JP5246587B2 - Interior material and manufacturing method thereof - Google Patents

Description

  The present invention relates to an interior material and a method for manufacturing the interior material, and more particularly, to an interior material that can remove odor components and the like and can be suitably used in the interior of an automobile or a building, and a method for manufacturing the interior material.

In indoor spaces such as automobiles and buildings, many odorous components (such as volatile organic compounds (VOC) such as formaldehyde, toluene, xylene, and ethyl acetate) and cigarette smoke are present in the air. Substance).
In order to remove these VOCs and odor components, conventionally, fabrics and fiber structures used for interior materials such as automobiles and buildings have been given a deodorizing effect.

As a fabric or fiber structure imparted with a deodorizing effect, a backing adhesive containing a deodorant containing activated carbon is applied to the back surface of a fabric having air permeability mixed with antistatic fibers. (Patent Document 1).
Moreover, what the activated carbon, the inorganic oxide, and the organic nitrogen-type compound were fixed to the fiber structure comprised from polyester through the resin binder is disclosed (patent document 2).
JP-A-6-17377 JP-A-10-292268

  As disclosed in Patent Documents 1 and 2, a conventional interior material imparted with a deodorizing effect is a chemical or odor component that chemically adsorbs an odor component to a fabric or fiber structure constituting the interior material. Activated carbon or the like that physically adsorbs is fixed with a binder.

When an agent that chemically adsorbs odorous components is used as the adsorbent, the reaction between the agent and the odorous component is a sequential reaction. Therefore, the odorous component can be removed rapidly and in large quantities at the rate-limiting step. There is a problem that it is difficult.
Moreover, the chemical | medical agent which performs chemical adsorption also has the problem that a deodorizing effect is small with respect to the odor component (for example, solvent type odor components, such as formaldehyde) with low reactivity with this chemical | medical agent.

On the other hand, in the case of an adsorbent such as activated carbon that performs physical adsorption, it has a high deodorizing effect even for solvent-based odor components such as formaldehyde.
However, as disclosed in Patent Documents 1 and 2, when an adsorbent such as activated carbon is fixed to a fabric or fiber structure, the color of the adsorbent such as activated carbon (for example, black) appears on the surface. There is a problem in terms of design.
Further, when an adsorbent such as activated carbon is fixed with a binder, the adsorbent may be peeled off due to friction or the like.

In order to avoid problems such as designability and peeling, a material in which activated carbon is fixed to the back surface of a fabric with a backing adhesive or the like has been conventionally used, as in Patent Document 1, for example.
The adsorption performance of an adsorbent that performs physical adsorption, such as activated carbon, depends on the area of the micropores that the adsorbent has, so to maintain the adsorption performance over a long period, There is no choice but to increase the specific surface area.

However, if the adsorbent that performs physical adsorption such as activated carbon is fixed to the back surface of the fabric with a backing adhesive or the like, the micropores that are adsorption sites of the adsorbent are filled with the adhesive (binder). The adsorption performance of the adsorbent is impaired.
Moreover, the amount of activated carbon is not sufficient with respect to the amount of VOC and odor components present in the indoor space only by applying a backing adhesive containing activated carbon on the back surface (flat surface) of the fabric. Therefore, it is difficult to exhibit excellent adsorption performance over a long period of time simply by applying a mesh-like backing adhesive containing activated carbon to the back surface (flat surface) of the fabric.

  This invention is made | formed in view of the subject which such a prior art has, and the place made into the objective is VOC which exists in the air of a room | chamber interior or a motor vehicle, and an odor component (does not impair designability). It is an object of the present invention to provide an interior material and a method for producing the same, which can remove a substance that causes odors rapidly and over a long period of time.

That is, interior material of the present invention, Ri formed are joined by supporting an adsorbent and a urethane foam layer and a skin layer,
The adsorbent carried on the urethane foam layer has a concentration gradient that decreases toward the skin layer side .
Further, the other interior material of the present invention comprises a foamed urethane layer carrying an adsorbent and a skin layer joined together,
A second urethane foam layer is interposed between the urethane foam layer carrying the adsorbent and the skin layer.

  The interior material manufacturing method of the present invention includes a step of applying a water-repellent coating agent to at least one surface of a foamed urethane material, and a liquid in which an adsorbent is dispersed in the foamed urethane material coated with the water-repellent coating agent. Impregnating and adsorbing the adsorbent, and melting one surface of the foamed urethane material coated with the water-repellent coating agent to join the foamed urethane agent and the skin material.

  The interior material manufacturing method of the present invention includes a step of impregnating a first foamed urethane material with a liquid in which an adsorbent is dispersed and supporting the adsorbent, and at least one of the second foamed urethane material. Melting the surface of the second foamed urethane material and joining the second foamed urethane material and the first urethane foam material, melting the other surface of the second foamed urethane material, And a step of joining the epidermis.

  ADVANTAGE OF THE INVENTION According to this invention, the interior material which can remove VOC and the odor component which exist in the air in a room | chamber interior or a motor vehicle rapidly and for a long period of time without impairing designability, and its manufacturing method can be provided. .

Hereinafter, the interior material of the present invention and the manufacturing method thereof will be described in detail.
FIG. 1 is an exploded perspective view schematically showing an example of an interior material .
The interior material 1 of this example is formed by joining a urethane foam layer 2 carrying an adsorbent and a skin layer 3.
The interior material 1 of the present example includes a foamed urethane layer 2 and an outer skin by pressure adhesion with a mesh-like hot melt adhesive 4 interposed between the foamed urethane layer 2 and the outer skin layer 3 carrying an adsorbent. Layer 3 is joined.

The foamed urethane layer 2 is preferably made of soft foamed urethane such as slab urethane having continuous cells (bubbles).
Since the urethane foam layer has continuous cells (bubbles), it has good air permeability. By adsorbing the adsorbent in the bubbles, the adsorbent is fixed in a large amount, and a large amount of VOC and odor components are rapidly absorbed. And can be removed over a long period of time.

The urethane foam layer preferably has a thickness of 1.0 mm or more.
The thickness of the urethane foam layer varies depending on the space where the interior material is used (automobile, indoor, etc.) and where it is used (for example, the ceiling of the automobile, door trim, rear corner trim, etc.), but the thickness is 1.0 to 10.0 mm. It is preferable to use one.
When the thickness of the foamed urethane layer is less than 1.0 mm, the amount of adsorbent adhering decreases and the deodorizing effect decreases.
Also, if the thickness of the foamed urethane layer is less than 1.0 mm, the foamed urethane layer is too thin when the foamed urethane layer is subjected to frame treatment to melt the surface and join the foamed urethane layer and the skin layer. Thus, the urethane foam layer cannot be sufficiently melted, and it becomes difficult to join the urethane foam layer and the skin layer with sufficient adhesive strength.

The adsorbent is preferably activated carbon or calcined carbide that physically adsorbs VOCs and odor components.
As the activated carbon or the calcined carbide, it is preferable to use one type selected from the group consisting of coconut shell activated carbon, coal-based activated carbon, charcoal-based activated carbon, bamboo charcoal-based activated carbon and bamboo charcoal, or a combination of two or more.
Adsorbents made of activated carbon or calcined carbide have micropores with various pore sizes, and these micropores become adsorption sites suitable for VOC and various odor components, so that a large amount of VOC and odor components can be rapidly and long-term. Can be captured.
The activated carbon or the calcined carbide preferably has an average particle size of 50 μm or less so that it can be easily carried by the cells (bubbles) of the urethane foam layer.

The amount of the adsorbent supported on the foamed urethane layer varies depending on the thickness of the foamed urethane layer, the space in which the interior material is used, the installation location, and the like, and is not particularly limited, but is preferably 50 with respect to the foamed urethane layer having a thickness of 3 mm. ˜300 g / m ² , more preferably 150 to 250 g / m ² .
If the amount of adsorbent is small, the effect of adsorbing VOCs and odor components will be reduced, and the duration of the adsorption effect will be shortened. It may cause a decrease.

It is preferable to further carry an organic nitrogen compound on the foamed urethane layer.
Organic nitrogen compounds react chemically with low boiling point formaldehyde present in the interior space of automobiles and buildings, and adsorb formaldehyde by chemical bonding, and the reaction rate is fast and does not re-evaporate. Have advantages.

  Examples of organic nitrogen compounds include aliphatic polyamines such as hydroxylamine and ethylenediamine, heterocyclic amines such as pyrrolidine, aromatic polyamines such as metaphenylenediamine, heterocyclic polyamines such as melamine, and amides such as urea and dicyandiamine. And amino compounds such as a polymer having an amino group such as chitosan, hydrazide compounds, and the like.

An organic nitrogen compound may be impregnated with an adsorbent in a liquid in which the organic nitrogen compound is dispersed, and attached to the adsorbent, or foamed in the liquid in which the organic nitrogen compound is dispersed together with the adsorbent. A urethane material may be impregnated and supported on the foamed urethane layer.
The amount of the organic nitrogen compound is preferably 5 to 10% by mass with respect to 100% by mass of the adsorbent supported on the foamed urethane layer.

The skin layer 3 is formed as a skin constituting the interior appearance of an indoor space such as an automobile, and leather, woven fabric, knitted fabric, nonwoven fabric, or the like can be used.
As the skin layer used for the interior material of this example, it is preferable to use a woven fabric, a knitted fabric or a non-woven fabric using a polyester fiber having a relatively high melting point and air permeability.
In addition, since melting | fusing point of materials, such as a woven fabric which comprises a skin layer, changes with places or a site | part etc. which use a skin layer, it is not specifically limited. Further, the air permeability is not particularly limited as long as it has general air permeability.

As a network-like hot melt adhesive for joining the urethane foam layer 2 and the skin layer 3 of the interior material 1 of this example, for example, a hot melt resin such as polyolefin, polyurethane, polyamide or polyester is made into a fiber. Thus, it is preferable to use a net-like one.
The network-like hot melt adhesive preferably has a basis weight of 20 to 50 g / m ² . If the mass per unit area is too large, the air permeability is affected.

  The interior material 1 of this example has a urethane foam layer 2 and a skin layer 3 with a mesh-like hot melt adhesive 4 so as not to fill fine pores such as activated carbon and maintaining air permeability. Can be joined. Since the interior material 1 of this example maintains the adsorption site and air permeability of the adsorbent, a large amount of VOC and odor components can be removed rapidly and over a long period of time.

In addition, although illustration was abbreviate | omitted, in order to improve the intensity | strength of an interior material, you may join a back base fabric to the interior material to the side which is not joined to the skin layer of a foaming urethane layer.
As the backing base fabric, nylon half knitted from nylon fibers or a nonwoven fabric of polyester fibers can be used.

Next, an example of a method for manufacturing the interior material exemplified above will be described.
First, the foamed urethane material constituting the foamed urethane layer is impregnated with a liquid in which the adsorbent is dispersed, and then dried to fix the adsorbent in the open cells of the foamed urethane material.
Next, the foamed urethane material carrying the adsorbent and the skin material are laminated with a mesh-like hot melt adhesive interposed, and the foamed urethane material and the skin material are pressure-bonded.
In this way, it is possible to form the interior material 1 in which the foamed urethane layer 2 carrying the adsorbent and the skin layer 3 are bonded with a network-like hot melt adhesive.

Next, based on FIG. 2, the 1st example of embodiment of the interior material of this invention is demonstrated. In FIG. 2, members similar to those in FIG.
The interior material 10 of this example includes a first foamed urethane layer 2 carrying an adsorbent and a skin layer 3, and the first foamed urethane layer 2 carrying an adsorbent, and the skin layer 3 In between, the 2nd foaming urethane layer 5 which is not carrying | supporting adsorption agent is interposed. In this example, the same foamed urethane layer, adsorbent, and skin layer as those of the above interior material can be used.
In the interior material 10 of this example, two opposing surfaces of the second foamed urethane layer 5 are melted by frame processing or the like, one surface is joined to the first foamed urethane layer 2, and the other surface is the skin layer. 3 is joined.

If an adsorbent such as activated carbon is carried on the foamed urethane material, the adsorbent inhibits the melting of the foamed urethane material, and the foamed urethane material and the skin material may not be joined with sufficient adhesive strength.
The interior material 10 of this example has a second foamed urethane layer 5 interposed between the first foamed urethane layer 2 and the skin layer 3 on which an adsorbent that is difficult to melt is supported, and this second foamed urethane. The layer 5 is melted to weld the first foamed urethane layer 2 and the skin layer 3. Therefore, the interior material 10 of this example can join the first foamed urethane layer 2, the second foamed urethane layer 5, and the skin layer 3 with sufficient adhesive strength.
Further, since the interior material 10 of this example does not need to reduce the amount of the adsorbent to be carried on the first foamed urethane layer 2 by interposing the second foamed urethane layer 5, a large amount of VOC is produced over a long period of time. And odor components can be removed.
In the interior material 10 of this example, the second foamed urethane layer 5 is interposed, so that the color of the adsorbent such as activated carbon supported on the first foamed urethane layer is not seen through from the skin layer side. The design of the material is not impaired.

As the urethane foam material used for the second urethane foam layer 5, the same urethane foam material as the first urethane foam layer 2 carrying the adsorbent can be used, and the foam used for the first urethane foam layer is used. It may be the same as or different from the urethane material.
The thickness of the second urethane foam layer is preferably 0.5 to 1.0 mm.
If the thickness of the second foamed urethane layer is less than 0.5 mm, the adhesive strength may not be satisfactory. If the thickness exceeds 1.0 mm, the thickness is too thick and the entire frame process does not melt, In some cases, the first urethane foam layer and the skin layer 3 cannot be bonded.

Next, an example of the manufacturing method of the interior material of the first example embodiment will be described.
Drawing 3 is an explanatory view of each process showing an example of a manufacturing method of interior material.
As shown in FIG. 3, first, as the first step (a), the foamed urethane material 2 ′ constituting the first foamed urethane layer is impregnated with the liquid in which the adsorbent is dispersed, and then dried. The adsorbent is fixed in the open cells of the foamed urethane material 2 ′.
The amount of the solvent and the adsorbent in which the adsorbent is dispersed can be the same as in the above interior material .

Next, as a second step (b), a frame treatment is applied to one of the two opposite surfaces of the second foamed urethane material 5 ′ to melt the surface of the second foamed urethane material 5 ′. Then, the first foamed urethane layer 2 and the second foamed urethane layer 5 were joined by welding the second foamed urethane material 5 ′ and the first foamed urethane material 2 ′ supporting the catalyst. A laminate 10 ′ is obtained.
Here, the frame treatment refers to a treatment in which the surface of the second foamed urethane material 5 ′ is irradiated with flame plasma or the like and the surface of the second foamed urethane material 5 ′ is melted by this heat.

Next, as a third step (c), the surface of the second foamed urethane layer 5 of the laminate 10 ′ is subjected to frame treatment, and this surface is melted.
Thereafter, as a fourth step (d), the first foamed urethane layer 2, the second foamed urethane layer 5, the skin material 3 and the second foamed urethane layer 5 are welded to the skin material. Are laminated in this order, and the joined interior material 10 can be formed.

Next, based on FIG. 4, the 2nd example of embodiment of the interior material of this invention is demonstrated.
The interior material 11 of this example has a foamed urethane layer 12 carrying an adsorbent and a skin layer 13. In this example, the urethane foam layer, the adsorbent, and the skin layer may be the same as the above interior material .

In the interior material 11 of this example, the adsorbent carried on the foamed urethane layer 12 has a concentration gradient that decreases toward the skin layer 13 side.
Since the adsorbent supported on the foamed urethane layer 12 has a concentration gradient that decreases toward the skin layer 13 side, the adsorbent such as activated carbon supported on the foamed urethane layer 12 is converted to the foamed urethane layer 12. The melted foamed urethane layer 12 and the skin layer 13 can be welded with a sufficient adhesive strength without hindering the melting.
The concentration of the adsorbent carried on the urethane foam layer 12 may decrease continuously toward the skin layer 13 side, or may decrease in multiple steps.

The thickness of the portion T where the concentration of the adsorbent supported so as to have a concentration gradient is smallest is preferably 0.2 mm or more, more preferably 0.2 to 0 from the surface of the foamed urethane layer 12 on the skin layer 13 side. .5 mm.
In the foamed urethane layer 12, if the thickness of the portion T where the concentration of the adsorbent supported is the smallest is 0.2 mm or less, the adsorbent inhibits the melting of the foamed urethane layer, and the foamed urethane layer 12 and the skin layer 13. The adhesive strength may decrease.
On the other hand, if the thickness of the portion T where the concentration of the adsorbent is the minimum exceeds 0.5 mm, the amount of the adsorbent carried on the urethane foam layer 12 is not preferable.
When the adsorbent is supported on the foamed urethane layer so as to have a concentration gradient, the portion T where the adsorbent concentration is the smallest is the surface on the skin side of the foamed urethane layer with respect to 100% of the total thickness of the urethane foam layer. Is preferably in the range of 2 to 20%.

The adhering amount of the adsorbent at the site T having the lowest concentration is preferably 20 g / m ² or less, more preferably 10 g / m ² or less.
When the adhering amount of the adsorbent in the portion T having the lowest concentration exceeds 20 g / m ² , the adsorbent such as activated carbon inhibits the melting of the foamed urethane layer, and strengthens the foamed urethane layer 12 and the skin layer 3. Since it cannot weld, it is not preferable.
In the urethane foam layer, the adhering amount of the adsorbent other than the portion T having the lowest concentration is not particularly limited as long as it is an amount exceeding 20 g / m ^2. The amount of fixation can be set.

Next, an example of the manufacturing method of the interior material of the second example embodiment will be described.
FIG. 5 is an explanatory diagram of each step showing an example of the method for manufacturing the interior material of this example.
As shown in FIG. 5, first, as a first step (a), a water repellent coating agent is applied to at least one surface of the foamed urethane material 12 ′. In FIG. 5, an area A surrounded by an ellipse is an area where a water-repellent coating agent is applied.
As the water repellent coating agent, for example, silicone, a fluorine compound, or the like can be used.
The application range and the application amount of the water-repellent coating agent are not particularly limited as long as the adsorbent can be carried on the foamed urethane layer with a concentration gradient. It is preferable that the water-repellent coating agent is applied in a thickness range of 2 mm or less.

Next, as a second step (b), the foamed urethane material 12 ′ coated with a water-repellent coating agent is impregnated with a liquid in which an adsorbent is dispersed, and then dried, so that the inside of the open cell of the foamed urethane material The adsorbent is fixed to the surface. The amount of the solvent in which the adsorbent is dispersed and the amount of the adsorbent can be the same as in the first example.
Since the water-repellent coating agent is applied to one surface of the foamed urethane material 12 ′, the adsorbent is fixed so as to have a concentration gradient that decreases toward the one surface.

Next, as a third step (c), the surface of the foamed urethane material 12 ′ is melted by applying a frame treatment to the surface of the foamed urethane material 12 ′ to which the water-repellent coating agent is applied.
Thereafter, as a fourth step (d), the adsorbent has a concentration gradient that decreases toward the skin layer 13 and the skin layer 13 side by welding the foamed urethane material 12 ′ and the skin material. It is possible to form the interior material 11 bonded to the foamed urethane layer 12 on which is supported.

When an adsorbent such as activated carbon is supported on the foamed urethane material, the adsorbent inhibits the melting of the foamed urethane material, and the foamed urethane material and the skin material may not be welded with sufficient strength.
In this example, a water-repellent coating agent is applied in advance to one surface of the foamed urethane material to limit the adhering amount of the adsorbent supported on the foamed urethane material.
Therefore, even if a large amount of adsorbent is carried on the foamed urethane material, melt the surface with a small amount of adsorbent adhering, and join the foamed urethane material and the skin material with sufficient adhesive strength. be able to.

  Since the interior material of the present invention can support a large amount of adsorbent in the continuous fine pores of the foamed urethane layer without impairing the design, VOC and odor components (which cause odors) present in the air. Material) can be removed rapidly and over a long period of time, and can be suitably used as an interior material for automobiles and buildings.

Next, although a reference example, an example, and a comparative example explain the present invention in detail, the present invention is not limited to these examples.

In Reference Examples, Examples and Comparative Examples, the following raw materials were used.
[Foamed urethane material]
Slab urethane sheet (Inoac Corporation)
[Adsorbent]
Coconut shell activated carbon (Kuraray Chemical Co., Ltd.)
・ Average particle size: 20-50 μm
Coconut shell carbide (Kuraray Chemical Co., Ltd.)
・ Average particle size: 20-50 μm
[Skin material]
Polyester knit (made by Seiren)
-Mass weight; 280 g / m ²

( Reference Example 1 )
A foamed urethane material having a thickness of 10 mm was impregnated with an aqueous solution in which coconut shell activated carbon was dispersed, and then dried to fix the coconut shell activated carbon in the open cells of the foamed urethane material.
The fixed amount of the coconut shell activated carbon in the foamed urethane material was 120 g / m ² .
Next, one side of the foamed urethane material carrying coconut shell activated carbon is subjected to frame treatment, the surface of the foamed urethane material is melted, the skin material is welded, and the foamed urethane layer and skin layer carrying the adsorbent The interior material joined with was manufactured.

(Comparative Example 1)
An acrylic interior backing material (weight per unit area 80 g / m ² ) was mixed with an adhesive to fix the coconut shell carbide to an adhesive, thereby producing an interior material.
The fixed amount of the coconut shell carbide was 8 g / m ² .

The interior materials of the reference examples and comparative examples were evaluated as follows.
[VOC reduction effect confirmation evaluation]
The interior material (10 mm ² ) of each example was sealed in a 10 liter (L) Tedlar bag. Each gas having the concentration shown in Table 1 below was individually enclosed in a Tedlar bag and allowed to stand at 40 ° C. for 24 hours. Thereafter, the residual concentration of gas in each Tedlar bag was measured.

[Adhesion strength confirmation evaluation]
About the interior material of each example, the strip-shaped test piece of width 25mm and length 120mm was produced, and peeling strength was measured as follows at normal temperature.
A 40 mm skin layer was peeled from one end of the test piece in the length direction, the peeled skin layer was sandwiched between upper grips of an Instron type tensile tester, and the peeled urethane foam layer was sandwiched between lower grips. Next, the test machine is moved at a moving speed of 200 mm / min, and the skin layer and the urethane foam layer of the test piece are all peeled off. At the same time, the test machine is stopped, and the maximum strength (N / 30 mm, Or, N / 25 mm) was measured.

[Brightness evaluation]
The brightness of the interior material of each example was measured with an X-Rite SP64 measuring instrument (manufactured by X-Rite Co., Ltd.) under the conditions of light source: D65 / 10 and reflected light: SPEX.

About the interior material of the said reference example 1 and the comparative example 1, the graph of the reduction rate (%) of toluene is shown in FIG. 6, and the graph of the adsorption amount (g / m < ² >) of toluene is shown in FIG.
As shown in FIG. 6, the interior material of Reference Example 1 was able to reduce the amount of toluene exceeding 80% with respect to the initial amount of toluene. In contrast, the interior material of Comparative Example 1 had a toluene reduction rate of about 60% with respect to the initial amount of toluene.
Further, as shown in FIG. 7, the interior material of Reference Example 1 was able to adsorb a large amount of toluene at about 8.0 g / m ² , whereas the interior material of Comparative Example 1 was an adsorbent of toluene. The amount was as low as less than 2.0 g / m ² .

In FIG. 8, the graph of the brightness of the reference example 1 and the comparative example 1 is shown.
As shown in FIG. 8, the interior material of Reference Example 1 has a brightness that is almost the same as the brightness of the initial interior material that does not carry the adsorbent, and it was confirmed that the design was not impaired. On the other hand, the brightness of the interior material of Comparative Example 1 was nearly 10% lower than that of the initial interior material.

( Example 1 )
A water repellent coating agent was applied to one surface of a urethane foam material having a thickness of 10 mm.
Next, the foamed urethane material to which the water repellent coating agent was applied was impregnated in an aqueous solution in which coconut shell activated carbon was dispersed, and then dried to fix the coconut shell activated carbon in the open cells of the foamed urethane material.
The total fixed amount of the coconut shell activated carbon in the foamed urethane material was 120 g / m ² . Moreover, the fixed amount of the coconut shell activated carbon in the thickness of 0.2 mm from the surface which apply | coated the water-repellent coating agent of the foaming urethane material was 10 g / m < ² >.
Next, a flame treatment is applied to the surface of the foamed urethane material carrying the coconut shell activated carbon to which the water repellent coating agent is applied, the water repellent coating agent is removed and the surface of the foamed urethane material is melted, and the skin material is welded. It was.
In this way, an interior material was produced in which the skin layer and the foamed urethane layer carrying the adsorbent having a concentration gradient that decreases toward the skin layer side were joined (see FIG. 4).

( Example 2 )
The first foamed urethane material having a thickness of 10 mm was impregnated with an aqueous solution in which coconut shell activated carbon was dispersed, and then dried to fix the coconut shell activated carbon in the open cells of the first foamed urethane material.
The fixed amount of the coconut shell activated carbon in the first foamed urethane material was 120 g / m ² .
Next, frame processing is performed on one surface of the second foamed urethane material having a thickness of 2 mm, the surface of the second foamed urethane material is melted, and the first foamed urethane material and the second foamed urethane material are welded. I let you.
Next, the other surface of the second urethane foam material was subjected to frame treatment, the surface of the second urethane foam material was melted, and the skin material was welded.
In this way, an interior material was produced in which the first foamed urethane layer carrying the adsorbent, the second foamed urethane layer, and the skin layer were joined (see FIG. 2).

( Example 3 )
A foamed urethane material having a thickness of 10 mm is impregnated with an aqueous solution in which water coconut shell activated carbon and an organic nitrogen compound are dispersed, and then dried, so that the coconut shell activated carbon and the organic nitrogen compound are contained in open cells of the foamed urethane material. It was fixed. The fixed amount of coconut shell activated carbon in the foamed urethane material was 120 g / m ² , and the fixed amount of the organic nitrogen compound was 12 g / m ² .
Next, a flame treatment was applied to one surface of the foamed urethane material supporting coconut shell activated carbon, the surface of the foamed urethane material was melted, and the skin material was welded to support the adsorbent and the organic nitrogen compound. An interior material in which the urethane foam layer and the skin layer were joined was produced.

In FIG. 9, the graph of the adhesive strength (N / 30mm) of the reference example 1 and Example 1 is shown.
As shown in FIG. 9, the interior material of Example 1 has a concentration gradient in which the coconut shell activated carbon supported on the urethane foam layer decreases toward the skin layer side. The urethane foam layer and the skin layer could be joined with sufficient adhesive strength without hindering the melting of the urethane foam layer.

Table 2 shows the results of VOC reduction effect confirmation evaluation and adhesive strength confirmation evaluation of Reference Example 1, Examples 1 to 3 and Comparative Example 1.

As shown in Table 2, the interior materials of Reference Example 1 and Examples 1 to 3 have a higher VOC reduction efficiency than the interior material of Comparative Example 1, and the VOC and odor components present in the air are rapidly increased. And could be removed over a long period of time.
In particular, the interior material of Example 4 in which the organic nitrogen-based compound was supported on the foamed urethane layer together with the adsorbent was able to improve the aldehyde reduction rate.

It is a disassembled perspective view which shows an example of an interior material typically. It is explanatory drawing which shows typically the 1st example of embodiment of the interior material of this invention. It is explanatory drawing of each process which shows an example of the manufacturing method of the interior material of this invention. It is explanatory drawing which shows typically the 2nd example of embodiment of the interior material of this invention. It is explanatory drawing of each process which shows the other example of the manufacturing method of the interior material of this invention. It is a graph which shows the reduction rate of toluene about the interior material of a reference example and a comparative example. It is a graph which shows the adsorption amount of toluene about the interior material of a reference example and a comparative example. It is a graph which shows the brightness about the interior material of a reference example and a comparative example. It is a graph which shows adhesive strength about the interior material of a reference example and an Example.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Interior material 2 Foaming urethane layer which carried | supported adsorption agent 2 'Foaming urethane material 3 Skin layer 4 Reticulated hot melt adhesive 5 2nd foaming urethane layer 5' 2nd foaming urethane material 10 Interior material 10 'Lamination | stacking Body 11 Interior material 12 Urethane foam layer carrying an adsorbent having a concentration gradient 12 'Foam urethane material 13 Skin layer A Area where water-repellent coating agent is applied T The concentration of the adsorbent carried to have a concentration gradient is Smallest part

Claims (12)

Ri formed are joined by supporting an adsorbent and a urethane foam layer and a skin layer,
The interior material characterized in that the adsorbent supported on the urethane foam layer has a concentration gradient that decreases toward the skin layer side . The interior material according to claim 1 , wherein the concentration gradient of the adsorbent carried on the urethane foam layer is continuous or stepwise. The interior material according to claim 1 or 2 , wherein a second urethane foam layer is interposed between the urethane foam layer carrying the adsorbent and the skin layer. The urethane foam layer carrying the adsorbent and the skin layer are joined,
An interior material characterized in that a second urethane foam layer is interposed between a urethane foam layer carrying the adsorbent and a skin layer.   The interior material according to any one of claims 1 to 4, wherein the urethane foam layer and the skin layer are welded.   The interior material according to any one of claims 1 to 4, wherein the urethane foam layer and the skin layer are bonded with a network-like hot melt adhesive.   The interior material according to any one of claims 1 to 6, wherein the adsorbent is activated carbon or calcined carbide.   The interior material according to claim 7, wherein the activated carbon or calcined carbide is at least one selected from the group consisting of coconut shell activated carbon, coal-based activated carbon, charcoal-based activated carbon, bamboo charcoal-based activated carbon, and bamboo charcoal.   The interior material according to any one of claims 1 to 8, wherein an organic nitrogen-based compound is further supported on the urethane foam layer.   The interior material according to any one of claims 1 to 9, wherein the interior material is for an automobile. Applying a water-repellent coating agent to at least one surface of the foamed urethane material;
Impregnating the foamed urethane material coated with the water repellent coating agent with a liquid in which an adsorbent is dispersed, and supporting the adsorbent;
A method for producing an interior material, comprising a step of melting one surface of the urethane foam material coated with a water-repellent coating agent and joining the urethane foam agent and a skin material. Impregnating the first foamed urethane material with a liquid in which an adsorbent is dispersed, and supporting the adsorbent;
Melting at least one surface of the second urethane foam material, and joining the second urethane foam material and the first urethane foam material;
A method for producing an interior material, comprising a step of melting the other surface of the second urethane foam material and joining the second urethane foam material and the skin.

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