JP5060621B2 - Automotive interior materials - Google Patents

Description

  The present invention relates to an automobile interior material mainly used for flooring.

As this type of automobile interior material, a breathable material having a predetermined ventilation resistance is generally used. For example, Patent Document 1 discloses a nonwoven fabric having a basis weight of 150 to 800 g / m ² and a bulk density of 0.01 to 0.2 g / cm ³ , and an air flow rate measured based on JIS L-1096 of 50 cc / cm ^2. A sound-absorbing material laminated with a skin material of / sec or less is described, and Patent Document 2 laminates a nonwoven fabric having a basis weight of 150 to 800 g / m ² and a bulk density of 0.01 to 0.2 g / m ³ as a skin material. And a fiber / foam composite layer having a total resistance to air flow R _t = 500 Nsm ^{−3 to} R _t = 2500 Nsm ^−3. A sound insulation kit is described.
The sound-absorbing material or the sound-insulating kit absorbs the energy of sound that has entered the inside by converting it into frictional energy.
Furthermore, in order to enhance the sound absorbing performance of the sound absorbing material, a structure in which a rubber layer or a resin layer provided with a number of through holes is inserted in addition to the breathable material used in each of the sound absorbing materials has been proposed. Yes.
For example, Patent Document 4 describes a structure in which a sound absorbing material layer lined with a rubber layer provided with a plurality of through holes is laminated on the back surface of a floor mat, and Patent Document 5 discloses an opening above the shape retaining felt layer. By laminating a resin layer and laminating a non-breathable resin sheet on the lower side, the sound waves that have entered the shape-retaining felt layer from the perforated resin layer are confined between the perforated resin layer and the non-breathable resin sheet. It describes an interior material that diffusely reflects in a shape-retaining felt and absorbs sound energy with high efficiency.

International Publication No. 2005/019783 JP 2005-335279 A Special Table 2000-516175 JP 2007-126084 A JP 2007-161153 A

  When the rubber layer or the resin layer is configured to be inserted, needle stick processing is generally applied to a processing method for providing a through hole in the rubber layer or the resin layer. However, since the diameter of the through hole provided by the needle piercing process is determined by the thickness of the needle, there is a problem that it is almost impossible to provide a through hole with a minute diameter, particularly a minute through hole with a diameter of 0.1 mm or less. There is a point. Further, there is a problem that even if the through hole is formed, the through hole is blocked by the elastic restoring force of the resin layer or the rubber layer.

In the present invention, as a means for solving the above-described conventional problems, a non-breathable resin sheet 4 is laminated on a porous mat 5, and a moldable felt 3 is laminated on the non-breathable resin sheet 4. An automotive interior material 6 in which a breathable outer covering material 2 lined with a paper material 1 is laminated on a felt 3, wherein the paper material 1 has a beating degree of JIS P 8121-1995. 90% by mass or more of a porous pulp fiber having a Canadian standard freeness prescribed by Canadian Standard Freeness in the range of 350 to 650 ml (CSF) and having a large number of pores opened on the surface, The present invention provides an automobile interior material 6 characterized in that it is a paper having a ventilation resistance of 0.07 to 3.00 kPa · s / m.
The paper material 1 is desirably a crepe and / or embossed paper imparted with stretchability by forming a large number of irregularities on the surface, and the basis weight of the paper material 1 is 15 g / m ^{2 to} 50 g / m ² is desirable.
The moldable felt 3 has a basis weight of 50 to 1000 g / m ² , a thickness of 1.5 mm or more, and a low melting point thermoplastic resin fiber having a melting point of 180 ° C. or less and containing 10 to 50% by mass. The airflow resistance is preferably 0.04 to 1.50 kPa · s / m.

[Action]
In the present invention, the beating degree is 4 of JIS P 8121-1995 without using a rubber layer or a resin layer that has a limit on the minimum diameter of the through-hole that can be formed. 90% by mass or more of a porous pulp fiber having a Canadian standard freeness prescribed by Canadian Standard Freeness in the range of 350 to 650 ml (CSF) and having a large number of pores opened on the surface, The sound absorbing performance is enhanced by using the paper material 1 having a ventilation resistance set in a range of 0.07 to 3.00 kPa · s / m.
In the paper material 1, since voids are formed in the fibers themselves in addition to the gaps between the fibers, sound is taken into the gaps between the fibers of the paper material 1 and the fibers themselves. When the fiber vibrates, the sound energy is attenuated as the friction energy is absorbed between the fibers in the paper material 1 inside the paper material 1.
Furthermore, since there are a large number of cracks on the surface of the porous pulp fiber, the cracks also absorb sound energy as frictional energy by vibrating with sound.
When the freeness of the fiber exceeds 650 ml (CSF) in terms of freeness, the pulp fiber is not sufficiently crushed or concentrically loosened and becomes porous due to a large number of pores opening on the surface of the pulp fiber. Becomes insufficient, the porosity is lowered, and the sound absorbing performance of the interior material 6 is adversely affected. On the other hand, if it is less than 350 ml (CSF), the pulp fibers are fragmented by fibrillation and the number of ultrafine fibers increases, so that the density of the paper material 1 is increased and the ventilation resistance is increased. Adversely affects the sound absorption characteristics.

As described above, in the interior material 6 of the present invention, the energy has already been greatly absorbed by the paper material 1 before the sound reaches the moldable felt 3, and the sound is further absorbed in the moldable felt 3. It is confined by the paper material 1 and the non-breathable resin sheet 4 and efficiently absorbed by irregular reflection.
In addition, a large number of pores are provided in the pulp fiber itself, so that the air-permeable layer is distributed over the entire surface, and the sound absorption is lower than that in which through holes are provided only at predetermined sites such as conventional resin layers and rubber layers. It is excellent in performance, can be reduced in weight as a whole, and is inexpensive.

〔effect〕
The interior material 6 of the present invention has an extremely excellent sound absorbing performance, and a lightweight and inexpensive interior material 6 for an automobile is provided. The paper material 1 used for the interior material 6 is made of woody pulp fiber, does not generate a large amount of carbon dioxide gas in the production process like organic synthetic fiber, is decayable, and also has biomass energy (for example, bio-energy). Since it can also be used as a raw material for ethanol, it is also a material that contributes to energy saving measures and global warming prevention measures.

Explanatory drawing explaining the measuring method of ventilation resistance R Explanatory drawing explaining protrusion height h Sectional view of automotive interior material of the present invention

For example, as shown in FIG. 3, the automobile interior material 6 of the present invention is a laminate in which a porous mat 5, a non-breathable resin sheet 4, a moldable felt 3, a paper material 1, and a breathable surface covering material 2 are laminated in order from the lower layer. It is.
Each material is described in detail below.

[Porous mat]
The porous mat 5 imparts a suitable cushioning property to the interior material 6 and keeps the air-impermeable resin sheet 4 at a certain distance from the wall surface, floor surface, etc. in the automobile, thereby providing good sound insulation to the interior material 6. It is an effect.
As the porous mat 5, for example, a fiber sheet or a mat used for a breathable outer covering material 2 or a moldable felt 3 described later is used.
Examples of the material of the porous mat 5 include breathable polyurethane foam, breathable polyethylene foam, breathable polypropylene foam, breathable polystyrene foam, breathable phenolic resin foam, and breathable melamine resin foam. A sheet or mat made of a breathable plastic foam may be used.
In order to give a good cushioning and sound insulation effect to the interior material 6, the basis weight of the porous mat 5 is desirably 50 to 1000 g / m ² and the thickness is desirably 5 to 30 mm.

[Non-breathable resin sheet]
Non-breathable resin sheet 4 is, for example, polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl acetate, fluororesin, thermoplastic acrylic resin, Thermoplastic polyester, thermoplastic polyamide, thermoplastic urethane resin, acrylonitrile-butadiene copolymer, styrene-butadiene copolymer, acrylonitrile-butadiene-styrene copolymer, ethylene-propylene copolymer, ethylene-propylene terpolymer, ethylene -A sheet of thermoplastic resin such as vinyl acetate copolymer.
If necessary, the non-breathable resin sheet 4 may be added with a filler such as talc and calcium carbonate, or a colorant such as a pigment.
The non-breathable resin sheet 4 contributes good sound insulation performance to the interior material 6 and stabilizes the molded shape when the interior material 6 is molded into a predetermined shape.
The non-breathable resin sheet 4 desirably has a basis weight of 20 to 1000 g / m ² and a thickness of 0.01 to 3.0 mm from the viewpoint of exhibiting good sound insulation performance.

[Molding felt]
As the moldable felt 3, a thermosetting resin initial condensate is mixed with the fiber as a binder, and if desired, a thermosetting felt in which the initial condensate is in a B state, and a pseudo thermoplastic resin is mixed with the fiber as a binder. Pseudo thermoplastic felt, and thermoplastic felt in which a thermoplastic resin and / or a low melting point thermoplastic resin fiber is mixed as a binder with the fiber.
Examples of fibers used for the thermosetting felt, the pseudo thermoplastic felt, and the moldable felt 3 that is the thermoplastic felt include polyester fiber, polyamide fiber, acrylic fiber, urethane fiber, polyvinyl chloride fiber, poly Synthetic fibers such as vinylidene chloride fiber and acetate fiber, wool, mohair, cashmere, camel hair, alpaca, vicuña, angora, silk thread, kiwata, gama fiber, pulp, cotton, palm fiber, hemp fiber, bamboo fiber, kenaf fiber, etc. Natural fiber, starch-based, polylactic acid-based biodegradable fiber, rayon (man-made silk, sufu), polynosic, cupra, acetate, triacetate and other cellulosic artificial fibers, glass fiber, carbon fiber, ceramic fiber, asbestos fiber, etc. Obtained by defibrating scraps of inorganic fibers and fiber products using these fibers It was a recycled fiber and the like. These fibers are used alone or in combination of two or more.

  Examples of the thermosetting resin used in the thermosetting felt include a urethane resin, a melamine resin, a thermosetting acrylic resin, particularly a thermosetting acrylic resin that cures by forming an ester bond by heating, Urea resins, phenolic resins, epoxy resins, thermosetting polyester resins, etc. are used, but urethane resin prepolymers, urea resin prepolymers (initial condensates), phenolic resins that produce the synthetic resins Synthetic resin precursors such as prepolymers such as prepolymers (initial condensates), diallyl phthalate prepolymers, acrylic oligomers, polyvalent isocyanates, methacrylic ester monomers, diallyl phthalate monomers, oligomers, and monomers may be used. The thermosetting resin is preferably used in the form of an aqueous solution, an aqueous emulsion, or an aqueous dispersion because it is easy to handle, but may be used in the form of an organic solvent solution.

Particularly desirable as a thermosetting resin used for the moldable felt 3 is a phenolic resin. The phenolic resin is obtained by condensing a phenolic compound with formaldehyde and / or a formaldehyde donor.
The phenolic compound used in the phenolic resin may be a monohydric phenol, a polyhydric phenol, or a mixture of a monohydric phenol and a polyhydric phenol. When only monohydric phenol is used, formaldehyde is easily released during and after curing. Therefore, polyhydric phenol or a mixture of monohydric phenol and polyhydric phenol is preferably used.
Two or more of the above thermosetting resins or synthetic resin precursors may be used in combination.

The pseudo thermoplastic resin used for the pseudo thermoplastic felt is
(A) 5 to 100% by weight of a polymer obtained by radical polymerization consisting of an ethylenically unsaturated acid anhydride or an ethylenically unsaturated dicarboxylic acid in which a carboxylic acid group can form an acid anhydride group;
(B) an alkanolamine having at least two hydroxyl groups;
A phosphorus-containing reaction accelerator less than 1.5% by mass with respect to the sum of (A) + (B);
An aqueous binder containing no formaldehyde.
The aqueous binder is generally provided in the form of an aqueous emulsion, an aqueous solution, a water-soluble organic solvent solution such as isopropanol, ethanol, or glycol, or a mixed solvent solution of water and the water-soluble organic solvent. It hardens | cures by esterification reaction of the acid contained in A) and the hydroxyl group contained in alkanolamine (B), water solubility changes to water insolubility, and thermoplasticity changes to pseudo thermoplasticity.
The pseudo thermoplastic resin is currently marketed by BASF under the trade name Acrodur, and there are 950L, DS3530 as an aqueous solution type, and 958D as an aqueous emulsion type.
The above acrodea is crosslinked by the esterification reaction at a temperature of approximately 120 ° C. or higher and is cured at a temperature of 160 ° C. or higher. However, the acrodure has sufficient hardness even in a thermoplastic state before crosslinking and is easy to handle. Moreover, during thermoforming, the hardness is reduced by heating and becomes temporarily thermoplastic (pseudo-thermoplastic), exhibits good moldability, and high molding accuracy is obtained. Moreover, since the cross-linking of the acrodure is based on an esterification reaction, there is an advantage that only water is by-produced and no harmful substances such as formaldehyde are by-produced.
Two or more of the above-mentioned pseudo thermoplastic resins, for example, an aqueous solution type and an aqueous emulsion type may be mixed, or other thermoplastic resin aqueous emulsions and the like may be mixed.
The details of the pseudo thermoplastic resin are described in, for example, JP 2000-506940 A.

Examples of the thermoplastic resin used in the thermoplastic felt include acrylic ester resin, methacrylic ester resin, ionomer resin, ethylene-ethyl acrylate (EEA) resin, acrylonitrile / styrene / acrylic rubber copolymer (ASA) resin. , Acrylonitrile / styrene copolymer (AS) resin, Acrylonitrile / chlorinated polyethylene / styrene copolymer (ACS) resin, Ethylene vinyl acetate copolymer (EVA) resin, Ethylene vinyl alcohol copolymer (EVOH) resin, Methacrylic resin (PMMA) , Polybutadiene (BDR), polystyrene (PS), polyethylene (PE), acrylonitrile-butadiene-styrene copolymer (ABS) resin, chlorinated polyethylene (CPE), polyvinyl chloride (PVC), polyvinylidene chloride PVDC), polypropylene (PP), cellulose acetate (CA) resin, syndiotactic polystyrene (SPS), polyoxymethylene (= polyacetal) (POM), polyamide (PA), polyimide (PI), polyamideimide (PAI), polyetherimide (PEI), polyarylate (PAR), thermoplastic polyurethane (TPU) elastomer, thermoplastic elastomer (TPE), liquid crystal polymer (LCP), polyetheretherketone (PEEK), polysulfone (PSF) , Polyethersulfone (PES), fluororesin, polytetrafluoroethylene (PTFE), polyethylene terephthalate (PET), polycarbonate (PC), polyphenylene ether (PPE), modified PPE, poly E double sulfide (PPS), polybutylene terephthalate (PBT), polybenzimidazole (PBI), wholly aromatic polyester (POB), and the like.
The above thermoplastic resins may be used in combination of two or more, and may be used by mixing one or more of a certain amount of thermosetting resin to the extent that does not impair the ease of molding of the thermoplastic resin. . The thermoplastic resin is preferably used in the form of an aqueous solution, an aqueous emulsion, or an aqueous dispersion from the viewpoint of easy handling, but may be used in the form of an organic solvent solution.

Further, as means for imparting moldability to the moldable felt 3, low-melting-point thermoplastic resin fibers having a melting point of 180 ° C. or lower are used instead of the thermoplastic resin or together with the thermoplastic resin. Examples of the low-melting point thermoplastic resin fiber include polyolefin fibers such as polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, polyvinyl chloride fiber, polyurethane fiber, polyester fiber, and polyester copolymer. There are polymer fibers, polyamide fibers, polyamide copolymer fibers and the like. These low melting point thermoplastic resin fibers are used alone or in combination of two or more. Further, these low melting point thermoplastic resin fibers are used as cores and high melting point fibers having a melting point of 200 ° C. or higher are used as sheaths, or high melting point fibers having melting points of 200 ° C. or higher are used as cores, and low melting point thermoplastic resin fibers are used as sheaths. A core-sheath composite fiber or the like is used.
When the composite fiber having the core-sheath configuration is used, the rigidity of the felt is improved.
The fineness of the low-melting point thermoplastic resin fiber is in the range of 0.1 dtex to 60 dtex.
The low-melting point thermoplastic resin fiber is usually mixed with the fiber in an amount of 10 to 50% by mass.

The formable felt 3 is formed by a method in which the fiber web sheet or mat is entangled by needle punching, or the fiber web sheet or mat is made of the low-melting thermoplastic resin fiber, or the low-melting thermoplasticity. When resin fibers are mixed, the mixed fiber web is heated as it is or after the web is entangled by needle punching to soften the low melting point thermoplastic resin fibers and bind the fibers to each other. Or the fiber sheet or mat is impregnated with or mixed with a synthetic resin, or the fiber web sheet or mat is entangled by needle punching and then the synthetic resin or synthetic resin precursor powder. , Mixed, coated or impregnated with solution, emulsion or latex How to sintering wear, it is produced by a method in which woven knitted the fibers.
The basis weight and thickness of the moldable felt 3 can be arbitrarily set in principle. From the viewpoint of reducing the weight of the interior material 6, the basis weight is preferably 50 to 1000 g / m ² , more preferably 100 to 500 g / m. ² and the thickness is preferably 1.5 mm or more from the surface of shape retention.
When the moldable felt 3 contains 10 to 50% by mass of a low melting point thermoplastic resin fiber having a melting point of 180 ° C. or less, the moldability of the interior material 6 is improved.

[Paper materials]
The paper material 1 is a paper containing 90% by mass or more of porous pulp fibers and having a ventilation resistance in the range of 0.07 to 3.00 kPa · s / m.
When the paper material 1 has a ventilation resistance of less than 0.07 kPa · s / m, the interior material 6 with good sound absorption performance cannot be obtained. Cannot obtain the interior material 6 with good moldability.

(Porous pulp fiber)
The said porous pulp fiber means that the fiber itself has many pores opened on the surface. The porous pulp fiber is made of non-wood plant fiber and / or wood plant fiber, and is usually made of softwood or hardwood chips, and the beating degree is JIS P 8121-1995 4. It is a porous pulp fiber having a long diameter of 5 μm to 100 μm within the range of 350 to 650 ml (CSF) with a Canadian standard freeness prescribed by Canadian Standard Freeness.
The above beating is usually performed by a conical refiner, a disc refiner, or the like.
The average length of the porous pulp fibers is desirably in the range of 0.2 to 30 mm, and the major axis is desirably 5 to 100 μm. When the average length of the porous pulp fibers is less than 0.2 mm, the entanglement between the fibers in the paper material 1 is insufficient, and the strength of the interior material 6 is reduced. When the average length exceeds 30 mm, the fibers themselves Becomes easily entangled in a string shape, making it difficult to form a fiber into a sheet. On the other hand, when the fiber major axis is less than 5 μm, the sheet density becomes excessive, and the sheet strength is lowered.
Two or more kinds of porous pulp fibers used in the paper material 1 of the present invention may be mixed and used, and the porous pulp fibers and normal fibers (non-porous fibers) may be mixed. The mixing ratio in this case should contain 90% by mass or more of porous pulp fiber, preferably 95% by mass or more, and more preferably 100% from the viewpoint of improving the sound absorption performance of the interior material 6. Should be included by mass%.

(Normal fiber)
Examples of the normal fiber (non-porous fiber) used in combination with the porous pulp fiber include polyester fiber, polyethylene fiber, polypropylene fiber, polyamide fiber, acrylic fiber, urethane fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, and acetate. Synthetic fibers such as fibers, biodegradable fibers (polylactic acid fibers) made of starch extracted from plants such as corn and sugarcane, natural fibers such as pulp, cotton, palm fibers, hemp fibers, bamboo fibers, kenaf fibers, glass fibers In addition, inorganic fibers such as carbon fibers, ceramic fibers, asbestos fibers, or one or more kinds of recycled fibers obtained by defibrating scraps of textile products using these fibers are used. For example, inorganic fibers such as glass fiber, carbon fiber, ceramic fiber, asbestos fiber, stainless steel fiber, and polymetaphene If heat-resistant synthetic fibers having a melting point of 250 ° C. or higher, such as aramid fibers such as lenisophthalamide fibers and poly-p-phenylene terephthalamide fibers, polyarylate fibers, polyetheretherketone fibers and polyphenylene sulfide fibers, are preferably used. A fiber sheet with extremely high heat resistance can be obtained. Among them, carbon fiber is a useful inorganic fiber in that it can be incinerated and it is difficult for fine pieces to scatter, and aramid fiber is a flame-retardant synthetic fiber that is relatively inexpensive and easily available.

The ventilation resistance of the paper material 1 is in the range of 0.07 to 3.00 kPa · s / m. Here, the ventilation resistance (Pa · s / m) is the degree of ventilation of the breathable material. It is a measure to represent. This ventilation resistance is measured by a steady flow differential pressure measurement method. As shown in FIG. 1, a test piece T is arranged in a cylindrical air passage W, and the pressure in the air passage W on the start point side of the arrow in the figure in a state of a constant air flow V (the direction of the arrow in the figure). By measuring the pressure difference between P1 and the end point P2 of the arrow in the figure, the ventilation resistance R can be obtained from the following equation.
R = ΔP / V
Here, ΔP (= P1−P2): Pressure difference (Pa), V: Air flow rate per unit area (m ³ / m ² · s).
The ventilation resistance can be measured by, for example, an air permeability tester (product name: KES-F8-AP1, manufactured by Kato Tech Co., Ltd., steady flow differential pressure measurement method).

  As the paper material 1, an extensible paper material having a large number of irregularities on the surface may be used. When the stretchable paper material is used, a skin material having excellent sound absorbing performance and good moldability can be obtained.

Examples of the stretchable paper material include crepe paper having a crimped wrinkle formed on the surface, embossed paper having a large number of protrusions formed on the surface, and crepe embossed paper having a crimped wrinkle and many protrusions formed on the surface. Etc. are exemplified.
The creped paper is obtained by creping a raw material. In the crepe processing, a wet crepe that is compressed in the vertical direction using a press roll or a doctor blade in a wet paper state and brazed, and a sheet There is a dry crepe that is dried with a Yankee dryer or calendar and then compressed in the longitudinal direction using a doctor blade or the like.
In this case, it is desirable that the crepe rate calculated by the following formula is 10 to 50%.
Crepe rate (%) = (A / B) × 100
A: Paper making speed in the paper making process B: Paper winding speed That is, the crepe rate is the ratio at which the paper web is compressed in the longitudinal direction (paper making direction) by creping.
When the crepe rate is less than 10%, the sound absorbing performance of the creped paper is deteriorated and the stretchability is insufficient, and wrinkles are easily generated during molding. On the other hand, when the crepe rate exceeds 50%, Again, wrinkles are likely to occur during molding.

The embossed paper is formed by pressing a roll (embossing roll) or plate (embossing plate) having a large number of irregularities on the surface against the base paper to form a large number of protrusions on the surface of the paper. It is desirable that the thickness is 0.02 to 2.00 mm and the number of protrusions is 20 to 200 / cm ² . When the height of the protrusion is less than 0.02 mm, the sound absorption performance of the embossed paper is deteriorated and the stretchability is insufficient so that wrinkles are easily generated during molding. Even if it exceeds 0.000 mm, wrinkles are likely to occur during molding. On the other hand, when the number of protrusions is less than 20 / cm ² , the sound absorption performance of the embossed paper is deteriorated, the stretchability is insufficient, and wrinkles are easily generated during molding, while the number of protrusions is 200 Even if it exceeds / cm ² , the sound absorbing performance of the embossed paper deteriorates.
The embossed paper 1a (extensible paper material) shown in FIG. 2 has a large number of protrusions 1b on the surface, and the height of the protrusions 1b corresponds to “h” shown in FIG. If crepe paper is used as the base paper, it becomes embossed crepe paper.
By the way, the basis weight of the paper material is usually about 10 to 60 g / m ² , but the basis weight of the paper material according to the present invention is desirably 15 to 50 g / m ² . If the basis weight is too small, the ventilation resistance becomes too low to obtain the desired sound absorption performance, while if too large, the ventilation resistance becomes too high and the sound absorption performance is lowered.

(Breathable exterior material)
As the breathable outer covering material 2, a sheet or mat made of fibers similar to those used in the moldable felt 3 is usually used.
As with the moldable felt 3, low melting point thermoplastic resin fibers having a melting point of 180 ° C. or lower may be used as the fibers used in the breathable outer covering material 2. Further, the fineness of the low melting point thermoplastic resin fiber used in this case is in the range of 0.1 dtex to 60 dtex, and the low melting point thermoplastic resin fiber is usually mixed with the fiber in an amount of 1 to 50% by mass.

The fiber sheet or mat used as the breathable outer covering material 2 is a method in which the fiber web sheet or mat is entangled by needle punching in the same manner as described in the method for producing the moldable felt 3 or fiber. If the web sheet or mat is made of the low-melting point thermoplastic resin fiber, or if the low-melting point thermoplastic resin fiber is mixed, the web of the mixed fiber is left as it is or the web is entangled by needle punching. A method of softening the low-melting point thermoplastic resin fibers and bonding the fibers together by heating after combining, or impregnating or mixing the synthetic resin in the fiber sheet or mat, or binding the fibers The web sheet or mat is entangled by needle punching and then the synthetic resin Powder had synthetic resin precursor, solutions, emulsions or mixed latex, a method of forming wear by coating or impregnation, is prepared by a method in which woven knitted the fibers.
The basis weight of the fiber sheet or mat is usually set to 50 to 500 g / m ² and the thickness is usually set to 1 to 10 mm from the viewpoint of preferable design and appearance of the interior material 6.

When the breathable outer covering material 2 is used as a floor covering material, a raised cloth such as a carpet is usually used. A pile layer such as a cut pile or a loop pile is usually formed on the carpet. Tufting, needle punching, electrostatic flocking, or the like is applied to form the pile layer.
In conventional carpets, a felt made of organic synthetic fibers such as polyester fibers and polypropylene fibers is usually lined as a sound absorbing material.
In the interior material 6 of the present invention, the paper material 1 is lined instead of the felt, so that the sound absorbing performance is superior to the carpet lined with the conventional felt, and the weight of the felt is reduced and the thickness is reduced. It becomes possible, the thickness is reduced correspondingly, and the weight is greatly reduced.
The organic synthetic fiber used for the felt emits carbon dioxide in the production process. However, since the paper material of the present invention uses natural pulp fiber that hardly emits carbon dioxide in the production process as a raw material, carbon dioxide emissions can be reduced and natural pulp fiber is decaying. Waste disposal is also easy, and it can be used as biomass energy (for example, a raw material for bioethanol).

[Synthetic resin]
In the above-described breathable outer covering material 2 and / or paper material 1, synthetic resin or the like may be applied, impregnated, or mixed in order to impart rigidity or moldability. Examples of the synthetic resin include a thermoplastic resin and / or a thermosetting resin.

  Examples of the thermoplastic resin are the same as those used for the moldable felt 3 as the thermoplastic felt, such as acrylic ester resin, methacrylic ester resin, ionomer resin, ethylene-ethyl acrylate (EEA) resin, acrylonitrile / styrene.・ Acrylic rubber copolymer (ASA) resin, acrylonitrile / styrene copolymer (AS) resin, acrylonitrile / chlorinated polyethylene / styrene copolymer (ACS) resin, ethylene vinyl acetate copolymer (EVA) resin, ethylene vinyl alcohol copolymer ( EVOH resin, methacrylic resin (PMMA), polybutadiene (BDR), polystyrene (PS), polyethylene (PE), acrylonitrile-butadiene-styrene copolymer (ABS) resin, chlorinated polyethylene (CPE), polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polypropylene (PP), cellulose acetate (CA) resin, syndiotactic polystyrene (SPS), polyoxymethylene (= polyacetal) (POM), polyamide (PA) ), Polyimide (PI), polyamideimide (PAI), polyetherimide (PEI), polyarylate (PAR), thermoplastic polyurethane (TPU) elastomer, thermoplastic elastomer (TPE), liquid crystal polymer (LCP), polyetherether Ketone (PEEK), polysulfone (PSF), polyethersulfone (PES), fluororesin, polytetrafluoroethylene (PTFE), polyethylene terephthalate (PET), polycarbonate (PC), polyphenylene ether Ether (PPE), modified PPE, polyphenylene sulfide (PPS), polybutylene terephthalate (PBT), polybenzimidazole (PBI), wholly aromatic polyester (POB), and the like. Such a thermoplastic resin is impregnated and / or applied and / or mixed with the air permeable covering material 2 or the paper material 1 to improve the shape retention and rigidity.

  The above thermoplastic resins may be used in combination of two or more, and may be used by mixing one or more of a certain amount of thermosetting resin to the extent that does not impair the ease of molding of the thermoplastic resin. . The thermoplastic resin is preferably used in the form of an aqueous solution, an aqueous emulsion, or an aqueous dispersion from the viewpoint of easy handling, but may be used in the form of an organic solvent solution.

As the thermosetting resin, for example, a urethane resin, a melamine resin, a thermosetting acrylic resin, particularly an ester bond formed by heating, as used in the moldable felt 3 as the thermosetting felt. Thermosetting acrylic resins, urea resins, phenolic resins, epoxy resins, thermosetting polyester resins, and the like that are cured are used. Urethane resin prepolymers and urea resin prepolymers that produce the synthetic resins are used. Polymers (initial condensates), phenolic resin prepolymers (initial condensates), diallyl phthalate prepolymers, acrylic oligomers, polyvalent isocyanates, methacrylic ester monomers, prepolymers such as diallyl phthalate monomers, synthetic resins such as oligomers and monomers Precursors may be used. The thermosetting resin is preferably used in the form of an aqueous solution, an aqueous emulsion, or an aqueous dispersion because it is easy to handle, but may be used in the form of an organic solvent solution.
Two or more of the above thermosetting resins or synthetic resin precursors may be used in combination.
The addition of the synthetic resin, particularly the thermosetting resin, improves both the shape retention and rigidity of the breathable outer covering material 2 or the paper material 1.

Further, a phenolic resin is particularly desirable as the thermosetting resin used in the present invention. The phenolic resin can be obtained by reacting with phenolic compounds in an excess of formaldehyde and reacting with an alkali catalyst, and by reacting with phenolic compounds in excess of phenol with an acid catalyst. There are two types of novolak. The resole consists of a mixture of various phenol alcohols with added phenol and formaldehyde, and is usually provided in an aqueous solution. The novolak is composed of various derivatives of dihydroxydiphenylmethane based on phenol condensed with phenol alcohol, and is usually provided in powder form.
A desirable phenolic resin in the present invention is a phenol-alkylresorcin cocondensate. The phenol-alkylresorcin co-condensate has good stability of the aqueous solution of the co-condensate (initial condensate) and is stored for a long time at room temperature as compared with a condensate (initial condensate) composed only of phenol. There is an advantage that you can. Further, the breathable surface covering material 2 and the paper material 1 obtained by impregnating, coating, or mixing the air permeable surface covering material 2 and the paper material 1 and pre-curing have good stability. Even if the paper material 1 is stored for a long time, the moldability is not lost. Furthermore, alkylresorcin has a high reactivity with formaldehydes and captures and reacts with a free aldehyde, so that it also has an advantage of reducing the amount of free aldehyde in the resin.
A polyhydric phenol mixture obtained by dry distillation of an Estonia oil shale is inexpensive and contains a large amount of highly reactive various alkylresorcins in addition to 5-methylresorcin. Therefore, it is a particularly preferable polyhydric phenol raw material in the present invention.
In the production of the phenolic resin, a catalyst or a pH adjuster may be mixed as necessary. Furthermore, a hardener such as formaldehyde or an alkylolated triazone derivative may be added to and mixed with the initial condensate (including the initial cocondensate) of the phenolic resin of the present invention. Furthermore, when a water-soluble phenolic resin is used, the phenolic resin may be sulfomethylated and / or sulfimethylated to improve its stability.

  The synthetic resin or synthetic resin precursor used in the present invention further includes calcium carbonate, magnesium carbonate, barium sulfate, calcium sulfate, calcium sulfite, calcium phosphate, calcium hydroxide, magnesium hydroxide, aluminum hydroxide, magnesium oxide, Titanium oxide, iron oxide, zinc oxide, alumina, silica, colloidal silica, mica, diatomaceous earth, dolomite, gypsum, talc, clay, asbestos, mica, calcium silicate, bentonite, white carbon, carbon black, iron powder, aluminum powder, Inorganic fillers such as glass powder, stone powder, blast furnace slag, fly ash, cement, zirconia powder; natural rubber or derivatives thereof; styrene-butadiene rubber, acrylonitrile-butadiene rubber, chloroprene rubber, ethylene-propylene rubber Synthetic rubbers such as isoprene rubber and isoprene-isobutylene rubber; water-soluble polymers such as polyvinyl alcohol, sodium alginate, starch, starch derivatives, glue, gelatin, blood powder, methylcellulose, carboxymethylcellulose, hydroxyethylcellulose, polyacrylate, and polyacrylamide Organic gums such as wood powder, walnut powder, coconut powder, wheat flour and rice flour; higher fatty acids such as stearic acid and palmitic acid; higher alcohols such as palmityl alcohol and stearyl alcohol; butyryl stearate and glycerin Esters of fatty acids such as monostearate; fatty acid amides; natural waxes such as carnauba wax, synthetic waxes; paraffins, paraffin oil, silicone oil, silicone resin, fluororesin, polyvinyl Mold release agents such as alcohol and grease; organic compounds such as azodicarbonamide, dinitrosopentamethylenetetramine, P, P′-oxybis (benzenesulfonylhydrazide), azobis-2,2 ′-(2-methylgropionitrile) Foaming agent; inorganic foaming agent such as sodium bicarbonate, potassium bicarbonate, ammonium bicarbonate; hollow particles such as shirasu balloon, perlite, glass balloon, foamed glass, hollow ceramics; plastic such as foamed polyethylene, foamed polystyrene, foamed polypropylene, etc. Foam and foam particles: pigments, dyes, antioxidants, antistatic agents, crystallization accelerators, phosphorus compounds, nitrogen compounds, sulfur compounds, boron compounds, bromine compounds, guanidine compounds, phosphate compounds Compounds, phosphate compounds, flame retardants such as amino resins, flame retardants, water repellents, repellents Oils, insect repellents, preservatives, waxes, surfactants, lubricants, anti-aging agents, UV absorbers; phthalate plasticizers such as DBP, DOP, dicyclohexyl phthalate and other plastics such as tricresyl phosphate An agent or the like may be added and mixed.

  Examples of the water / oil repellent include natural wax, synthetic wax, fluororesin, and silicon resin.

In order to apply and impregnate the above breathable surface covering material 2 or paper material 1 with the above synthetic resin or the like, the breathable surface covering material 2 or paper material 1 is usually immersed in an aqueous emulsion or aqueous dispersion of the above synthetic resin, or Apply with a knife coater, roll coater, flow coater, etc.
In order to adjust the amount of resin in the air-permeable covering material 2 or paper material 1 impregnated or coated with the resin, after impregnating or applying the resin, the air-permeable covering material 2 or paper material 1 is drawn into a squeeze roll or press machine. Squeeze using. In this case, the thickness of the air permeable covering material 2 or the paper material 1 is reduced. However, when a fiber sheet or mat is used as the air permeable covering material 2 or the paper material 1, the fiber sheet or mat is low. When the thermoplastic resin fiber is composed of a melting point thermoplastic resin fiber or contains a low melting point thermoplastic resin fiber, the fiber sheet or mat is heated before the resin impregnation to melt the low melting point thermoplastic resin fiber. It is desirable to bind with the melt. As a result, the fiber sheet or mat as the breathable outer covering material 2 or the paper material 1 is further improved in strength and rigidity, the workability at the time of resin impregnation is improved, and the restoration of the thickness after drawing is also remarkable.
After the resin is impregnated or coated on the fiber sheet or mat as the air-permeable covering material 2 or the paper material 1, the air-permeable covering material 2 or the paper material 1 is dried at room temperature or by heating.
Impregnated amount of the resin is usually ^10g / ^{m 2 ~100g} / m 2 approximately. With this amount of resin impregnation, there is almost no influence on the ventilation resistance of the air-permeable outer covering material 2 or the paper material 1.

(Flame retardants)
In addition, a flame retardant may be added to the breathable outer covering material 2, the paper material 1, or the moldable felt 3. Examples of the flame retardant include phosphorus flame retardant, nitrogen flame retardant, sulfur flame retardant, boron flame retardant, bromine flame retardant, guanidine flame retardant, phosphate flame retardant, phosphate ester flame retardant, amino acid Resin-based flame retardant, expanded graphite, etc.
In the case of the automobile interior material 6 of the present invention, it is particularly desirable to use a powdery solid flame retardant that is hardly soluble or insoluble in water. The powdery solid flame retardant that is hardly soluble or insoluble in water imparts flame resistance excellent in water resistance and durability to the interior material 6 of the present invention. In particular, since the air-permeable outer covering material 2, the paper material 1, or the moldable felt 3 of the present invention has a rough structure, the above-mentioned powdered solid flame retardant smoothly penetrates into the interior and has high flame resistance. Or impart nonflammability.

[Automobile interior materials]
By laminating the breathable outer covering material 2, the paper material 1, the moldable felt 3, the non-breathable resin sheet 4 and the porous mat 5 in this order, for example, an interior material 6 for an automobile flooring as shown in FIG. Become.
In this embodiment, a breathable adhesive is applied to the breathable facing material 2 and the paper material 1 and the paper material 1 and the moldable felt 3 if necessary. As the adhesive used in the air-permeable adhesive, a normal solution type or aqueous emulsion type adhesive, a powder type, a web type, a solution type, or an aqueous emulsion type hot melt adhesive, etc. are used. The In the case of a hot melt adhesive in the form of a powder or a web, a porous adhesive layer is used so that air permeability can be secured, and the air permeability of the air permeable covering material 2, paper material 1, and moldable felt 3 is inhibited. do not do.
In the case of a solution-type or water-emulsion-type adhesive, the adhesive is applied in the form of dots by spray coating, silk printing coating, offset printing coating, or the like. Ensure breathability.
In the case of adhesion between the moldable felt 3 and the non-breathable resin sheet 4 and the non-breathable resin sheet 4 and the porous mat 5, it is not necessary to consider the breathability, so that it is limited to the breathable adhesive. A well-known bonding method can be applied.
In the present invention, the breathable outer covering material 2, the paper material 1, and the moldable felt 3 may be joined by a method other than adhesion, such as welding or fusion.

[Interior material moldings]
The interior material 6 is formed into a predetermined shape that conforms to the floor shape of an automobile, for example. A thermoplastic resin is applied and / or impregnated and / or mixed with the breathable outer covering material 2, the paper material 1, or the moldable felt 3, which is a component of the interior material 6, or the breathable outer covering material 2, Alternatively, when the formable felt 3 is made of low-melting point thermoplastic resin fibers or contains low-melting point thermoplastic resin fibers, in order to form the interior material 6, the interior material 6 is made of the thermoplastic resin or low-melting point heat. Hot pressing is performed at a temperature equal to or lower than the softening temperature of the plastic resin fiber, or cold pressing is performed after heating at a temperature equal to or higher than the softening temperature. Moreover, when a thermosetting resin is applied to these, it may be molded by hot pressing.

  Examples for describing the present invention more specifically will be described below, but the present invention is not limited to these examples.

[Example 1]
A breathable outer covering material which is a needle punching nonwoven fabric having a basis weight of 120 g / m ² and a thickness of 3 mm made of polyester fiber was prepared.
Next, a wood pulp composed of 50 parts by mass of softwood pulp and 50 parts by mass of hardwood pulp is used as a raw material, and the degree of beating is 4 according to JIS P 8121-1995 using a disc refiner. It is beaten to a Canadian standard freeness of 490 ml (CSF) as specified by Canadian Standard Freeness, and after a normal paper making process, the crepe rate is 25%, the basis weight is 30 g / m ² , and the ventilation resistance is 0.84 kPa. A paper material made of s / m porous pulp fibers was prepared.
A hot melt adhesive powder made of polyester resin having a melting point of 150 ° C. and a particle size of 200 to 300 μm was applied on one side of the paper material in a spreading amount of 3 g / m ² , and then the breathable surface material was laminated on the coated surface. The paper material was lined on the breathable outer covering material by lightly pressing from the paper material side with a heating roll at 0 ° C.
From the paper material side, a hot melt adhesive powder having a melting point of 120 ° C. and a particle size of 200 to 300 μm is applied to the laminate with a spreading amount of 3 g / m ² and heated to 140 ° C. to apply the hot melt adhesive to the paper material. Fused. The ventilation resistance of this product was 1.23 kPa · s / m.
Next, a fiber web consisting of 30 parts by mass of low-melting polyester fibers (fineness: 2.2 dtex, melting point: 120 ° C.) and 70 parts by mass of normal polyester fibers (fineness: 6.6 dtex) is heated while being sucked at 180 ° C. Thus, the low-melting-point polyester fiber was melted and adhered to the normal polyester fiber to produce a moldable felt having a basis weight of 300 g / m ² , a thickness of 15 mm, and a ventilation resistance of 0.06 kPa · s / m.
Furthermore, a non-breathable resin sheet which was a sheet of polyamide resin (thickness: 0.2 mm, basis weight: 100 g / m ² , softening point: 120 ° C.) was produced.
Furthermore, a porous mat, which is a felt sheet having a thickness of 10 mm and a weight per unit area of 800 g / m ² by the same composition as the moldable felt, was prepared.
At this time, the porous mat is laminated on the paper material side of the breathable covering material lined with the paper material, heated at 180 ° C., and then immediately cooled (breathable covering material-paper material) -formability. The airflow resistance of the laminates laminated in the order of felt was 1.29 kPa · s / m.
Next, each material obtained above is laminated in the order of (breathable outer covering material−paper material) −moldable felt−non-breathable resin sheet−porous mat (the paper material is made of the breathable outer covering material and the moldability). After being heated at 180 ° C. and immediately cooled, an interior material (No. 1) having a thickness of 26.0 mm and a weight of 1356 g / m ² was produced.

[Example 2]
An interior material (No. 2) having a thickness of 26.0 mm and a weight of 1206 g / m ² was produced in the same manner as in Example 1, except that the basis weight of the moldable felt was 150 g / m ² .
In addition, the ventilation resistance of the moldable felt at this time is 0.04 kPa · s / m, and in the same manner as in Example 1, (breathable outer covering material−paper material) −moldable felt are laminated in this order, and heated and cooled. The airflow resistance of the laminated adhesive was 1.27 kPa · s / m.

Example 3
An interior material (No. 3) having a thickness of 26.0 mm and a weight of 1156 g / m ² was produced in the same manner as in Example 1, except that the basis weight of the moldable felt was 100 g / m ² .
In addition, the ventilation resistance of the moldable felt at this time is 0.03 kPa · s / m. Similarly to Example 1, (breathable outer cover material−paper material) −moldable felt are laminated in this order, and heated and cooled. The airflow resistance of the laminated adhesive was 1.26 kPa · s / m.

Example 4
An interior material (No. 4) having a thickness of 20.0 mm and a weight of 1356 g / m ² was produced in the same manner as in Example 1, except that the thickness of the moldable felt was 10 mm.
In addition, the ventilation resistance of the moldable felt at this time is 0.07 kPa · s / m, and in the same manner as in Example 1, (air-permeable outer covering material−paper material) −moldable felt are laminated in this order, and heated and cooled. The ventilation resistance of the laminated adhesive was 1.30 kPa · s / m.

Example 5
In Example 1, a non-breathable resin sheet was used in the same manner except that a polyamide resin sheet (thickness: 1.0 mm, basis weight: 500 g / m ² ) was used, and the thickness was 26.0 mm and the weight was 1756 g / An interior material (No. 5) of m ² was produced.

[Comparative Example 1]
In Example 1, instead of paper material (including hot-melt adhesive used on both sides of the paper material), polyamide resin (thickness: 0.2 mm, basis weight: 60 g / m ² , softening point: 120 ° C.) Ventilation was performed in the same manner except that an apertured resin layer having through holes (diameter: about 0.9 to 1.0 mm, number of holes: 130/100 mm × 100 mm) was used with a heated needle on the sheet made of An interior material (No. 6) having a thickness of 26.0 mm and a weight of 1380 g / m ² made of a surface covering material, an apertured resin layer, a moldable felt, a non-breathable resin sheet, and a porous mat was produced.
In addition, the ventilation resistance of the apertured resin layer at this time is 1.17 kPa · s / m, and in the same manner as in Example 1, the breathable outer covering material, the apertured resin layer, and the moldable felt are laminated in this order, and heating-cooling is performed. The air flow resistance of the laminated and bonded materials was 1.28 kPa · s / m.

[Comparative Example 2]
In Comparative Example 1, an interior material (No. 7) having a thickness of 26.0 mm and a weight of 1230 g / m ² was produced in the same manner except that the weight of the moldable felt was 150 g / m ² .
In addition, the ventilation resistance of the moldable felt at this time is 0.04 g / m ² , and in the same manner as in Comparative Example 1, the breathable outer covering material, the aperture resin layer, and the moldable felt are laminated in this order, and heated and cooled to laminate. The gas flow resistance of the bonded material was 1.27 kPa · s / m.

[Comparative Example 3]
In Comparative Example 1, an interior material (No. 8) having a thickness of 26.0 mm and a weight of 1180 g / m ² was produced in the same manner except that the basis weight of the moldable felt was 100 g / m ² .
In addition, the ventilation resistance of the moldable felt at this time is 0.03 g / m ² , and in the same manner as in Comparative Example 1, the breathable outer covering material, the apertured resin layer, and the moldable felt are stacked in this order, heated and cooled, and stacked. The gas flow resistance of the bonded material was 1.25 kPa · s / m.

[Comparative Example 4]
In Comparative Example 1, an interior material (No. 9) having a thickness of 20.0 mm and a weight of 1380 g / m ² was produced in the same manner except that the thickness of the moldable felt was 10 mm.
In addition, the ventilation resistance of the moldable felt at this time is 0.07 g / m ² , and in the same manner as in Comparative Example 1, the breathable outer covering material, the apertured resin layer, and the moldable felt are laminated in this order, heated and cooled, and laminated. The gas flow resistance of the bonded material was 1.29 kPa · s / m.

[Comparative Example 5]
In Comparative Example 1, a non-breathable resin sheet was used in the same manner except that a polyamide resin sheet (thickness: 1.0 mm, basis weight: 500 g / m ² ) was used, and the thickness was 26.0 mm and the weight was 1780 g / An interior material (No. 10) of m ² was produced.

The interior material Nos. Obtained in Examples 1 to 4 and Comparative Examples 1 to 4 were used. Table 1 shows the results of measuring the sound absorption test of 1 to 8 according to JIS A 1409 “Reverberation chamber method sound absorption coefficient”.
In addition, the interior material Nos. Obtained in Example 1, Example 5, Comparative Example 1, and Comparative Example 5 were used. 1, no. 5, no. 6, no. Table 2 shows the results obtained by measuring 10 sound insulation tests according to JIS A 1416 “Sound transmission loss”.

From Table 1, where the basis weight of the moldability felt (mass) was subtracted from 300g / ^{m 2} 150g / ^{m 2} and up to 100 g / ^{m 2,,} interior material of the present embodiment 1 to 3 No. 1, no. 2, No. Although almost no decrease in the sound absorption coefficient was observed for No. 3, the interior material Nos. 1 to 3 in Comparative Examples 1 to 3 using an apertured resin layer instead of the paper material were used. 6, no. 7, no. For No. 8, it can be seen that the decrease in the sound absorption coefficient is remarkable with the decrease in the mass of the moldable felt.
Further, when only the thickness of the moldable felt was changed from 15 mm to 10 mm, the interior material No. 1 and No. 4 does not change much in the sound absorption coefficient, but the interior material No. 6 and no. 9 shows that the sound absorption coefficient is greatly reduced by reducing the thickness of the moldable felt from 15 mm to 10 mm.
From the above results, by using a paper material using porous pulp fibers consisting of a large number of pores opening on the surface according to the present invention, if the airflow resistance is about the same, the final product can be reduced in weight and thickness. It can be seen that this can be reduced. Further, the performance can be easily improved by adjusting the airflow resistance of the paper material regardless of the thickness, density, and airflow resistance of the formable felt and other materials.

From Table 2, in sound insulation, there is almost no difference between the paper material and the aperture resin layer, and the sound insulation performance improves as the basis weight (mass) of the non-breathable resin sheet increases.
From these things, when using the interior material in this embodiment as the interior material of an automobile, it is arranged so that the porous mat side comes to the vehicle body side, and the breathable surface material side comes to the inside of the vehicle. In addition, the leaked noise can be absorbed indoors. In this case, it is possible to reduce the thickness and reduce the thickness of the sound absorbing material provided with the conventional aperture resin layer.

Example 6
A breathable surface covering material, which is a needle punching nonwoven fabric having a basis weight of 80 g / m ² and a thickness of 2 mm, made of polyester fiber was produced.
Next, using wood pulp made of softwood pulp as a raw material, the degree of beating is 4 according to JIS P 8121-1995 using a disc refiner. It is beaten to a Canadian standard freeness of 420 ml (CSF) as specified by Canadian Standard Freeness, and after a normal paper making process, the crepe rate is 20%, the basis weight is 20 g / m ² , and the ventilation resistance is 1.14 kPa. A paper material made of s / m porous pulp fibers was prepared.
A hot melt adhesive powder made of polyester resin having a melting point of 150 ° C. and a particle size of 200 to 300 μm was applied on one side of the paper material in a spreading amount of 3 g / m ² , and then the breathable surface material was laminated on the coated surface. The paper material was lined on the breathable outer covering material by lightly pressing from the paper material side with a heating roll at 0 ° C.
20 parts by mass of a phenol-alkylresorcin initial condensate (solid content: 40% by mass aqueous solution), 5 parts by mass of a phosphorus-nitrogen flame retardant (solid content: 40% by mass aqueous solution), carbon black (solid content: 20) (Mass% aqueous dispersion) A mixed solution consisting of 2 parts by mass and 73 parts by mass of water was applied as a solid so as to have an impregnation amount of 20 g / m ² and then heated at 140 ° C. for 5 minutes, The curable resin was in the B state. The ventilation resistance of this product was 1.21 kPa · s / m.
Next, the above mixed solution is spray-coated on a fiber web composed of 30 parts by mass of kenaf fibers and 70 parts by mass of normal polyester fibers (fineness: 6.6 dtex) so as to have an application amount of 50 g / m ² in terms of solid content. A moldable felt having a weight per unit area of 200 g / m ² , a thickness of 20 mm, and a ventilation resistance of 0.16 kPa · s / m was produced by heating to 0 ° C. to bring the thermosetting resin into a B state.
As the non-breathable resin sheet, the same non-breathable resin sheet as in Example 1 was used.
Furthermore, a porous mat which is a melamine foam having a basis weight of 180 g / m ² and a thickness of 20 mm was produced.
Next, each material obtained above is laminated in the order of (breathable outer covering material−paper material) −moldable felt−non-breathable resin sheet−porous mat (the paper material is made of the breathable outer covering material and the moldability). The inner material having a predetermined shape was manufactured by hot press molding at 200 ° C. The obtained interior material was lightweight with a total weight of 653 g / m ² and was a molded product excellent in flame retardancy, sound absorption and sound insulation.

Example 7
In Example 6, the phenol-alkylresorcin initial condensate (solid content: 40% by mass aqueous solution) in the mixed solution used for resin impregnation of the laminate and the moldable felt was converted to Acrodure 958D (solid content: 42% by mass aqueous emulsion). In the same manner as above, other components were used to produce laminates and moldable felts. The laminate had a ventilation resistance of 1.34 kPa · s / m, a moldable felt having a basis weight of 200 g / m ² , a thickness of 20 mm, and a ventilation resistance of 0.18 kPa · s / m.
Using the laminate and the moldable felt, heat press molding was performed at 200 ° C. in the same manner as in Example 6 to prepare an interior material having a predetermined shape. The obtained interior material was lightweight and was a molded product excellent in sound absorption and sound insulation.

Example 8
In Example 6, the phenol-alkylresorcin initial condensate (solid content: 40 mass% aqueous solution) in the mixed solution used for resin impregnation of the laminate and the moldable felt was added to Acrodure 950 L (solid content: 50 mass% aqueous solution). Acrodea 958D (solid content: 42 mass% aqueous emulsion) was replaced with a 50:50 mass ratio mixed solution, and other components were similarly produced to produce laminates and moldable felts. The laminate had a ventilation resistance of 1.26 kPa · s / m, a moldable felt having a basis weight of 200 g / m ² , a thickness of 20 mm, and a ventilation resistance of 0.23 kPa · s / m.
Using the laminate and the moldable felt, heat press molding was performed at 200 ° C. in the same manner as in Example 6 to prepare an interior material having a predetermined shape. The obtained interior material was lightweight and was a molded product excellent in sound absorption and sound insulation.

[Comparative Example 6]
In Example 1 above, except that the paper material was omitted, in the same manner, the breathable outer covering material-moldable felt-non-breathable resin sheet-porous mat were laminated in this order, heated at 180 ° C., and then immediately cooled. An interior material having a predetermined shape was produced by press molding. The obtained interior material was poor in sound absorption as compared with Example 1, and was unsuitable for use as an automotive interior material.

  The interior material 6 of the present invention has good sound absorption performance and sound insulation performance, is lighter in weight, and can be made thinner than conventional materials, so that it can be used industrially.

1 Paper material 1a Embossed paper (extensible paper material)
2 Breathable surface material 3 Moldable felt 4 Non-breathable resin sheet 5 Porous mat 6 Automotive interior material R Ventilation resistance

Claims (4)

For automobiles in which a non-breathable resin sheet is laminated on a porous mat, a moldable felt is laminated on the non-breathable resin sheet, and a breathable surface material lined with a paper material is laminated on the moldable felt Interior material,
The paper material has a beating degree of JIS P 8121-1995. 90% by mass or more of a porous pulp fiber having a Canadian standard freeness prescribed by Canadian Standard Freeness in the range of 350 to 650 ml (CSF) and having a large number of pores opened on the surface, An interior material for automobiles, wherein the ventilation resistance is paper having a range of 0.07 to 3.00 kPa · s / m.   The automotive interior material according to claim 1, wherein the paper material is a crepe and / or embossed paper imparted with stretchability by forming a large number of irregularities on the surface. Automobile interior material according to claim 1 or claim 2 basis weight is ^15g / ^{m 2 ~50g} / m 2 of the paper material. The basis weight of the moldable felt is 50 to 1000 g / m ² , the thickness is 1.5 mm or more, the low melting point thermoplastic resin fiber having a melting point of 180 ° C. or less is contained in an amount of 10 to 50% by mass, and the airflow resistance The interior material for automobiles according to any one of claims 1 to 3, wherein is 0.04 to 1.50 kPa · s / m.