JP5453801B2 - Fiber laminates for vehicles - Google Patents

Description

  The present invention relates to a fiber laminate for a vehicle in which a skin material, a cushion material, and a back base fabric are laminated.

  Since this type of fiber laminate is exclusively used as a vehicle interior material, it is necessary to satisfy various flame retardant regulations. For example, in the general flame retardant regulation “US automobile safety standard FMVSS302”, the burning speed (burning distance per unit time) when the burner flame is applied to the fiber laminate under a certain condition is 100 mm / min or less. Desired.

Therefore, a technique for controlling the burning rate of the fiber laminate is known by focusing on one of the burning behaviors of the fiber laminate (behavior in which only the backing fabric burns) (see Patent Document 1 and Patent Document 2). .
In these known techniques, only the backing fabric is stably burned and the backing fabric material is used so that the burning rate is lower than the standard, so that the burning rate of the fiber laminate is made below the standard value. is there.

For example, in patent document 1, the burning rate of a fiber laminated body can be 50-60 mm / min by using the backing base fabric (weight per unit area of 60 g / m < ² > or more) of a cellulosic fiber.
Moreover, in patent document 2, the burning rate of a fiber laminated body can be 70-80 mm / min by using the back base fabric formed by physically entanglement of a cellulose short fiber (fiber length of 100 mm or less). . And in this well-known technique, the back base fabric which is comparatively excellent in an elongation characteristic can be manufactured by making a several short fiber entangle three-dimensionally with a water punch (jet of high-pressure water).
Japanese Patent No. 3419611 JP 2001-341220 A

However, in the above-described known fiber laminate, the clear cause is unknown, but the combustion behavior sometimes becomes unbalanced in length and width (see FIG. 1B and Table 2). For this reason, in the fiber laminated body of a well-known technique, even if it uses the back base fabric of a cellulosic fiber, there is a possibility that the above-mentioned standard may not be satisfied depending on the combination with other configurations (skin material and cushion material). It has been suggested.
Of course, a flame retardant may be applied to the fiber laminate to lower the combustion rate, but considering the manufacturing cost of the vehicle, it is not a structure that can be easily adopted.
The present invention has been made in view of the above points, and the problem to be solved by the present invention is to clear the US automobile safety standard FMVSS 302 with a simpler configuration.

As means for solving the above-described problems, the vehicle fiber laminate according to the first invention is configured by laminating a skin material, a cushion material, and a back base fabric. And since this kind of fiber laminated body is exclusively used for vehicle interior materials, it is desired to satisfy US automobile safety standard FMVSS302.
Therefore, in the present invention, the above-described back base fabric is a fabric material (woven fabric, knitted fabric or non-woven fabric) containing non-flammable carbon fibers and incombustible . As described above, in the present invention, the above-mentioned standard can be cleared without requiring a flame retardant by making the back base fabric incombustible with carbon fibers (by a relatively simple configuration).

The fiber laminate for a vehicle according to the first invention, the surface material described above, a member that is not subjected to flame retardant treatment, by providing a coating layer containing an oil component with a combustible, fiber laminate The improvement of quality is aimed at. Here, the coating layer is formed of at least one of a softening agent, a ground yarn breakage preventing agent, a raising property improving agent, an abrasion resistance improving agent, a hair fall prevention agent, and a water repellent agent.
And in this invention, the quality improvement can be aimed at, preventing or reducing the deterioration of the combustibility of a fiber laminated body by suppressing combustion of a skin material with a nonflammable back base fabric.
In the vehicle fiber laminate according to the first invention, the conductivity of the back base fabric is suppressed to be relatively low by setting the carbon ratio of the carbon fibers to 20% to 70%. For this reason, the fiber laminated body of this invention can be used for a vehicle, without affecting the sensors inside a vehicle as much as possible, for example .

In the vehicle fiber laminate according to the first invention, only the back base fabric contains carbon fibers, and only the skin material has a coating layer.

According to the fiber laminate of the first invention of the present invention, the US automobile safety standard FMVSS 302 can be cleared with a simpler configuration. Moreover, according to 1st invention, the quality of a fiber laminated body can be improved. And according to 1st invention, the use range of a fiber laminated body becomes wider.

Hereinafter, the best mode for carrying out the present invention will be described with reference to FIGS. 1 and 2. FIG.
The fiber laminate 2 for a vehicle according to the present embodiment is configured by laminating a skin material 4, a cushion material 6, and a back base fabric 8 with reference to FIGS. 1 and 2 (details of each configuration are described). Will be described later). And since this kind of fiber laminated body 2 is exclusively used for a vehicle interior material, it is desired to satisfy US automobile safety standard FMVSS302.
Therefore, in the present embodiment, the back base fabric 8 is made nonflammable by carbon fibers to be described later in order to more reliably clear the above criteria.

(Skin material)
The skin material 4 is a member that constitutes the design surface of the fiber laminate 2, and is composed of, for example, a jersey, woven fabric, moquette, tricot, natural leather, artificial leather, or a synthetic resin sheet.
Material and basis weight of the skin material 4 is not particularly limited but, for example, the typical skin material 4 made of PET, basis weight is ^{250g / m 2 ~650g / m 2} . Table skin material 4 is not such subjected to flame retardant treatment from cost surface or the like.

(Coating layer)
The surface of the skin material 4 is provided with a coating layer containing a combustible oil component such as a softening agent or an anti-thread breaker, and its quality (designability by dyeing or printing, antibacterial properties, antibacterial properties) It is desirable to improve the deodorizing property, antifouling property, water repellency, slipperiness, raising property, etc.). On the surface of the skin material 4, in addition to a softener and a ground yarn breakage preventive agent, a film layer (a single type of film layer or a plurality of types) may seed coat layer) is formed, these contain all combustion of the oil component. Examples of combustible oil components include wax-based, paraffin-based, silicon-based, acrylic-based, and fluorine-based resins.

(Cushion material)
Moreover, the cushion material 6 should just be provided with the cushioning property which ensures a passenger | crew's seating property, for example, is comprised with a polyurethane foam, a polyethylene foam, or a polyester foam. As the cushion material 6, it is desirable to use a polyurethane foam (density: 10 kg / m ^{3 to} 30 kg / m ³ ) having excellent sag resistance.
The cushion material 6 may be subjected to a flame retardant treatment separately, but is preferably not subjected to the flame retardant treatment from the viewpoint of cost.

(Back fabric)
The back base fabric 8 is a fabric material (woven fabric, knitted fabric or non-woven fabric) containing carbon fibers. Examples of the carbon fiber include polyacrylonitrile-based carbon fiber (PAN-based carbon fiber), pitch-based carbon fiber, and blended fibers thereof.
And the back base fabric 8 of this embodiment has a nonflammable effect by carbon fiber, and it is not necessary to mix | blend a flame-retardant processing agent (it is a comparatively simple structure). In addition, it is desirable not to use a general flame retardant treatment material (chlorinated organic phosphorus compound or the like) for the back base fabric 8 in order to induce a fogging phenomenon (so-called fogging phenomenon) of an automobile window.

Here, the PAN-based carbon fiber is a fiber typically formed by carbonizing and baking polyacrylonitrile (PAN), and examples thereof include flame-resistant fiber, carbonized fiber, and graphitized fiber.
The flame resistant fiber is a carbon fiber that has been made flame resistant (heat treated at 200 ° C. to 300 ° C. in air) after spinning polyacrylonitrile (PAN). Carbonized fiber is carbon fiber obtained by carbonizing flame resistant fiber (heat treatment at 1000 ° C. to 1500 ° C. in an inert atmosphere). The graphitized fiber is a carbon fiber obtained by graphitizing carbonized fiber (heat treatment at 2000 ° C. to 3000 ° C. in an inert atmosphere).

The pitch-based carbon fiber is typically a fiber obtained by carbonizing and firing petroleum pitch or coal pitch, and examples thereof include infusible fibers, carbonized fibers, and graphite fibers.
The infusible fiber is a carbon fiber obtained by infusibilizing pitch fibers (heat treatment at 200 ° C. to 350 ° C. in an oxidizing atmosphere). Carbonized fibers are carbon fibers obtained by carbonizing infusible fibers (heat treatment at 1000 ° C. to 1500 ° C. in an inert atmosphere). The graphitized fiber is a carbon fiber obtained by graphitizing carbonized fiber (heat treatment at 2000 ° C. to 3000 ° C. in an inert atmosphere).

(Carbon ratio of carbon fiber)
The carbon ratio (carbon content) of the carbon fiber is not particularly limited as long as nonflammability can be imparted to the back base fabric, but is desirably 70% or less (typically 20% to 70%). . Carbon fibers having a carbon ratio of 20% or less tend not to have sufficient strength and elasticity.
Here, carbon fibers having a carbon ratio of 70% or less (for example, flame-resistant fibers) can be produced at low cost because they are obtained by treating acrylonitrile fibers at a low temperature (200 ° C. to 300 ° C.). Carbon fibers having a carbon ratio of 70% or less are known to have relatively low fiber strength (easy to bend).
Carbon fibers having a carbon ratio of 95% or more (for example, carbonized fibers and graphitized fibers) are produced at a relatively high cost because they are obtained by processing at a relatively high temperature (1000 ° C. or more).

Incidentally, it is known that carbon fibers having a carbon ratio of 95% or more (carbon fibers processed at 1000 ° C. or more) have good electrical conductivity (conductivity).
Various sensors are often built in the vehicle. For this reason, when the highly conductive fiber laminate 2 is disposed in the vicinity of the sensors (when the fiber laminate 2 is used as the back base fabric of the vehicle skin material), adverse effects such as malfunction on the sensors inside the vehicle. There is a concern that
Here, it is known that carbon fibers having a carbon ratio of 70% or less (carbon fibers processed at 200 ° C. to 300 ° C.) have relatively low conductivity. For this reason, if the carbon fiber has a carbon ratio of 70% or less, it can be used in a vehicle without adversely affecting the sensors in the vehicle (the use range of the fiber laminate 2 is widened).

(Manufacture of backing fabric)
The back base fabric as a fabric can be produced by a general-purpose knitting method, and the back base fabric can also be produced by a general-purpose method as a non-woven fabric.
For example, a non-woven fabric is produced by creating a sheet (web) of carbon fibers and then entwining the web. For web production, a dry method in which carbon fibers (short fibers) are loosened by a cotton spreader and then made into a sheet, or a wet method in which carbon fibers are dispersed in a liquid and then made into a sheet by using a paper machine Any of these can be used.
At this time, the fiber thickness (fiber diameter) of the carbon fiber is typically φ50 μm or less, and preferably φ10 μm to 15 μm. The fiber length of the carbon fiber is typically 100 mm or less, and preferably 20 mm to 60 mm. By using carbon fibers having a fiber thickness or fiber length in this range, the stretch characteristics of the back base fabric 8 can be improved.

And it is preferable to entangle the above-mentioned web three-dimensionally by a physical entanglement method such as a water punch or a mechanical entanglement method such as a needle punch to form a back base fabric 8.
By doing so, the short fibers are closely intertwined with each other, and a stable base fabric 8 (non-woven fabric) can be obtained simply by intertwining the fibers without using an adhesive or heat fusion. In particular, by interlacing the short fibers of the web three-dimensionally with a water punch (jet of high-pressure water), it is possible to eliminate contamination of impurities such as machine oil (impurities that promote combustion) as much as possible.

The basis weight of the back base fabric 8 is typically ^{20g / m 2 ~60g / m 2} , preferably ^{30g / m 2 ~60g / m 2} . Here, when the basis weight of the back base fabric 8 is less than 20 g / m ^2, it becomes difficult to exert a combustion suppressing action on other materials (skin material 4 and cushion material 6). In addition, although the fabric weight of the back base fabric 8 may be larger than 60 g / m < ² >, while it becomes high cost, the weight of the fiber laminated body 2 increases more than necessary.

[Fiber laminate]
Referring to FIG. 2, after the skin material 4, the cushion material 6, and the back base fabric 8 are arranged in this order, they are joined by a technique such as sewing, adhesion, or welding (laminating).
Since the fiber laminate 2 produced in this way includes the non-combustible backing base fabric 8, the US automobile safety standards can be more reliably cleared (see [Table 2]). Further, the fiber laminate 2 has elongation characteristics comparable to conventional products (see [Table 2]). For this reason, the fiber laminated body 2 can be used suitably, for example as a skin cover material of a vehicle seat.
And in a present Example, by suppressing the combustion of the skin material 4 with the nonflammable back base fabric 8, the quality improvement can be aimed at, preventing or reducing the deterioration of the combustibility of the fiber laminated body 2. FIG.

[Test example]
Hereinafter, although this Embodiment is demonstrated based on a test example, this invention is not limited to a test example.
In this test, it was decided to use the back base fabric 8 of Example 1 and the back base fabric 9 of Comparative Example 1 according to the configuration and manufacturing method of [Table 1] below (see FIG. 1).

(Fiber laminate of Example 1)
And the fiber laminated body 2 of Example 1 was produced by laminating and joining the skin material 4, the cushion material 6 and the back base fabric 8 in this order (see FIGS. 1 and 2). In addition, the skin material 4, the cushion material 6, and the back base fabric 8 used what was not mixed with the flame-retardant processing material.
A jersey made of PET (weight per unit area: 250 g / m ² ) was used as the skin material 4. Further, polyurethane foam (density: 20 Kg / m ³ , plate thickness: 1.3 mm) was used as the cushion material 6.

  A non-woven fabric made of PAN-based carbon fiber was used for the back base fabric 8. The carbon ratio of the carbon fibers was 60% to 70% (so-called C grade carbon fibers were used). The fiber thickness of the carbon fiber was φ10.1 μm to 14.4 μm (average value: φ11.9 μm, σ: 0.9, 3σ: 2.7). The fiber length of the carbon fiber was 20.9 mm to 50.7 mm (average value: 38.1 mm, σ: 7.4, 3σ: 22.2).

(Fiber laminate of Comparative Example 1)
Moreover, the fiber laminated body 20 of the comparative example 1 was produced by laminating | stacking and joining the skin material 4, the cushion material 6, and the back base fabric 9 in this order (refer FIG.1 and FIG.2). The detailed configuration of the skin material 4 and the cushion material 6 was the same as that of Example 1. As the backing base fabric 9, a nonwoven fabric made of a blended fiber of rayon and polyethylene terephthalate (PET) was used (see Patent Document 2).

(Test method)
Then, a “longitudinal sample Sh1” (350 mm long × 100 mm wide) long in the conveying direction F of the belt conveyor was collected from the fiber laminate 2 of Example 1 (see FIG. 1A). Further, a “horizontal sample Sw1” (100 mm long × 350 mm wide) that was long in the direction perpendicular to the same direction F was collected. The maximum burning rates of these “longitudinal sample Sh1” and “horizontal sample Sw1” were measured in accordance with US automobile safety standard FMVSS302 (see FIG. 2).
Further, the breaking elongation and tensile strength of the “back base fabric of the vertically long sample Sh1” and the “back base fabric of the horizontally long sample Sw1” were measured in accordance with “JIS L1018 8.13 tensile strength and elongation”.

Similarly, “longitudinal sample Sh2” and “horizontal sample Sw2” were collected from the fiber laminate 20 of Comparative Example 1 as in Example 1 (see FIG. 1B). Then, the maximum burning rate of each of these “longitudinal sample Sh2” and “laterally long sample Sw2” was measured in accordance with US automobile safety standard FMVSS302.
Further, the breaking elongation and tensile strength of the “back base fabric of the vertically long sample Sh2” and the “back base fabric of the horizontally long sample Sw2” were measured according to “JIS L1018 8.13 tensile strength and elongation”.

The measurement results of each test are shown in [Table 2] below.

(Maximum burning rate test results)
In the fiber laminate 2 of Example 1, both the “vertically long sample Sh1” and the “horizontal sample Sw1” were nonflammable.
From this, according to the fiber laminate 2 of Example 1, it was found that the US automobile safety standards can be more reliably cleared by making the back base fabric 8 nonflammable. That is, it turned out that the back base fabric 8 can have a non-flammable effect by the carbon fiber and does not need to contain a flame retardant.

On the other hand, in the fiber laminate 20 of Comparative Example 1, the difference between the maximum combustion rate of the “longitudinal sample Sh2” and the maximum combustion rate of the “laterally long sample Sw2” was extremely large (the vertical and horizontal combustion behavior was undefined). It was a balance). In particular, the maximum burning rate of the vertically long sample Sh2 was the upper limit (100 mm / min) of the US automobile safety standard.
The unbalanced combustion speed in Comparative Example 1 is presumed to be because combustion in the same direction was promoted by arranging the short fibers of the back base fabric 9 perpendicularly to the conveying direction F of the belt conveyor. From this, the fiber laminate 20 (back base fabric 9) of Comparative Example 1 may not meet US automobile safety standards depending on the combination with other configurations (skin material 4 and cushion material 6). It was strongly suggested.

(Test results of elongation at break and tensile strength)
In the fiber laminate 2 of Example 1, the breaking elongation of the “back base fabric of the vertically long sample Sh1” and the breaking elongation of the “back base fabric of the horizontally long sample Sw1” show values comparable to those of Comparative Example 1. It was. Similarly, the tensile strength of the “back base fabric of the vertically long sample Sh1” and the tensile strength of the “back base fabric of the laterally long sample Sw1” showed values comparable to those of Comparative Example 1.

From this, it was found that the fiber laminate 2 of Example 1 had a relatively high elongation at break of the backing base fabric 8 and was easily stretched. For this reason, when the fiber laminate 2 is used, for example, as a skin cover material for a vehicle seat, the fiber laminate 2 can be neatly stretched corresponding to the outer shape of the seat without generating wrinkles and twists as much as possible (appearance and seating feeling). It turned out to be a good finish.
Further, it was found that the fiber laminate 2 can be stably pulled because the tensile strength of the back base fabric 8 is moderately low. For example, sewing work is involved in the production of the skin cover material. At this time, if the skin cover material (fiber laminate 2) can be stably pulled, the sewing work is facilitated and a clean sewing line is formed. (It will be a nice looking finish).
From this, it was found that the fiber laminate 2 (back base fabric 8) of Example 1 has suitable elongation characteristics and can be suitably used for a skin cover material for covering a three-dimensional structure such as a vehicle seat.

The vehicle fiber laminate and the manufacturing method thereof according to the present embodiment are not limited to the above-described examples, and may take other various embodiments.
(1) In this example, the back base fabric 8 made exclusively of carbon fibers is exemplified. At this time, other fibers (natural fibers or synthetic fibers) can be blended as long as the non-flammability and elongation characteristics of the back base fabric 8 are not adversely affected.
(2) In the entanglement process of this embodiment, the configuration in which the web is physically or mechanically entangled has been described, but this does not mean that no adhesive or binder fiber is used. That is, an amount of adhesive or the like that does not adversely affect the nonflammability and elongation characteristics of the back base fabric 8 can be used.
(3) In the present embodiment, the fiber laminate 2 including only the skin material 4, the cushion material 6, and the back base fabric 8 has been described. However, each of these configurations is a main configuration, and other configurations (resin) A plate or a coating layer).

(A) is a perspective view of the fiber laminated body for vehicles which concerns on a present Example, (b) is a perspective view of the fiber laminated body for vehicles which concerns on a prior art example. It is a longitudinal cross-sectional view of the fiber laminated body which shows the measuring method of a burning rate.

Explanation of symbols

2 Fiber laminate 4 Skin material 6 Cushion material 8 Back base fabric 20 Fiber laminate (comparative example)
9 Back fabric (comparative example)

Claims (1)

In a fiber laminate for a vehicle in which a skin material, a cushion material and a back base fabric are laminated,
The back base fabric is a cloth material containing carbon fibers and incombustible, and the carbon ratio of the carbon fibers is 20% to 70%,
The skin material is a member that is not subjected to flame retardant treatment, and includes a coating layer containing a combustible oil component, and the coating layer includes a softening agent, a ground yarn breakage preventing agent, a raising property improving agent, Formed with at least one of an abrasion resistance improver, a hair fall prevention agent and a water repellent ,
A fiber laminate for a vehicle in which only the back base fabric contains carbon fibers and only the skin material includes the coating layer .

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