JP4880938B2 - Vehicle interior materials and ceiling materials - Google Patents

Description

  The present invention relates to a vehicle interior material and a ceiling material that have good moldability, are less likely to be contaminated by airflow in a vehicle compartment, and have particularly excellent rigidity.

  As characteristics required for vehicle interior materials, not only decorative properties and contact feeling, but also low air permeability, rigidity, and moldability are required. If the air permeability is high, the indoor air passes through the interior material due to the pressure difference and moves toward the body, and dust and tobacco fine particles floating in the indoor air are trapped on the interior material surface and become dirty on the interior material. And become attached. Moreover, when the rigidity is low, when the vehicle interior material is used as a ceiling material, the form retainability is impaired and the product value is lowered.

  As a method for reducing the air permeability, for example, in Patent Document 1, a vehicle comprising a skin material / urethane cushion material / a multilayer resin film having a low melting point and thermal adhesiveness / a glass wool base material. Interior materials have been proposed. According to such a vehicle interior material, it is possible to reduce the air permeability because the air flow is blocked by the multilayer resin film. However, since a special technique is required to obtain the multilayer resin film, the cost increases. There was a risk of becoming. Further, since the vehicle interior material is composed of a plurality of materials, there is a problem in terms of recyclability.

  Patent Documents 2 and 3 propose that a vehicle interior material is configured using a low-melting hot-melt film. However, when such a hot melt film is applied to an adherend, it is difficult to control the melt viscosity of the film, so that adhesion between the film and the adherend tends to occur, peeling strength is generated, and rigidity and moldability are impaired. There was a fear.

On the other hand, the inventor previously molded in Japanese Patent Application No. 2004-0665416 by bonding a film made of a copolyester to a fiber base material containing inelastic crimped short fibers and heat-bondable composite short fibers. We proposed a vehicle interior material that has good properties, is less susceptible to contamination by airflow in the vehicle compartment, and has rigidity.
However, in applications such as ceiling materials, it has been found that even better rigidity is required.

Japanese Patent Laid-Open No. 7-117571 JP-A-7-261769 JP 2001-322193 A

  SUMMARY OF THE INVENTION The present invention has been made in view of the above-described background, and an object of the present invention is to provide a vehicle interior material and a ceiling material that have excellent moldability, are less likely to generate dirt due to airflow in the vehicle compartment, and have particularly excellent rigidity. It is to provide.

  As a result of intensive studies to achieve the above-mentioned problems, the inventor laminated a woven / knitted fabric and a film in this order on a fiber base material including inelastic crimped short fibers and heat-adhesive composite short fibers, whereby the moldability is improved. It has been found that a vehicle interior material that is excellent and has little contamination due to airflow in the vehicle compartment and has particularly excellent rigidity can be obtained, and the present invention has been completed by intensive studies.

Thus, according to the present invention, “a non-elastic crimped short fiber and a polymer having a melting point lower by 40 ° C. or more than the polymer constituting the non-elastic crimped short fiber are arranged on the surface as a heat-sealing component. The composite short fibers are mixed so that the weight ratio is 90/10 to 30/70, and the contact points between the heat-adhesive composite short fibers and / or the heat-adhesive composite short fibers and the inelastic crimped short fibers are mixed. To the fiber base material where a part of the contact point is thermally bonded,
A vehicle interior material comprising a woven / knitted fabric made of organic fibers and a woven / knitted fabric having a warp and / or weft density of 30 / 2.54 cm or less , and a film made of a synthetic resin laminated in this order. Is provided.

In that case, it is preferable that the said non-elastic crimped short fiber is a non-elastic polyester type | system | group crimped short fiber. Moreover, it is preferable that the said heat-fusion component consists of a polyester-type polymer. The apparent density of the fiber substrate is preferably in the range of 0.02 to 0.20 g / cm ³ . The thickness of the fiber base material is preferably in the range of 1 to 70 mm.

In the vehicle interior material of the present invention, the organic fiber forming the woven or knitted fabric is preferably a polyester fiber .

In the vehicle interior material of the present invention, the synthetic resin forming the film is preferably a polyester resin. Furthermore, it is preferable that a polyester-based skin material and / or a polyester-based back material is laminated on the vehicle interior material.
Moreover, according to this invention, the ceiling material which uses the said vehicle interior material is provided.

  According to the present invention, it is possible to obtain a vehicle interior material and a ceiling material that have good moldability, are less likely to be contaminated by airflow in the vehicle compartment, and have particularly excellent rigidity.

Hereinafter, embodiments of the present invention will be described in detail.
Examples of inelastic crimped short fibers used in the present invention include polyethylene terephthalate, polybutylene terephthalate, polyhexamethylene terephthalate, polytetramethylene terephthalate, poly-1,4-dimethylcyclohexane terephthalate, polyethylene naphthalate, polypivalolactone, or The short fiber which consists of these copolymers, the mixed cotton body of these short fibers, or the composite short fiber which consists of two or more types of the said polymer component etc. can be mentioned. Among these short fibers, short fibers made of polyethylene terephthalate or polybutylene terephthalate are particularly preferable from the viewpoint of fiber forming property and the like. In view of heat resistance, short fibers made of polyethylene naphthalate are preferable.

  In this case, as a method for imparting crimps, spiral crimps are imparted using composite fibers obtained by laminating polymers having different heat shrinkage rates to side-by-side types, spiral crimps are imparted by anisotropic cooling, and the number of crimps is Various methods may be used such as imparting mechanical crimping by an ordinary indentation crimper method so as to be 3 to 40 pieces / 2.54 cm (preferably 7 to 15 pieces / 2.54 cm). It is optimal to provide mechanical crimping in terms of cost and the like.

  In the above-mentioned inelastic crimped short fibers, the single yarn fineness is preferably 0.5 to 30 dtex (more preferably 1 to 25 dtex, particularly preferably 2 to 20 dtex). The fiber length is preferably cut to 3 to 100 mm. In addition, when it is desired to further improve the rigidity, a small amount of short fibers having a large fineness can be mixed.

  Next, it is necessary that the heat-sealing component disposed on the surface of the heat-adhesive composite short fiber has a melting point that is 40 ° C. or lower than the polymer component constituting the inelastic crimped short fiber. If this temperature is less than 40 ° C., the adhesion becomes insufficient, and the fiber structure that is difficult to handle and has no waist is formed, and the object of the present invention cannot be achieved.

  Here, as a polymer arranged as a heat-fusion component, polyurethane elastomer, polyester elastomer, inelastic polyester polymer and copolymer thereof, polyolefin polymer and copolymer thereof, polyvinyl alcohol polymer, etc. Can be mentioned.

  Examples of polyurethane elastomers include low-melting-point polyols having a molecular weight of about 500 to 6000, such as dihydroxy polyether, dihydroxy polyester, dihydroxy polycarbonate, dihydroxy polyester amide, and the like, and organic diisocyanates having a molecular weight of 500 or less, such as p, p′-diphenylmethane. Diisocyanate, tolylene diisocyanate, isophorone diisocyanate hydrogenated diphenyl methane isocyanate, xylylene isocyanate, 2,6-diisocyanate methyl caproate, hexamethylene diisocyanate and the like, and a chain extender having a molecular weight of 500 or less, such as glycol amino alcohol or triol It is a polymer obtained by the reaction.

  Among these polymers, particularly preferred is a polyurethane using polytetramethylene glycol, poly-ε-caprolactam or polybutylene adipate as a polyol. Examples of the organic diisocyanate in this case include p, p'-bishydroxyethoxybenzene and 1,4-butanediol.

  In addition, as a polyester-based elastomer, a polyetherester copolymer obtained by copolymerizing thermoplastic polyester as a hard segment and poly (alkylene oxide) glycol as a soft segment, more specifically, terephthalic acid, isophthalic acid, phthalic acid Alicyclic dicarboxylic acids such as naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid, diphenyl-4,4′-dicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, succinic acid, oxalic acid, At least one dicarboxylic acid selected from aliphatic dicarboxylic acids such as adipic acid, sebacic acid, dodecanedioic acid, dimer acid, or ester-forming derivatives thereof, 1,4-butanediol, ethylene glycol trimethylene glycol, Tetramethylene glycol, Aliphatic diols such as tamethylene glycol, hexamethylene glycol neopentyl glycol, decamethylene glycol, or alicyclic diols such as 1,1-cyclohexanedimethanol, 1,4-cyclohexanedimethanol, tricyclodecane methanol, or the like At least one diol component selected from ester-forming derivatives and the like, and polyethylene glycol, poly (1,2- and 1,3-polypropylene oxide) glycol, poly (tetramethylene oxide) having an average molecular weight of about 400 to 5000 ) Consists of at least one of poly (alkylene oxide) glycols such as glycols, copolymers of ethylene oxide and propylene oxide, copolymers of ethylene oxide and tetrahydrofuran, etc. It can be mentioned terpolymer.

  In particular, from the viewpoint of adhesiveness, temperature characteristics, and strength, a block copolymer polyether ester having polybutylene terephthalate as a hard component and polyoxybutylene glycol as a soft segment is preferable. In this case, the polyester portion constituting the hard segment is polybutylene terephthalate in which the main acid component is terephthalic acid and the main diol component is a butylene glycol component. Of course, part of this acid component (usually 30 mol% or less) may be substituted with another dicarboxylic acid component or oxycarboxylic acid component, and part of the glycol component (usually 30 mol% or less) is also butylene. It may be substituted with a dioxy component other than the glycol component. Further, the polyether portion constituting the soft segment may be a polyether substituted with a dioxy component other than butylene glycol.

Copolyester polymers include aliphatic dicarboxylic acids such as adipic acid and sebacic acid, aromatic dicarboxylic acids such as phthalic acid, isophthalic acid and naphthalenedicarboxylic acid and / or fats such as hexahydroterephthalic acid and hexahydroisophthalic acid. A co-polymer containing a predetermined number of cyclic dicarboxylic acids and aliphatic or alicyclic diols such as diethylene glycol, polyethylene glycol, propylene glycol, and paraxylene glycol, with addition of oxyacids such as parahydroxybenzoic acid as desired. Polymerized esters and the like can be mentioned. For example, polyesters obtained by adding and copolymerizing isophthalic acid and 1,6-hexanediol in terephthalic acid and ethylene glycol can be used.
Examples of the polyolefin polymer include low density polyethylene, high density polyethylene, and polypropylene.

Among the above-mentioned heat fusion components, a copolymerized polyester polymer and a thermoplastic polyester elastomer are preferable. In addition, it is more preferable to use a polyester-based elastomer when adding noise reduction performance to the vehicle interior material.
In addition, various stabilizers, ultraviolet absorbers, thickening branching agents, matting agents, coloring agents, other various improving agents, and the like may be blended in the above-described polymer as necessary.

  In the heat-bondable composite short fiber, the non-elastic polyester as described above is preferably exemplified as the counterpart component of the heat-sealing component. In that case, it is preferable that the heat fusion component occupies at least a half of the surface area. The weight ratio is suitably in the range of 30/70 to 70/30 in terms of the composite ratio of the heat fusion component and the non-elastic polyester. Although it does not specifically limit as a form of a heat bondable composite staple fiber, It is preferable that a heat-fusion component and inelastic polyester are side-by-side and a core-sheath type, More preferably, it is a core-sheath type. In that case, the core part may be concentric or eccentric.

  In such a heat-adhesive conjugate short fiber, the single yarn fineness is preferably 1 to 15 dtex (more preferably 2 to 13 dtex, particularly preferably 2 to 10 dtex). Such heat-adhesive composite short fibers are preferably cut to a fiber length of 3 to 100 mm.

  In the vehicle interior material of the present invention, the fiber base material is obtained by blending the above-mentioned inelastic crimped short fibers and the above-mentioned heat-adhesive composite short fibers and heat-treating them so that the heat-adhesive composite short fibers intersect each other. The fiber structure is formed by interspersing the fixing points heat-sealed in such a state and the fixing points heat-sealed in a state where the heat-adhesive composite short fibers and the inelastic crimped short fibers intersect.

  At this time, the weight ratio between the inelastic crimped short fibers and the heat-bonded composite short fibers needs to be 90/10 to 30/70. When the ratio of the heat-bonding composite short fiber is less than this range, the fixing points are extremely reduced, the fiber structure is not loose, and the moldability is poor. On the other hand, when the ratio of the heat-bonding composite short fibers is larger than this range, the number of adhesion points becomes excessive, and the handleability and moldability in the heat treatment process are lowered.

  Such a fiber base material can be manufactured by various methods. For example, after blending inelastic crimped short fibers and heat-adhesive composite short fibers and opening them with a card or the like to form a web, the webs are laminated as necessary and heat treated to fuse the fibers together or in a predetermined shape A predetermined amount of web is packed into a mold with compression and compression-heated, or a laminated web is sandwiched between a flat plate made of a punching plate and a conveyor with a caterpillar type upper and lower punching plate, and heat treatment is performed. And a method of obtaining a fiber base material by compressing vertically and horizontally before cooling immediately after heating. In addition, there is a method in which, after spinning as a uniform web with a roller card, the web is heated while being folded into an accordion shape, and a fixing point is formed by thermal fusion, for example (see JP-T-2002-516932). Can be manufactured using a commercially available apparatus (such as a STRUTO equipment manufactured by STRUTO, Inc.) Further, the fiber substrate can be made substantially perpendicular to the thickness direction, or slightly inclined as necessary. The slices may be sliced by a slicer facility.

The average density of the fiber substrate is preferably in the range of 0.015 to 0.20 g / cm ³ . It said seal of handling is difficult too soft and fibrous structure is less than 0.015 g / cm ^3, whereas, it is plate-shaped exceeds 0.20 g / cm ^3, not only the subsequent molding becomes difficult, Sound comes to be reflected, and there is a possibility that sound absorbing property cannot be added to the vehicle interior material.

  Next, a woven or knitted fabric made of organic fibers is laminated on the fiber base material. When the woven or knitted fabric is not laminated, it is not preferable because sufficient rigidity cannot be obtained. Organic fibers that form woven and knitted fabrics include natural fibers such as cotton, hemp, and silk, regenerated fibers such as rayon, semi-synthetic fibers such as acetate, polyester fibers represented by polyethylene terephthalate, polytrimethylene terephthalate, polylactic acid, and the like. And synthetic fibers such as polyetherester fiber, acrylic fiber, nylon fiber, and aramid fiber. One kind of these fibers may be used, or a plurality of combinations may be used. Of these, polyester fibers are preferably exemplified in terms of excellent rigidity and easy recyclability.

  The form of these organic fibers is not particularly limited, and long fibers (multifilaments, monofilaments), short fibers, composite yarns thereof, false twisted crimped yarn, air processed yarn, spun yarn, twisted yarn Etc. are exemplified. The cross-sectional shape of the fiber is not particularly limited, and is appropriately selected from a circle, a triangle, a flat shape, a hollow shape, and the like.

  The total fineness and single yarn fineness of the organic fiber are not particularly limited, but in terms of rigidity, the total fineness is 150 to 2000 dtex (more preferably 300 to 1500 dtex), and the single yarn fineness is 1 to 1000 dtex (more preferably 2 to 500 dtex). ) Is preferable.

  The structure of the woven or knitted fabric is not particularly limited, and a woven fabric having a plain structure, a twill structure, a satin structure, and their changed structures, and a knitted fabric such as a circular knitted fabric and a warp knitted fabric are used. Of these, a plain woven fabric or a twill woven fabric is preferable.

In such a woven or knitted fabric, the smaller the woven / knitted density, the better the moldability. Therefore, the woven / knitted density in the warp and / or weft direction is preferably 30 / 2.54 cm or less. However, if the weaving and knitting density is too small, the rigidity is impaired. Therefore, in order to achieve both formability and rigidity, the warp density ranges from 2 to 25 yarns / 2.54 cm and the weft density ranges from 2 to 25 yarns / 2.54 cm. Is preferred. Further, the mesh opening (width between adjacent warps or wefts) of the woven or knitted fabric is preferably 0.1 to 5 mm, and the basis weight is preferably 10 to ²⁰⁰ g / m ² . Even if a resin such as poval is applied to the woven or knitted fabric, there is no problem.

  Next, the film to be bonded is not particularly limited as long as it is a film made of a synthetic resin, and various films such as an olefin film and a nylon film can be used. In particular, a copolymer polyester film having a melting point of 210 to 245 ° C. is preferable in terms of recyclability, moldability, and the like, and those constituting the main repeating unit of the copolymer polyester film used in the present invention include ethylene terephthalate, tetramethylene terephthalate, Examples thereof include ethylene-2,6-naphthalate and tetramethylene-2,6-naphthalate. Among them, copolymerized polyethylene terephthalate having an ethylene terephthalate unit as a main constituent heats mold followability, adhesion, and corrosion resistance. It is preferable because it can be maintained well after the history. Here, “the one having an ethylene terephthalate unit as a main constituent” means that the terephthalic acid component is at least 75 mol% of the total dicarboxylic acid component and the ethylene glycol component is at least 75 mol% of the total diol component.

  The copolymer component of the copolymerized polyethylene terephthalate is not particularly limited. Preferred dicarboxylic acid components include aromatic dicarboxylic acids such as isophthalic acid, orthophthalic acid, 2,6-naphthalenedicarboxylic acid, 2,7-naphthalenedicarboxylic acid, 1,4-naphthalenedicarboxylic acid, and 4,4′-biphenylenedicarboxylic acid. Preferred diol components such as an acid component, an alicyclic dicarboxylic acid component such as cyclohexane-1,4-dicarboxylic acid, and an aliphatic dicarboxylic acid component such as succinic acid, adipic acid, and sebacic acid include propylene glycol, trimethylene glycol, Aliphatic diol components such as tetramethylene glycol and neopentyl glycol, alicyclic diol components such as cyclohexane-1,4-dimethanol, aromatic diol components such as bisphenol A, diethylene glycol, polyethylene glycol, polytetramethyl As ether-condensed diol components such as N-glycol, and as components other than preferred dicarboxylic acid and diol components, hydroxycarboxylic acid components such as p-hydroxybenzoic acid, ω-hydroxybutyric acid, ω-hydroxyvaleric acid, and lactic acid, polycarbonate In addition, a carbonic acid component such as that shown in (2) above, and a trifunctional or higher functional component such as trimellitic acid, pyromellitic acid, and glycerin. Among these, isophthalic acid, 2,6-naphthalenedicarboxylic acid, or diethylene glycol is particularly preferable because of the ease of exhibiting various properties, the availability of raw materials, the ease of production of the copolyester, and the like. The proportion of these copolymer components may be adjusted so that the melting point of the copolymer polyester is in the range of 210 to 245 ° C. For example, when isophthalic acid is copolymerized with polyethylene terephthalate, The proportion of isophthalic acid occupied is preferably in the range of approximately 5.5 to 18 mol%.

  The film may be composed of a single layer or a laminate of two or more layers. In the case of a laminate, the layer made of the above-mentioned copolymer polyethylene glycol is preferably 50% or more of the total thickness. Other layers of the copolymer polyethylene glycol layer may be made of homopolyethylene glycol, or may be made of a copolyester.

  It is preferable that the film contains particles having an average particle size of 2.5 μm or less because appropriate slipperiness can be obtained, and as a result, the handleability and moldability of the film are excellent. The type of particles is not particularly limited, but inorganic fine particles such as silica, alumina, titanium oxide, calcium carbonate, and kaolin, precipitated fine particles of catalyst residue and / or organic fine particles such as silicone, polystyrene cross-linked product, and acrylic cross-linked product are preferable. Can be mentioned. In addition to the above-described particles, various additives such as a stabilizer, an antistatic agent, a dye, a pigment, and a flame retardant may be contained within a range not impairing the effects of the present invention. The thickness of the film is 10 μm to 250 μm, preferably 20 μm to 200 μm. If the thickness is less than 10 μm, sufficient rigidity is not obtained after molding. On the other hand, if it exceeds 250 μm, wrinkles are likely to enter during molding. For example, a film described in JP-A-2001-257129 can be used.

  The vehicle interior material of the present invention can be obtained by laminating and bonding the fiber base material, the woven / knitted fabric, and the film in this order. Here, they may be bonded together when creating the fiber base material, or may be bonded by heat treatment in a separate process. Further, as described later, the skin material and / or the back material may be molded. In addition, the fiber substrate, film, and woven / knitted fabric may each be a single layer or multiple layers. For example, a structure in which a film is sandwiched between fiber substrates may be used, but at least a layer in which a woven or knitted fabric is sandwiched between the film and the fiber substrate is required. By adhering the woven or knitted fabric to the film, it greatly contributes to the improvement of the rigidity of the film, and further seems to work to suppress the shrinkage of the film at a high temperature.

  In addition, it is possible to bond by using only the thermocompression bonding without using an adhesive using the same material, but it is possible to bond by using various adhesives at the time of fiber base preparation or lamination. Polyester resin is preferable from the viewpoint of recycling.

  In the vehicle interior material of the present invention, it is preferable that the skin material and / or the back material is laminated. As the skin material and / or the back material, those having air permeability are preferable. For example, non-woven fabric or woven fabric made of polyester fiber, polypropylene fiber or the like, knit, or raised knit, but polyester fiber is preferred from the viewpoint of recyclability.

The vehicle interior material of the present invention may be added with known functional processing such as water repellent processing, flameproof processing, flame retardant processing, and negative ion generation processing.
In the vehicle interior material of the present invention thus obtained, since the woven or knitted fabric layer is sandwiched between the fiber base material and the film, excellent rigidity can be obtained without impairing moldability and air permeability.

  The vehicle interior material of the present invention can be suitably used as a vehicle interior material such as a door trim, a quarter trim, a package tray trim, and a floor mat. Furthermore, there is no problem even if it is used as a partition of a house. In particular, since the vehicle interior material of the present invention has excellent rigidity, it can be particularly suitably used as a vehicle ceiling material.

Next, although the Example and comparative example of this invention are explained in full detail, this invention is not limited by these. In addition, each measurement item in an Example was measured with the following method.
(1) Melting point Using a differential thermal analyzer 990 manufactured by Du Pont, measured at a temperature increase of 20 ° C./min, and obtained a melting peak. If the melting temperature is not clearly observed, the melting point is the temperature at which the polymer softens and starts to flow (softening point) using a trace melting point measuring device (manufactured by Yanagimoto Seisakusho).
(2) Fiber fineness Measured by the method described in JIS L 1015 7.5.1 Method A.
(3) The number of crimps of the fiber and the crimp rate were measured by the method described in JIS L 1015 7.12.
(4) Measurement of thickness and density of base material (bonded product) The basis weight (g / m ² ) of the base material adjusted to a flat plate shape was measured, and 4.9 mN / cm ² (0.5 g / cm ² ). The thickness (cm) under the load was measured, and the apparent density (g / cm ³ ) was calculated.
(5) Flexural strength of laminate As a substitute characteristic of rigidity, a test piece having a size of 50 mm (width) x 150 mm (length) is used in accordance with JIS K 7203, with a span of 100 mm and a bending speed of 10 mm / min. The maximum bending strength was measured.
(6) Heat resistance Three horizontal 50 x 250 mm test pieces are cut out from the vertical and horizontal directions of the substrate, 50mm is fixed with the design side down, and 200mm is overhanged and dried with hot air After leaving it in a furnace at 70 ° C. for 24 hours, it is taken out from the drying furnace and the amount of sagging at the tip when the substrate reaches room temperature is measured. The test result is displayed as an average value.
(7) Molding followability An adhesive spunbond sheet and a skin material are overlapped on a film and a fiber base material, and pressed for 180 seconds using a 10 mm thick spacer in a press machine set at 195 ° C. A vehicle interior material in which the material / base material / back surface material was laminated and integrated was produced. Immediately after the substrate was dry-heated at 180 ° C. for 180 seconds, the substrate was squeezed with a room temperature mold having an inner diameter of 200 mm × height of 100 mm × thickness of 5 mm with the hot film surface inside. processed. The appearance of this processed product was observed and evaluated according to the following criteria.
○: The shape of the mold is beautifully reproduced, and no peeling of each layer is observed.
(Triangle | delta): The peeling of a film etc. and the shape of a metal mold | die are not reproduced in part.
X: Film or woven or knitted fabric is not integrated. Or, the shape of the mold cannot be reproduced at all.

[Example 1]
Polyethylene (terephthalate-isophthalate) copolymer (terephthalic acid (TA) component / isophthalic acid (IA) component molar ratio) of an intrinsic viscosity of 0.65 (measured in o-chlorophenol at 35 ° C., the same applies hereinafter) = 88/12) pellets (containing 0.1% by weight of spherical silica particles having an average particle size of 1.5 μm) were supplied to an extruder and melt-extruded on a rotary cooling drum maintained at 20 ° C. to obtain a thickness of 240 μm. An unstretched film was obtained. Next, the unstretched film is stretched 3.0 times in the MD direction, both ends along the MD direction of the unstretched film are gripped and stretched 3.2 times in the TD direction, and the both ends are gripped. While being given 3% relaxation in the TD direction, heat treatment was performed at 190 ° C. to obtain a biaxially stretched polyester film having a thickness of 180 μm.

Next, a plain weave was woven using normal polyethylene terephthalate multifilament 1250dtex / 192fil for warp and weft (5 warps / 2.54cm, 5 wefts / 2.54cm). The opening is 4 mm. The basis weight was 55 g / m ² .

  Next, an acid component obtained by mixing terephthalic acid and isophthalic acid at 80/20 (mol%) as a copolyester of the thermal adhesive component, and ethylene glycol and tetramethylene glycol are mixed at 50/50 (mol%). Copolyester was obtained from the diol component. The melting point of the copolyester was 155 ° C. This copolymerized polyethylene terephthalate is placed in the sheath as a heat-adhesive component, polyethylene terephthalate having a glass transition point of 67 ° C. and a melting point of 256 ° C. is dried under reduced pressure, and then the core is supplied to a core-sheath compound melt spinning apparatus. Melt spinning was performed from a spinneret having a spinning hole number of 450 at a spinning ratio of 50/50, a spinning temperature of 290 ° C., and a discharge rate of 650 g / min. An oil agent was applied and taken out at 900 m / min to obtain an unstretched core-sheath type composite fiber.

  The unstretched fibers are bundled to make a 110,000 dtex (100,000 denier) tow, first stretched 2.5 times in warm water at 72 ° C., and further stretched 1.15 times in warm water at 80 ° C. After applying the oiling agent, crimping was performed with an indentation type crimper naturally cooled to 35 ° C., and cut into a fiber length of 51 mm to obtain a heat-adhesive composite short fiber having a single yarn fineness of 4.4 dtex. The number of crimps at this time was 10 pieces / 25 mm, and the crimp rate was 15%.

50% (by weight) of this composite fiber, a hollow cross-section polyethylene terephthalate short fiber (melting point 256 of polyethylene terephthalate) having a single fiber thickness of 20 dtex, a fiber length of 64 mm, and a crimp number of 9/25 mm. C.) 50% (weight) was mixed with a card to obtain a web of 30 g / m ³ . This web is stacked and placed in a flat plate mold so as to have a thickness of 20 mm and a density of 0.020 g / cm ^3, and heat-treated at 180 ° C. for 10 minutes to obtain a flat plate fiber substrate (weight per unit area of 1050 g / m ² , thickness). 15 mm and an apparent density of 0.070 g / cm ³ ) were obtained.

Next, the film, woven fabric, fiber substrate, thermal adhesive sheet (spun fab manufactured by Nittobo Co., Ltd., basis weight 30 g / m ² , thickness 0.8 mm), skin material (ordinary polyester nonwoven fabric with basis weight 230 g / m ² ) In this order, the plate was pressed at 190 ° C. for 5 minutes and pressed to a thickness of 5 mm to obtain a ceiling material. The obtained ceiling material had a bending strength of 17.7 N / 5 cm, heat resistance of 2.7 cm, and moldability.

[Example 2]
A ceiling material was obtained in the same manner as in Example 1 except that the thickness of the film was 50 μm. The obtained ceiling material had a bending strength of 16.0 N / 5 cm, heat resistance of 2.2 cm, and moldability.

[Comparative Example 1]
A ceiling material was obtained in the same manner as in Example 1 except that no woven fabric was used. The obtained ceiling material had a bending strength of 12.0 N / 5 cm, heat resistance of 4.9 cm, and moldability.

[Comparative Example 2]
Although it is the same as that of Example 1, the order of the structure was made into the skin, the adhesive sheet, the textile fabric, the fiber base material, and the film, and the ceiling material was obtained. In the obtained ceiling material, the bending strength was 13.0 N / 5 cm, the heat resistance was 3.5 cm, and the moldability was good.

[Example 3]
In Example 1, plain warp was woven using normal polyethylene terephthalate multifilament 450 dtex / 72 fil for warp and weft (12 warps / 2.54 cm, 12 wefts / 2.54 cm). The opening is 0.2 mm. The basis weight was 50 g / m ² . Except for this, a ceiling material was obtained in the same manner as in Example 1. The obtained ceiling material had a bending strength of 19.0 N / 5 cm, a heat resistance of 1.8 cm, and a moldability of Δ to ○.

  According to the present invention, it is possible to obtain a vehicle interior material and a ceiling material having good moldability, little occurrence of contamination due to airflow in the vehicle interior, and particularly excellent rigidity, and the industrial value thereof is extremely large. .

Claims (9)

The weight ratio of the inelastic crimped short fiber and the heat-adhesive composite short fiber disposed on the surface of the polymer having a melting point lower by 40 ° C. or lower than the polymer constituting the inelastic crimped short fiber as a heat-fusible component 90/10 to 30/70, and the contact point between the heat-adhesive composite staple fibers and / or part of the contact point between the heat-adhesive composite staple fibers and the inelastic crimped staple fibers is To the fiber substrate that is thermally bonded,
A vehicle interior material comprising a woven / knitted fabric made of organic fibers and a woven / knitted fabric having a warp and / or weft density of 30 / 2.54 cm or less , and a film made of a synthetic resin laminated in this order.   The vehicle interior material according to claim 1, wherein the inelastic crimped short fibers are inelastic polyester-based crimped short fibers.   The vehicle interior material according to claim 1, wherein the heat fusion component is made of a polyester polymer. The vehicle interior material according to any one of claims 1 to 3, wherein an apparent density of the fiber base material is in a range of 0.02 to 0.20 g / cm ³ .   The vehicle interior material according to any one of claims 1 to 4, wherein a thickness of the fiber base is in a range of 1 to 70 mm.   The vehicle interior material according to any one of claims 1 to 5, wherein the organic fiber forming the woven or knitted fabric is a polyester fiber. The vehicle interior material according to any one of claims 1 to 6, wherein the synthetic resin forming the film is a polyester resin. A vehicle interior material obtained by further laminating a polyester-based skin material and / or a polyester-based back material on the vehicle interior material according to claim 1. A ceiling material using the vehicle interior material according to claim 1.