0017】
表面層2を構成するバインダー繊維としては、軟化、溶融して接着性を示す繊維であれば良く、特に制限はないが、軟化温度については、80〜140℃の範囲のものが生産性、品質の点から好ましい。このようなバインダー繊維としてはポリエステル、ポリエチレン、ポリプロピレン等の熱可塑性合成樹脂よりなる繊維を用いることができる。なお、このバインダー繊維は長さ38〜76mmで4〜65デニールの範囲にあるものが剛性、性能の面から好適であり、このようなバインダー繊維は開繊機で単繊維状に開繊して用いるのが、繊維のからみ合いによる結合強度の向上効果の面で好ましい。
【0018】
ウレタンチップ成形層1を構成するウレタンチップとしては、従来、車両用内装材に用いられているもので良く、その形状等には特に制限はないが、大きさについては、粒径が5〜30mm、即ち、開口径が5〜30mmのスクリーンを通過する大きさであることが好ましい。この粒径が5mm未満のものでは切断、粉砕に時間がかかり、30mmを超えると成形性、成型外観が損なわれる。特に好ましいウレタンチップの粒径は5〜15mmである。
【0019】
ウレタンチップ成形層1のバインダーとしては、従来から用いられているウレタン系接着剤は作業環境の面で難があることから、このウレタンチップ成形層1のバインダーとしては上述のバインダー繊維を用いる。この場合、ウレタンチップ成形層1のバインダー繊維は、材料管理の面から表面層2のバインダー繊維と同一のものを用いる。
【0020】
本発明において、バインダー繊維で構成される表面層2は、厚さ1〜5mmで目付量100〜500g/m 2 であり、軽量性を損なうことなく硬度を高めると共に、遮音、吸音性能を確保する上で好ましい。
【0021】
また、ウレタンチップ成形層1の密度は0.05〜0.12g/cm3であるため、硬度、遮音、吸音性能及び軽量化の面で好適であり、通常の場合、ウレタンチップ成形層1の厚さは10〜50mm程度とされる。
【0022】
このような密度のウレタンチップ成形層1を形成するためには、ウレタンチップ100重量部に対して、バインダー繊維を10〜40重量部混合するのが好ましい。
【0023】
このような本発明の車両用内装材は、本発明の方法に従って、次の手順で製造するのが好ましい。
(1) バインダー繊維を開繊機で単繊維状に開繊し、開繊したバインダー繊維の所定量をエアーによって金型に吹き込む。このバインダー繊維の投入は、単に開繊したバインダー繊維を金型内にばらまいて行っても良いが、エアーで吹き込むことにより成形効率が向上すると共に、均一な製品を得ることができ、好ましい。
(2) 金型内に開繊したバインダー繊維を吹き込んだ後は、金型に設けられた多数の通気孔より、熱風或いは加熱蒸気を型内に吹き込んで加熱しながら、プレス成形して表面層を形成する。この加熱温度はバインダー繊維を軟化、溶融できる温度以上であれば良い。この加熱成形後、冷風を吹き込むことにより、固化速度を速めることができ、成形サイクルを短縮できる。
(3) 開繊したバインダー繊維とウレタンチップとを所定割合で混合したものを、上記と同様に金型内の表面層上に吹き込み、同様に加熱しながらプレス成形する。その後、冷風を吹き込んで固化させ、製品を取り出す。なお、このバインダー繊維とウレタンチップとの混合物の金型内への投入は、これを金型内にばらまいて行っても良い。
【0024】
このような本発明の車両用内装材は、軽量で踏み心地が良く、遮音、吸音性能にも優れるため、自動車のフロアーインシュレーター材として特に好適であるが、その他、ダッシュインシュレーター等の車両用内装材にも好適である。
【0025】
【実施例】
以下に実施例及び比較例を挙げて本発明をより具体的に説明する。
【0026】
実施例1
バインダー繊維として軟化温度110℃のポリエステル繊維(ユニチカ社製「4080」,繊維長さ51mm,15デニール)を開繊機で単繊維状に開繊して用い、ウレタンチップとして粒径15mmのものを用いて本発明の車両用内装材を製造した。
【0027】
まず、金型にバインダー繊維を吹き込み熱風で150℃に加熱しながらプレス成形して表面層を形成し、次いで、ウレタンチップ100重量部にバインダー繊維を20重量部混合したものを金型内に吹き込み熱風で150℃に加熱しながらプレス成形してウレタンチップ成形層を表面層上に一体成形した。
【0028】
得られた車両用内装材の表面層は厚さ2mm,目付量400g/m2で、ウレタンチップ成形層は厚さ26mm,密度0.071g/cm3で、総厚み28mm,500mm×600mmのもので、この車両用内装材の重量は673g(0.071×2.6×50×60+400×0.5×0.6)であった。
【0029】
この車両用内装材から300mm×300mmのサンプルを切り出し、中央に加圧面φ60mmで5kgの荷重を加えたときのたわみ量と10kgの荷重を加えたときのたわみ量を調べ、結果を表1に示した。
【0030】
また、各周波数での音響透過損失を調べ、結果を図2に示した。
【0031】
比較例1
実施例1で用いたものと同様のウレタンチップ100重量部にウレタン系接着剤15重量部を混合し、これを金型に充填し、蒸気で加熱しながらプレス成形することにより、厚さ28mmで500mm×600mmのウレタンチップ成形品よりなる車両用内装材を製造した。
【0032】
この車両用内装材の重量は966gであり、実施例1と同様にして測定したたわみ量及び音響透過損失はそれぞれ表1,図2に示す通りであった。
【0033】
【表1】
【0034】
表1及び図2より、本発明の車両用内装材は、従来品に比べて軽量でたわみ量が少なく従って踏み心地が良く、しかも遮音、吸音性能にも優れることが明らかである。
【0035】
【発明の効果】
以上詳述した通り、本発明によれば、自動車のフロアーインシュレーター材として好適な、遮音、吸音性能に優れ、軽量で踏み心地の良い車両用内装材が提供される。
【図面の簡単な説明】
【図1】 本発明の車両用内装材の実施の形態を示す断面図である。
【図2】 実施例1及び比較例1における音響透過損失の測定結果を示すグラフである。
【符号の説明】
1 ウレタンチップ成形層
2 表面層[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a vehicle interior material and a method for producing the same, and more particularly, a vehicle interior material that is excellent in sound insulation and sound absorbing performance as a floor insulator material of an automobile, is lightweight and comfortable to step on, and a method for producing the vehicle interior material. About.
[0002]
[Prior art]
Conventionally, as a vehicle interior material, a urethane chip molded product produced by mixing a urethane chip with a binder made of a urethane-based adhesive and putting it into a mold and press-molding it has been provided. Yes. Urethane chip molded products are excellent in sound insulation and sound absorption performance, and because the main raw material is urethane chips that are cut from foam cut pieces and urethane foam waste products produced in the production of urethane foam, There is an advantage that it is useful in terms of reduction of waste by recycling, cost reduction, and the like.
[0003]
Such vehicle interior materials are required to have excellent sound insulation and sound absorption performance for the purpose of reducing noise in the passenger compartment. Especially for automobile floor insulator materials, the weight of the vehicle body is further reduced to reduce fuel consumption. In order to achieve this, it is required to be lightweight; there is little sinking when it is stepped on, and it is excellent in stepping comfort. In addition, a certain degree of hardness is required in order to prevent the sinking when stepped on and to improve the stepping comfort.
[0004]
[Problems to be solved by the invention]
However, a urethane chip molded product has a defect that density and hardness are in a proportional relationship, and increasing the hardness to improve the stepping comfort results in an increase in weight and cannot be reduced in weight. Urethane chip molded products are relatively excellent in sound insulation and sound absorption performance, but further improvement in sound insulation and sound absorption performance is desired from the viewpoint of use as an interior material for vehicles.
[0005]
Moreover, the conventional urethane chip molded product using a urethane-based adhesive as a binder also has a drawback that the working environment during production is poor.
[0006]
The present invention solves the above-mentioned conventional problems, and provides a vehicle interior material that is excellent in sound insulation and sound absorption performance, is lightweight and comfortable to step on, and a method for producing the vehicle interior material as a floor insulator material for an automobile. With the goal.
[0007]
[Means for Solving the Problems]
The interior material for a vehicle according to the present invention is an interior material for a vehicle in which a surface layer of a binder fiber that is softened and exhibits adhesiveness is integrally formed on the surface of a urethane chip molding layer formed by molding a urethane chip using a binder. , The density of the urethane chip molding layer is 0.05 to 0.12 g / cm 3 , the basis weight of the surface layer is 100 to 500 g / m 2 , and the binder fiber is 4 with a length of 38 to 76 mm. Ri Ah at 65 denier, the softening temperature of the binder fiber is a 80 to 140 ° C., the binder of the polyurethane chips molded layer is a binder fibers soften showing adhesion, binders of the polyurethane chips molded layer If, and the binder fiber constituting the surface layer, characterized in der Rukoto same.
[0008]
According to the present invention, by providing a surface layer of a fiber (hereinafter sometimes referred to as “binder fiber”) that softens and adheres to the surface of the urethane chip molding layer, the hardness of the surface layer of the binder fiber is increased. As a result, the density of the urethane chip molding layer can be reduced to reduce the weight of the vehicle interior material as a whole. In addition, with regard to sound insulation and sound absorption performance, a significantly superior sound insulation and sound absorption performance can be obtained by using a laminate of a binder fiber surface layer and a urethane chip molding layer.
[0009]
In the present invention, since, also by using the binder fibers as the binder of the polyurethane chips molded layer, as compared with a conventional product using a urethane-based adhesive as the binder, it is possible to improve the manufacturing time of the working environment.
[0010]
The binder fiber constituting the surface layer or the binder fiber as the binder of the urethane chip molding layer has a softening temperature of 80 to 140 ° C., and such a binder fiber is opened into a single fiber by a spreader. Is preferably used in terms of the effect of improving the bond strength due to the entanglement of the fibers.
[0011]
The urethane chip used for the urethane chip molding layer preferably has a particle size of 5 to 30 mm, particularly 5 to 15 mm.
[0012]
The vehicle interior material of the present invention, since the density of the polyurethane chips molded layer is in 0.05~0.12g / cm 3, the basis weight of the surface layer is 100 to 500 g / m 2, even higher hardness, light weight Can be achieved.
[0013]
Such a vehicle interior material of the present invention is a vehicle of the present invention in which a binder fiber is blown into a mold and heat-pressed, and then a mixture of a urethane chip and a binder is blown into the mold to be heat-pressed. It can be manufactured easily and efficiently by the manufacturing method of interior materials for automobiles.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
[0015]
FIG. 1 is a sectional view showing an embodiment of a vehicle interior material of the present invention.
[0016]
As shown in the drawing, the interior material for a vehicle of the present invention is formed by integrally forming a surface layer 2 of a binder fiber on the surface of a urethane chip molding layer 1 formed by molding a urethane chip using a binder.
[0017]
The binder fiber constituting the surface layer 2 is not particularly limited as long as it is a fiber that is softened and melted to exhibit adhesiveness, but the softening temperature is in the range of 80 to 140 ° C. for productivity and quality. From the point of view, it is preferable. As such a binder fiber, a fiber made of a thermoplastic synthetic resin such as polyester, polyethylene, or polypropylene can be used. In addition, this binder fiber having a length of 38 to 76 mm and a range of 4 to 65 denier is preferable in terms of rigidity and performance, and such a binder fiber is used after being opened into a single fiber by a spreader. This is preferable in terms of the effect of improving the bond strength due to the entanglement of the fibers.
[0018]
The urethane chip constituting the urethane chip molding layer 1 may be one conventionally used for vehicle interior materials, and there is no particular limitation on the shape and the like, but the size is 5 to 30 mm. That is, it is preferable that the opening diameter is a size that passes through a screen of 5 to 30 mm. When the particle size is less than 5 mm, it takes time to cut and pulverize, and when it exceeds 30 mm, the moldability and the molded appearance are impaired. The particle size of a particularly preferable urethane chip is 5 to 15 mm.
[0019]
As the binder for the urethane chip molding layer 1, the urethane adhesive which has been conventionally used since there is a fire in terms of work environment, Ru using the above binder fibers as the binder for the urethane chip molding layer 1. In this case, the binder fibers of the urethane chips molded layer 1, Ru used as terms of wood charge management of the surface layer 2 of the same binder fiber.
[0020]
Ensured in the present invention, the surface layer 2 consists of binder fibers, Ri Oh in basis weight 100 to 500 g / m 2 with a thickness 1 to 5 mm, to increase the hardness without deteriorating the light weight, sound insulation, sound absorption performance This is preferable.
[0021]
The density of the urethane chip molding layer 1 is suitable 0.05~0.12g / cm 3 der because, hardness, sound insulation, in terms of sound absorption performance and light weight, usually, polyurethane chips molded layer 1 Is about 10-50 mm.
[0022]
In order to form the urethane chip molding layer 1 having such a density, it is preferable to mix 10 to 40 parts by weight of the binder fiber with respect to 100 parts by weight of the urethane chip.
[0023]
Such a vehicle interior material of the present invention is preferably manufactured by the following procedure according to the method of the present invention.
(1) The binder fiber is opened into a single fiber by a spreader, and a predetermined amount of the opened binder fiber is blown into a mold by air. This binder fiber may be introduced by simply spreading the opened binder fiber into the mold, but blowing it with air improves the molding efficiency and can provide a uniform product, which is preferable.
(2) After blowing the opened binder fiber into the mold, the surface layer is subjected to press molding while blowing hot air or heated steam into the mold and heating from a large number of air holes provided in the mold. Form. The heating temperature may be higher than the temperature at which the binder fiber can be softened and melted. By blowing cold air after this heat forming, the solidification speed can be increased and the forming cycle can be shortened.
(3) A mixture of the spread binder fibers and urethane chips in a predetermined ratio is blown onto the surface layer in the mold in the same manner as described above, and press-molded while heating in the same manner. Then, cool air is blown to solidify and the product is taken out. In addition, the mixture of the binder fiber and the urethane chip may be charged into the mold while being dispersed in the mold .
[0024]
The vehicle interior material of the present invention such as this is comfortable stepping lightweight good, sound insulation, since the excellent sound absorbing performance, is particularly suitable as a floor insulator material of an automobile, other interior vehicle such as a dash insulator It is also suitable for the material.
[0025]
【Example】
Hereinafter, the present invention will be described more specifically with reference to Examples and Comparative Examples.
[0026]
Example 1
As a binder fiber, a polyester fiber having a softening temperature of 110 ° C. (“4080” manufactured by Unitika Ltd., fiber length 51 mm, 15 denier) is used by opening it into a single fiber with a spreader, and a urethane chip having a particle diameter of 15 mm is used. The vehicle interior material of the present invention was manufactured.
[0027]
First, a binder fiber is blown into a mold and press-molded while being heated to 150 ° C. with hot air to form a surface layer, and then 20 parts by weight of binder fiber mixed with 100 parts by weight of a urethane chip is blown into the mold. The urethane chip molding layer was integrally formed on the surface layer by press molding while heating to 150 ° C. with hot air.
[0028]
The surface layer of the obtained vehicle interior material has a thickness of 2 mm and a basis weight of 400 g / m 2. The urethane chip molding layer has a thickness of 26 mm and a density of 0.071 g / cm 3 , and has a total thickness of 28 mm and 500 mm × 600 mm. The weight of the vehicle interior material was 673 g (0.071 × 2.6 × 50 × 60 + 400 × 0.5 × 0.6).
[0029]
A 300 mm x 300 mm sample was cut out from this vehicle interior material, and the amount of deflection when a 5 kg load was applied with a pressure surface of 60 mm in the center and the amount of deflection when a 10 kg load was applied were examined. The results are shown in Table 1. It was.
[0030]
Further, the sound transmission loss at each frequency was examined, and the results are shown in FIG.
[0031]
Comparative Example 1
By mixing 15 parts by weight of a urethane-based adhesive with 100 parts by weight of the same urethane chip as used in Example 1, filling this into a mold, and press-molding while heating with steam, the thickness is 28 mm. A vehicle interior material made of a urethane chip molded product of 500 mm × 600 mm was manufactured.
[0032]
The weight of this vehicle interior material was 966 g, and the amount of deflection and sound transmission loss measured in the same manner as in Example 1 were as shown in Table 1 and FIG.
[0033]
[Table 1]
[0034]
From Table 1 and FIG. 2, it is clear that the interior material for a vehicle of the present invention is lighter in weight and less in deflection than the conventional product, so that it is comfortable to step on and has excellent sound insulation and sound absorption performance.
[0035]
【The invention's effect】
As described above in detail, according to the present invention, there is provided an interior material for a vehicle that is excellent in sound insulation and sound absorption performance, is lightweight and comfortable to step on, and is suitable as a vehicle floor insulator material.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an embodiment of a vehicle interior material of the present invention.
2 is a graph showing measurement results of sound transmission loss in Example 1 and Comparative Example 1. FIG.
[Explanation of symbols]
1 Urethane chip molding layer 2 Surface layer
Claims (5)
該ウレタンチップ成形層の密度が、0.05〜0.12g/cm3で、該表面層の目付が100〜500g/m2であり、
該バインダー繊維が、長さ38〜76mmで4〜65デニールであり、
該バインダー繊維の軟化温度が、80〜140℃であり、
該ウレタンチップ成形層のバインダーが、軟化して接着性を示すバインダー繊維であり、
該ウレタンチップ成形層のバインダーと、該表面層を構成するバインダー繊維とが同一のものであることを特徴とする車両用内装材。In the interior material for a vehicle in which a surface layer of a binder fiber which is softened and shows adhesiveness is integrally formed on the surface of a urethane chip molding layer formed by molding a urethane chip using a binder,
The density of the urethane chip molding layer is 0.05 to 0.12 g / cm 3 , and the basis weight of the surface layer is 100 to 500 g / m 2 ,
Said binder fibers, Ri Ah at 4 to 65 denier length 38~76Mm,
The binder fiber has a softening temperature of 80 to 140 ° C .;
The binder of the urethane chip molding layer is a binder fiber that softens and exhibits adhesiveness,
The vehicle interior material and the binder of the polyurethane chips molded layer, and the binder fiber constituting the surface layer, characterized in der Rukoto same.
軟化して接着性を示す繊維を型内に吹き込んで加熱加圧成形した後、更にウレタンチップとバインダーとの混合物を型内に吹き込んで加熱加圧成形することを特徴とする車両用内装材の製造方法。A method for manufacturing the vehicle interior material according to any one of claims 1 to 4 ,
A vehicle interior material characterized in that a softened and adhesive fiber is blown into a mold and heated and pressed, and then a mixture of a urethane chip and a binder is further blown into the mold and heated and pressed. Production method.
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