JP4757523B2 - 自動車用内装基材及びその製造方法 - Google Patents
自動車用内装基材及びその製造方法 Download PDFInfo
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- JP4757523B2 JP4757523B2 JP2005114870A JP2005114870A JP4757523B2 JP 4757523 B2 JP4757523 B2 JP 4757523B2 JP 2005114870 A JP2005114870 A JP 2005114870A JP 2005114870 A JP2005114870 A JP 2005114870A JP 4757523 B2 JP4757523 B2 JP 4757523B2
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Description
(1)繊維層の作製
基材構成繊維として、次の熱接着性短繊維と潜在捲縮性中空短繊維の2種類の繊維を用意した。
[熱接着性短繊維]
材料 :芯鞘型ポリエステル系樹脂(鞘成分:イソフタル酸で改質したポリブチレンテレフタレート[軟化点110℃、融点160℃]、芯成分:ポリエチレンテレフタレート[軟化点:237〜238℃、融点240℃])
繊度 :4.4dtex(繊維径20μm)
繊維長 :38mm
[潜在捲縮性中空短繊維]
材料 :東レテトロンT−70[東レ株式会社製](固有粘度の異なるポリエチレンテレフタレート/ポリエチレンテレフタレート複合繊維)
繊度 :14.3dtex(繊維径45μm)
繊維長 :51mm
熱可塑性樹脂シート層として、ポリエチレンテレフタレートの長繊維(融点:240℃、軟化点:237〜238℃)80質量%と低融点ポリエチレンテレフタレートの長繊維(融点:195℃、軟化点:150℃)20質量%とからなるスパンボンド不織布(面密度:70g/m2、厚さ:0.3mm、通気性有り)を用意した。また、接着層として、低融点ポリエステル(融点:120℃)を有する低融点樹脂不織布(面密度:24g/m2、厚さ:0.2mm、通気性有り)を用意した。次いで、この熱可塑性樹脂シート層と接着層とを温度150℃に設定した加熱ロールを用い加圧加熱することで予め複合不織布として一体化した。
(1)繊維層の作製
基材構成繊維の1つとして、次のような繊維を用意した。
材料 :東レテトロンT−201[東レ株式会社製](丸断面かつ中実のポリエチレンテレフタレート繊維)
繊度 :20dtex(繊維径43μm)
繊維長 :64mm
軟化点 :237〜238℃
融点 :240℃
熱可塑性樹脂シート層として、ポリエチレンテレフタレート(融点:240℃、軟化点:237〜238℃)のみから構成されたスパンボンド不織布(面密度:20g/m2、厚さ:0.3mm、通気性有り)を用意した。また、接着層として、変性オレフィン/ナイロン/変性オレフィンの3層フィルム(面密度:50g/m2、厚さ:0.05mm、通気性なし)を用意した。次いで、この熱可塑性樹脂シート層と接着層とを150℃に設定した加熱ロールを用い加圧加熱することで予め複合一体化した複合不織布とした。
(1)繊維層の作製
基材構成繊維の1つとして、次のような繊維を用意した。
材料 :バサルト繊維(basalt fiber:玄武岩を主成分とする人工の中実無機繊維)
繊維径 :10μm
繊維長 :50mm
融点 :1500℃
熱可塑性樹脂シート層として、実施例2と同様のポリエチレンテレフタレート(融点:240℃、軟化点:237〜238℃)のみから構成されたスパンボンド不織布(面密度:20g/m2、厚さ:0.3mm、通気性有り)を用意した。また、接着層として、変性オレフィン/ナイロン/変性オレフィンの3層フィルム(面密度:50g/m2、厚さ:0.05mm、通気性なし)を用意した。次いで、この熱可塑性樹脂シート層と接着層とを150℃に設定した加熱ロールを用い加圧加熱することで予め複合一体化した複合不織布とした。
(1)繊維層の作製
繊維ウエブに対してニードルパンチ加工を行わなかったことを除き、実施例1と同一の繊維配合及びウエブ形成工程により、繊維ウエブ(面密度600g/m2、厚さ80mm)を形成した。次いで、この繊維ウエブに対し、熱風の温度を175℃に設定した上下バンド型の熱風循環炉を用い、上下のバンド間隔を10mmに規制して加熱することで、面密度が600g/m2、厚さが10mmの比較例1に係る繊維層を得た。
繊維層を作製した後、実施例1と同一の複合不織布、即ち、予め熱可塑性樹脂シート層と接着層とを加熱加圧により接着したものを用いて、図3に示される内装基材100の構成と同一の構成で積層し、熱風の温度を230℃に設定した熱風循環炉による再度加熱したところ、厚さは30mmであった。加熱終了後、実施例1と同様に冷間プレスを行った。これらの工程を経て、各層間を圧着一体化し、面密度が788g/m2、厚さが8mmの比較例1に係る内装基材を調製した。
(1)繊維層の作製
繊維ウエブの主面方向内で二方向性の繊維配向(クロスレイ)を有することを除き、実施例1と同一の繊維配合及びニードルパンチ加工条件で、繊維ウエブ(面密度600g/m2、厚さ60mm)を作製した。次いで、熱風の温度を175℃に設定した熱風循環炉で加圧することなく加熱接着処理することによって、面密度600g/m2、厚さ10mmの比較例2に係る繊維層を得た。
繊維層を作製した後、実施例1及び比較例1と同様に、複合不織布の積層、熱風循環炉における再加熱及び冷間プレスの工程を経て、各層間を圧着一体化し、面密度788g/m2、厚さ8mmの比較例2に係る内装基材を調製した。
(1)繊維層の作製
繊維ウエブに対してニードルパンチ加工を行わなかったことを除き、比較例2と同一の条件で、繊維ウエブ(面密度600g/m2、厚さ60mm)を作製した。次いで、175℃に設定した加熱ロールで加圧接着し、面密度600g/m2、厚さ10mmの比較例3に係る繊維層を得た。
繊維層を作製した後、実施例1、比較例1及び比較例2と同様に、複合不織布の積層、熱風循環炉における再加熱及び冷間プレスの工程を経て、各層間を圧着一体化し、面密度788g/m2、厚さ8mmの比較例3に係る内装基材を得た。
次に、上述した実施例及び比較例に係る内装基材に対して、高温環境における形状維持特性を評価した。まず、上述した各内装基材の縦方向(繊維層の生産工程における流れ方向)に300mm、横方向に50mmの寸法で短冊状試験片を採取した。この短冊状試験片の縦方向における一端から70mmまでの領域を直方体の台上に載置固定し、残りの230mmの領域を直方体の台から突出させた。次いで、この状態を維持したまま、温度90℃に設定した恒温槽に4時間放置し、直方体の台から突出した部分の先端における垂下り量(単位:mm)を測定した。この垂下り量が10mm以下であれば、形状維持特性に優れていると評価できる。
また、常温における剛性の評価として、室温である25℃での剛性測定を実施した。まず、各内装基材の縦方向に150mm、横方向に50mmの寸法で短冊状試験片を採取した。この短冊状試験片を、100mmの間隔をおいて配置した2つの支持台上に、またがるように載置した。次いで、この支持台間の中央部(支持台から50mmの部分)を加圧くさびにより、加圧速度20mm/minで重力方向へ加圧した。この加圧時の荷重を、当該くさびが装着された引張試験機「テンシロンUCT−500」(オリエンテック製)により経時的に計測し、荷重が最大となる点の荷重(最大点荷重)を記録した。
Claims (10)
- 熱接着性短繊維を含む2種類以上の基材構成繊維が厚さ方向に配向された状態で厚さ方向と直交する方向に連続して集積し、前記基材構成繊維が絡まり合っている繊維ウエブを有する繊維層と、
前記繊維層の少なくとも一方の主面に接着して積層された熱可塑性樹脂シート層と、を備え、
前記繊維層には、ただし、2種類以上の短繊維を含む繊維ウエブを繊維層の厚さ方向へ配向させた不織布からなる繊維層が含まれず、
天井材、リアパッケージトレー材、ドアトリム材、及びダッシュインシュレーター材のうちのいずれかとして用いられる自動車用内装基材。 - 熱接着性短繊維を含む2種類以上の基材構成繊維をエアレイ法によって厚さ方向に配向させた状態で厚さ方向と直交する方向に連続して集積させた繊維ウエブにニードルパンチ加工を施してなる繊維層と、
前記繊維層の少なくとも一方の主面に接着して積層された熱可塑性樹脂シート層と、を備え、
天井材、リアパッケージトレー材、ドアトリム材、及びダッシュインシュレーター材のうちのいずれかとして用いられる自動車用内装基材。 - 前記熱接着性短繊維の軟化点が90℃以上であることを特徴とする請求項1もしくは請求項2に記載の自動車用内装基材。
- 前記繊維ウエブが、前記基材構成繊維として、前記熱接着性短繊維と捲縮性中空短繊維とを含むことを特徴とする請求項1から請求項3のいずれかに記載の自動車用内装基材。
- 前記熱可塑性樹脂シート層を、互いの融点が30℃以上異なる2種類の長繊維を含むスパンボンド不織布としたことを特徴とする請求項1から請求項4のいずれかに記載の自動車用内装基材。
- 前記基材構成繊維が何れもポリエステル系樹脂からなることを特徴とする請求項1から請求項5のいずれかに記載の自動車用内装基材。
- 熱接着性短繊維を含む2種類以上の基材構成繊維を厚さ方向に配向させた状態で厚さ方向と直交する方向に連続して集積させることで繊維ウエブを形成するウエブ形成工程と、
前記繊維ウエブの基材構成繊維を絡まり合わせる絡合工程と、
前記繊維ウエブを加熱して、前記熱接着性短繊維を他の基材構成繊維に接着させて繊維層を形成する加熱接着工程と、を備え、
天井材、リアパッケージトレー材、ドアトリム材、及びダッシュインシュレーター材のうちのいずれかとして用いられる自動車用内装基材の製造方法。 - 熱接着性短繊維を含む2種類以上の基材構成繊維をエアレイ法によって厚さ方向に配向させた状態で厚さ方向と直交する方向に連続して集積させて繊維ウエブを形成するウエブ形成工程と、
前記繊維ウエブにニードルパンチ加工を施す絡合工程と、
前記繊維ウエブを加熱して、前記熱接着性短繊維を他の基材構成繊維に接着させて繊維層を形成する加熱接着工程と、を備え、
天井材、リアパッケージトレー材、ドアトリム材、及びダッシュインシュレーター材のうちのいずれかとして用いられる自動車用内装基材の製造方法。 - 前記繊維ウエブが、前記基材構成繊維として、前記熱接着性短繊維と潜在捲縮性中空短繊維とを含むことを特徴とする請求項7もしくは請求項8に記載の自動車用内装基材の製造方法。
- さらに、前記繊維層の少なくとも一方の主面に熱可塑性樹脂シート層を接着して積層する積層工程を備えることを特徴とする請求項7から請求項9のいずれかに記載の自動車用内装基材の製造方法。
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JP5142677B2 (ja) * | 2007-11-14 | 2013-02-13 | 日本バイリーン株式会社 | 自動車用内装材及び自動車用内装基材 |
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JP5585222B2 (ja) * | 2010-06-08 | 2014-09-10 | トヨタ紡織株式会社 | 繊維構造体及びその製造方法 |
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JP6011253B2 (ja) | 2012-11-02 | 2016-10-19 | 東洋紡株式会社 | 成型性の優れた熱圧着長繊維不織布 |
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