JP6560353B2 - 自動車内外装用成形体の製造方法 - Google Patents
自動車内外装用成形体の製造方法 Download PDFInfo
- Publication number
- JP6560353B2 JP6560353B2 JP2017534057A JP2017534057A JP6560353B2 JP 6560353 B2 JP6560353 B2 JP 6560353B2 JP 2017534057 A JP2017534057 A JP 2017534057A JP 2017534057 A JP2017534057 A JP 2017534057A JP 6560353 B2 JP6560353 B2 JP 6560353B2
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- thermoplastic resin
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- interior
- resin layer
- hole
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Images
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Landscapes
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Description
前記繊維層の一方の面に積層された熱可塑性樹脂層と、を備え、
前記熱可塑性樹脂のメルトフローレートが2g/10分〜500g/10分の範囲であり、
前記熱可塑性樹脂層に該樹脂層の厚さ方向に貫通する貫通孔が複数個形成されていることを特徴とする自動車用内外装材。
前記基布の他方の面に前記熱可塑性樹脂層が積層されている前項1または2に記載の自動車用内外装材。
前記一対のロールのうち熱可塑性樹脂膜に接触する第1ロールとして、外周面に複数個の穿孔用突起部が突設形成された冷却式ロールを用いることを特徴とする自動車用内外装材の製造方法。
図4に示すように、メルトフローレートが100g/10分であるポリエチレン樹脂を押出機の押出ダイス31から押し出して得られた押出直後のポリエチレン樹脂膜3、及び構成繊維の繊度が6.6デシテックスで目付が250g/m2の通気性のニードルパンチ不織布2を重ね合わせた状態でこれらを前項で説明した第1ロール(水冷式ロール)32と第2ロール33の間で挟圧した。この時、図4に示すように、第1ロール(水冷式ロール)32が前記押出直後のポリエチレン樹脂膜3に接触し、第2ロール33が前記ニードルパンチ不織布2に接触する態様で挟圧したので、第1ロール32の外周面の穿孔用突起部32Aが、ポリエチレン樹脂膜(熱可塑性樹脂層)3およびニードルパンチ不織布2を厚さ方向に貫通し、これにより、厚さ方向に貫通する複数個の貫通孔11が設けられたポリエチレン樹脂層3が形成されると共に、複数個の通気孔12が厚さ方向に貫通して形成されたニードルパンチ不織布層2が前記ポリエチレン樹脂層3の片面に積層一体化され、貫通孔11と通気孔12が連通してなる自動車用内外装材1を得た(図1参照)。
メルトフローレートが100g/10分であるポリエチレン樹脂に代えて、メルトフローレートが150g/10分であるポリエチレン樹脂を用いた以外は、実施例1と同様にして図1に示す自動車用内外装材1を得た。さらに、この自動車用内外装材1を用いて実施例1と同様にして熱プレスを行うことによって自動車内外装用成形体40を製造した。
メルトフローレートが100g/10分であるポリエチレン樹脂に代えて、メルトフローレートが400g/10分であるポリエチレン樹脂を用いた以外は、実施例1と同様にして図1に示す自動車用内外装材1を得た。さらに、この自動車用内外装材1を用いて実施例1と同様にして熱プレスを行うことによって自動車内外装用成形体40を製造した。
メルトフローレートが100g/10分であるポリエチレン樹脂に代えて、メルトフローレートが10g/10分であるポリエチレン樹脂を用いた以外は、実施例1と同様にして図1に示す自動車用内外装材1を得た。さらに、この自動車用内外装材1を用いて実施例1と同様にして熱プレスを行うことによって自動車内外装用成形体40を製造した。
メルトフローレートが100g/10分であるポリエチレン樹脂に代えて、メルトフローレートが50g/10分であるポリエチレン樹脂を用いた以外は、実施例1と同様にして図1に示す自動車用内外装材1を得た。さらに、この自動車用内外装材1を用いて実施例1と同様にして熱プレスを行うことによって自動車内外装用成形体40を製造した。
機械的孔(貫通孔11と通気孔12が連通してなる機械的孔)の配置密度を7800個/m2に設定した以外は、実施例1と同様にして図1に示す自動車用内外装材1を得た。さらに、この自動車用内外装材1を用いて実施例1と同様にして熱プレスを行うことによって自動車内外装用成形体40を製造した。
機械的孔(貫通孔11と通気孔12が連通してなる機械的孔)の配置密度を7800個/m2に設定した以外は、実施例2と同様にして図1に示す自動車用内外装材1を得た。さらに、この自動車用内外装材1を用いて実施例2と同様にして熱プレスを行うことによって自動車内外装用成形体40を製造した。
機械的孔(貫通孔11と通気孔12が連通してなる機械的孔)の配置密度を7800個/m2に設定した以外は、実施例3と同様にして図1に示す自動車用内外装材1を得た。さらに、この自動車用内外装材1を用いて実施例3と同様にして熱プレスを行うことによって自動車内外装用成形体40を製造した。
機械的孔(貫通孔11と通気孔12が連通してなる機械的孔)の配置密度を7800個/m2に設定した以外は、実施例4と同様にして図1に示す自動車用内外装材1を得た。さらに、この自動車用内外装材1を用いて実施例4と同様にして熱プレスを行うことによって自動車内外装用成形体40を製造した。
機械的孔(貫通孔11と通気孔12が連通してなる機械的孔)の配置密度を7800個/m2に設定した以外は、実施例5と同様にして図1に示す自動車用内外装材1を得た。さらに、この自動車用内外装材1を用いて実施例5と同様にして熱プレスを行うことによって自動車内外装用成形体40を製造した。
機械的孔(貫通孔11と通気孔12が連通してなる機械的孔)の配置密度を11700個/m2に設定した以外は、実施例4と同様にして図1に示す自動車用内外装材1を得た。さらに、この自動車用内外装材1を用いて実施例4と同様にして熱プレスを行うことによって自動車内外装用成形体40を製造した。
機械的孔(貫通孔11と通気孔12が連通してなる機械的孔)の配置密度を11700個/m2に設定した以外は、実施例5と同様にして図1に示す自動車用内外装材1を得た。さらに、この自動車用内外装材1を用いて実施例5と同様にして熱プレスを行うことによって自動車内外装用成形体40を製造した。
メルトフローレートが100g/10分であるポリエチレン樹脂に代えて、メルトフローレートが0.8g/10分であるポリエチレン樹脂を用いた以外は、実施例1と同様にして図1に示す自動車用内外装材1を得た。さらに、この自動車用内外装材1を用いて実施例1と同様にして熱プレスを行うことによって自動車内外装用成形体40を製造した。得られた成形体40には、ポリエチレン樹脂層(熱可塑性樹脂層)3を厚さ方向に貫通する熱成形時穿設孔13は形成されなかった。
メルトフローレートが100g/10分であるポリエチレン樹脂に代えて、メルトフローレートが550g/10分であるポリエチレン樹脂を用いた以外は、実施例1と同様にして図1に示す自動車用内外装材1を得た。さらに、この自動車用内外装材1を用いて実施例1と同様にして熱プレスを行うことによって自動車内外装用成形体40を製造した。
第1ロールとして、外周面に穿孔用突起部が設けられた水冷式ロールに代えて、このような穿孔用突起部を有しない略円柱形状の常温ロールを用いた以外は、実施例1と同様にして自動車用内外装材を得た。得られた自動車用内外装材において、機械的孔は、形成されていない。さらに、この自動車用内外装材を用いて実施例1と同様にして熱プレスを行うことによって自動車内外装用成形体を製造した。
第1ロールとして、外周面に穿孔用突起部が設けられた水冷式ロールに代えて、このような穿孔用突起部を有しない略円柱形状の常温ロールを用いた以外は、実施例2と同様にして自動車用内外装材を得た。得られた自動車用内外装材において、機械的孔は、形成されていない。さらに、この自動車用内外装材を用いて実施例2と同様にして熱プレスを行うことによって自動車内外装用成形体を製造した。
KES通気性試験機(カトーテック株式会社製)を用いて各自動車内外装用成形体の通気抵抗を測定した。通気抵抗(AFR;airflow resistance)が1000Pa・sec/m〜16000Pa・sec/mの範囲内にあるものが吸音性能に優れていると判定できる。なお、KES通気性試験機は、試験片の圧力損失(標準測定で一定流量4cm3/cm2・secのときの試験片の抵抗による大気圧との差圧)を圧力センサーを用いて測定し、通気抵抗を直接表示するものである。
2…繊維層
3…熱可塑性樹脂層
11…貫通孔
12…通気孔
13…熱成形時穿設孔
32…第1ロール(冷却式ロール)
32A…穿孔用突起部
33…第2ロール
40…自動車内外装用成形体
Claims (9)
- 通気性の繊維層と、前記繊維層の一方の面に積層された充填剤含有熱可塑性樹脂層と、を備え、前記熱可塑性樹脂のメルトフローレートが2g/10分〜500g/10分の範囲であり、前記熱可塑性樹脂層に該樹脂層の厚さ方向に貫通する貫通孔が複数個形成されている自動車用内外装材に熱成形を行うことによって成形体を得ることを特徴とする自動車内外装用成形体の製造方法。
- 前記貫通孔の内径が0.1mm〜5.0mmであり、前記貫通孔の配置密度が1000個/m2〜30000個/m2である請求項1に記載の自動車用内外装用成形体の製造方法。
- 前記繊維層は、構成繊維の繊度が0.1デシテックス〜100デシテックスである不織布からなる請求項1または2に記載の自動車用内外装用成形体の製造方法。
- 前記繊維層は、目付80g/m2〜150g/m2の基布の一方の面に、目付250g/m2〜2000g/m2のパイルが植設されたカーペット原反であり、
前記基布の他方の面に前記熱可塑性樹脂層が積層されている請求項1または2に記載の自動車用内外装用成形体の製造方法。 - 前記熱可塑性樹脂層の形成量は、50g/m2〜5000g/m2の範囲である請求項1〜4のいずれか1項に記載の自動車用内外装用成形体の製造方法。
- 前記繊維層の前記一方の面から、厚さ方向の中間位置まで又は該繊維層の他方の面まで通気孔が複数形成されており、該通気孔は、前記熱可塑性樹脂層の貫通孔と連通していることを特徴とする請求項1〜5のいずれか1項に記載の自動車用内外装用成形体の製造方法。
- 前記通気性の繊維層は、目付量200g/m 2 〜2000g/m 2 の不織布からなる請求項1〜6のいずれか1項に記載の自動車用内外装用成形体の製造方法。
- 前記熱成形の際に熱可塑性樹脂層が繊維層の前記一方の面側の一部に含浸されることにより部分的に破断して前記得られた成形体の熱可塑性樹脂層に厚さ方向に貫通する熱成形時穿設孔が形成されている請求項1〜7のいずれか1項に記載の自動車内外装用成形体の製造方法。
- 前記熱成形の際に熱可塑性樹脂層の軟化又は溶融により、前記貫通孔の両端の開口部の内径が減縮する請求項1〜8のいずれか1項に記載の自動車内外装用成形体の製造方法。
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