JP6844848B2 - Interior base material, interior material, interior material - Google Patents

Description

The present invention is obtained by molding an interior base material used as a material for interior materials such as automobiles, aircrafts, and building materials, an interior material obtained by using the interior base material, and the interior material thereof into a predetermined shape. It is about interior materials.

Usually, the interior material is obtained by forming a sheet-shaped interior material obtained by laminating a skin material on the surface of an interior base material into a predetermined shape by heat press molding. In many cases, a fiber material such as glass wool is used for the interior base material, and a non-woven fabric or knitted fabric is used for the skin material (for example, Patent Document 1). However, as in Patent Document 1, in the interior material using only the fiber material such as glass wool as the interior base material, the fiber material compressed by heat press molding becomes very hard, and the feel is poor and the feel is inferior. Therefore, it is difficult to use it as a material for interior materials that users touch, such as automobile instrument panels.
Therefore, a flexible foam elastic foam is used as the interior material of the interior material that is required to have a tactile sensation. However, when the foamed elastic foam is used alone as an interior material, it is inferior in rigidity, for example, even if it is compressed during heat press molding, it bends and the desired shape retention cannot be obtained. For this reason, the foamed elastic foam is used as an interior material by laminating a fiber material for reinforcement and a non-woven fabric / knitted fabric.
For example, the interior material for vehicles of Patent Document 2 is made by laminating a breathable skin material on the surface of a flexible polyurethane foam sheet, and is made of a thermoplastic synthetic resin fiber cotton and a fiber reinforcing material as a base material. There is.
The sound absorbing material of Patent Document 3 is composed of a polyurethane foam, a surface material laminated on one side of the polyurethane foam, and a thermosetting resin-containing felt laminated on the surface of the polyurethane foam opposite to the surface material. It is integrated and shaped by a hot press.

Japanese Unexamined Patent Publication No. 08-142077 Japanese Unexamined Patent Publication No. 03-147830 Japanese Unexamined Patent Publication No. 2006-78709

When the interior material using the foamed elastic foam as in Patent Document 2 and Patent Document 3 is heat-press molded into the interior material, the compressed foamed elastic foam and the fiber material have a desired feel. There was a problem that it did not have rigidity. This is because there is a difference in compressive strength between the foamed elastic foam and the fiber material, and this difference in compressive strength affects each compression ratio between the foamed elastic foam and the fiber material. When the foamed elastic foam is compressed more than expected, the desired tactile sensation cannot be obtained, while when the fiber material is not compressed more than expected, the desired rigidity cannot be obtained.

The present invention has focused on such problems existing in the prior art. An object of the present invention is to provide an interior base material and an interior material capable of exhibiting suitable rigidity and tactile sensation when compressed by heat press molding, and also to provide tactile sensation while maintaining rigidity. The purpose is to provide interior materials that can be improved.

As a means for solving the above-mentioned conventional problems, the invention of the interior base material according to claim 1 is an interior base material having an elastic layer made of a foamed elastic foam and a reinforcing layer made of a fiber material. The gist is that the ratio of 50% compressive strength (fiber material / foam elastic foam) of the fiber material to the foamed elastic foam is more than 0.26 / 100 and less than 25/100.
The gist of the invention according to claim 2 is that the material used for the foamed elastic foam in the invention according to claim 1 is a melamine resin or polyurethane.
The gist of the invention of the interior material according to claim 3 is that it has the interior base material according to claim 1 or 2, and a non-woven fabric skin material laminated on one side or both sides of the interior base material. And.
The invention of the interior material according to claim 4 is obtained by heat-press molding the interior material according to claim 3 into a predetermined shape, and comprises a reinforcing layer made of the fiber material and an elastic layer made of the foamed elastic foam. The gist is that the thickness ratio (reinforcing layer / elastic layer) of is more than 1/100 and less than 55/100.

[Action]
According to the interior base material of the present invention, the interior base material having an elastic layer made of a foamed elastic foam and a reinforcing layer made of a fiber material has a compression strength of 50% between the fiber material and the foamed elastic foam. The ratio (fiber material / foam elastic foam) is set to more than 0.26 / 100 and less than 25/100.
Here, the 50% compressive strength of the present invention refers to the compressive stress at the time of 50% strain specified in 7.2.3 of JIS K6767. The lower the 50% compression strength, the easier it is to be crushed during compression, so that the thickness is likely to be smaller, and the higher the 50% compression strength, the less likely it is to be crushed during compression, so that the thickness is likely to be large.
Focusing on the ratio of 50% compressive strength (fiber material / foam elastic foam) between the foamed elastic foam and the fiber material, the interior base material exceeds 0.26 / 100 and is less than 25/100. By setting, the foamed elastic foam and the fiber material can be compressed in a suitable balance during heat press molding. Therefore, it is possible to prevent the fiber material from being unable to function as a reinforcing layer or the foamed elastic foam from being unable to function as an elastic layer due to insufficient compression or excessive compression. It is possible to improve the tactile sensation by the elastic layer (claim 1).
Further, when the material used for the foamed elastic foam is melamine resin or polyurethane, flame retardancy and heat resistance can be imparted (claim 2).
According to the interior material of the present invention, since the skin material made of non-woven fabric is laminated on one side or both sides of the interior base material, the elastic layer and the reinforcing layer are not exposed to the outside, and the design can be improved. (Claim 3).
According to the interior material of the present invention, the thickness ratio (reinforcing layer / elastic layer) of the reinforcing layer made of the fiber material and the elastic layer made of the foamed elastic foam is more than 1/100 and less than 55/100. Therefore, the reinforcing layer can be made thick enough to maintain rigidity, while the elastic layer can be made thick enough to have sufficient flexibility to improve the tactile sensation (claim 4).

〔effect〕
According to the present invention, it is an object of the present invention to provide an interior base material and an interior material capable of exhibiting suitable rigidity and tactile sensation when compressed by heat press molding, and also to provide tactile sensation while maintaining rigidity. It is possible to provide an interior material that can be improved.

The cross-sectional view which shows the interior base material of embodiment. Sectional drawing which shows the interior material of embodiment. Sectional drawing which shows the interior material of another form. The cross-sectional view which shows the interior material of embodiment.

Hereinafter, an embodiment embodying the present invention will be described.
As shown in FIG. 1, the interior base material 10 has an elastic layer 11 made of a foamed elastic foam and a reinforcing layer 12 made of a fiber material.
The elastic layer 11 is for exhibiting a suitable feel when compressed by heat press molding, due to the elasticity (elasticity) and cushioning of the foamed elastic foam in the compressed state. Is.
The reinforcing layer 12 is for reinforcing the elastic layer 11 and suppressing bending and deformation due to the rigidity of the compressed fiber material when compressed by heat press molding.

As the foamed elastic foam, a foam made of a synthetic resin as a material, which is flexible and soft, is used from the viewpoint of exhibiting a suitable feel in a compressed state.
Examples of the synthetic resin include melamine resin, polyurethane, polystyrene, polyolefins such as polyethylene and polypropylene, phenol resin, polyvinyl chloride, urea resin, silicone resin, and polyimide. Among these, melamine resin and polyurethane are easily available, and because they are thermosetting resins, they have flame retardancy and heat resistance, and because they have a high elasticity, they have an advantage that they have a good feel in a compressed state. Therefore, the material used for the foamed elastic foam is preferably melamine resin or polyurethane.

The foam has an open cell structure and a closed cell structure, and any of them can be used for the foam elastic foam. However, in the foam having a closed cell structure, the wall that separates the bubbles may break (bubble rupture) during compression, and the 50% compression strength may change significantly. Therefore, the foam has an open cell structure. It is preferable to use one.
In particular, a foam having an open cell structure has breathability, and is preferable as a foamed elastic foam from the viewpoint that sound absorption performance utilizing this breathability can be imparted.

Since the foamed elastic foam exhibits a suitable feel in a compressed state by heat press molding, it is preferable that the foam has a 50% compression strength of more than 5N from the viewpoint of making it as hard as possible to be crushed during compression and increasing the thickness. , 6N or more is more preferable, and 7N or more is further preferable. If the 50% compression strength is excessively low, it may be crushed during compression and the thickness may be reduced, resulting in a hard material having inferior flexibility and not being able to exhibit a desired tactile sensation.
The upper limit of the 50% compressive strength of the foamed elastic foam is not particularly limited, but is preferably 25 N or less, more preferably 15 N or less, and further preferably 10 N or less. If the 50% compression strength is excessively high, it is difficult to be compressed and the moldability is inferior, and on the contrary, there is a possibility that problems such as inferior feel and easy bending and deformation may occur.

In the foamed elastic foam, the mass per unit area (hereinafter, also abbreviated as "unit area mass") is appropriately set according to the synthetic resin used, the foaming ratio, and the desired 50% compression strength, and is particularly limited. Not done. ^{The unit area mass is preferably 100 g / m 2 to} 500 g / m ² , more preferably 120 g / m ² to 100 g / m 2 to 500 g / m 2 from the viewpoint of reducing the weight while maintaining an appropriate flexibility by setting 50% compressive strength in the above range. 400 g / ^{m 2,} more preferably from ^{140g / m 2 ~350g / m 2} . When the unit area mass is excessively small, it becomes excessively soft, and when the unit area mass is excessively large, it becomes hard with inferior flexibility and it becomes difficult to reduce the weight.
The thickness of the foamed elastic foam is appropriately set according to the desired thickness of the interior material, the desired 50% compression strength, the synthetic resin to be used, the foaming ratio, and the like, and is not particularly limited. Usually, the thickness of the foamed elastic foam is preferably set to be the same as the desired thickness of the interior material or to exceed the thickness of the interior material, and is concrete from the viewpoint of setting the 50% compression strength in the above range. More preferably, it is set in the range of 10 mm to 30 mm.

The fibers used in the fiber material are not particularly limited, and specific examples thereof include inorganic fibers such as glass wool (glass fiber), rock wool (rock wool), asbestos fiber, carbon fiber, ceramic fiber, metal fiber, and whisker. Biodecomposition consisting of synthetic fibers such as polyester fiber, polyethylene fiber, polypropylene fiber, polyamide fiber, acrylic fiber, urethane fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, acetate fiber, and starch extracted from plants such as corn and sugar cane. Examples include natural fibers such as fibers (polylactic acid fibers), pulp, cotton, palm fibers, hemp fibers, bamboo fibers, and Kenaf fibers, or recycled fibers obtained by defibrating scraps of textile products using these fibers. Be done. These fibers are not limited to using only one type, and may be used by mixing two or more types.
Among the above fibers, glass wool and polyester fibers are preferable as fibers used for fiber materials from the viewpoints of high heat resistance, flame retardancy, easy availability, and easy handling.

Heat-resistant synthetic fibers having a melting point of 250 ° C. or higher may be mixed with the fibers from the viewpoint of improving heat resistance. Specific examples of the heat-resistant synthetic fiber include aramid fibers such as polymetaphenylene isophthalamide fiber and poly-p-phenylene terephthalamide fiber, polyallylate fiber, polyether ether ketone fiber, and polyphenylene sulfide fiber.
Further, low melting point thermoplastic fibers having a melting point of 180 ° C. or less may be mixed with the fibers from the viewpoint of improving the binding property between the fibers. Specific examples of low melting point thermoplastic fibers include polyolefin fibers such as polyethylene, polypropylene, ethylene-vinyl acetate copolymer, and ethylene-ethyl acrylate copolymer, polyvinyl chloride fiber, polyurethane fiber, polyester fiber, and polyester co-weight. Examples thereof include coalesced fibers, polypropylene fibers, and polyamide copolymer fibers.

Specific examples of the form of the fiber material include non-woven fabric, knitted fabric, lace, felt and the like. Among these, the non-woven fabric is preferable as a form of the fiber material from the viewpoint that it is easily available, easy to handle, and easy to compress during heat press molding.
Nonwoven fabrics include a needle punching method in which a web sheet or mat made of fibers is entangled by needle punching, a thermal bond method in which a web sheet or mat made of fibers is heated and bonded by melting, or a web sheet or mat made of fibers. Those manufactured by a chemical bond method in which a mat is bound with a binder made of synthetic resin, a stitch bond method in which a web sheet made of fibers or a mat is sewn together, or the like is used. Among these, the non-woven fabric obtained by the chemical bond method or the needle punching method is preferable as a fiber material because the unit area mass and the like can be easily adjusted and the production is easy.

Since the fiber material exhibits suitable rigidity in the compressed state by heat press molding, the fibrous material has a 50% compression strength of 5 N or less from the viewpoint of being compressed and reducing the thickness by making it as easy to crush as possible during compression. Is preferable, those of 3N or less are more preferable, and those of 2N or less are further preferable. If the 50% compression strength is excessively high, it becomes difficult to be crushed and the compression becomes insufficient, so that sufficient rigidity may not be exhibited.
For the fiber material, the lower limit of the 50% compressive strength is not particularly limited, but usually, the lower limit exceeds 0 N, preferably 0.02 N or more, and more preferably 0.1 N or more. If the 50% compression strength is excessively low, the fiber material is compressed endlessly, so that the reinforcing layer 12 cannot have a sufficient thickness to reinforce the elastic layer 11.

In the fiber material, the unit area mass is appropriately set according to the fiber used, the form of the fiber material, and the desired 50% compression strength, and is not particularly limited. Unit area weight, while those appropriate stiffness in compression, in terms of suppressing the 50% compressive strength is too high, preferably greater than 100 g / m ^2, less than 800 g / m ^2, more preferably ^{150g / m 2 ~500g / m 2} , more preferably from ^{200g / m 2 ~400g / m 2} . If the unit area mass is excessively small, the rigidity in the compressed state will be inferior, and if the unit area mass is excessively large, the 50% compression strength will be excessively high.
The thickness of the fiber material is appropriately set according to the desired thickness of the interior material, the desired 50% compression strength, the thickness of the foamed elastic foam to be used, and the like, and is not particularly limited. Usually, the thickness of the fiber material is preferably set to be about the same as the thickness of the foamed elastic foam used, and specifically, from the viewpoint of setting the 50% compressive strength in the above range, specifically in the range of 10 mm to 30 mm. It is more preferable to set to.

In the interior base material 10, the ratio of 50% compressive strength between the fiber material and the foamed elastic foam (fiber material / foamed elastic foam) is such that the foamed elastic foam and the fiber material are in a suitable balance during heat press molding. From the viewpoint of compression, it is more than 0.26/100 and less than 25/100, preferably 0.5 / 100 or more and less than 25/100, and more preferably 1/100 to 20/100.
In other words, when the 50% compressive strength of the foamed elastic foam is 100, the ratio of the 50% compressive strength of the fiber material is in the range of more than 0.26 and less than 25, preferably 0.5 or more. The range is less than 25, more preferably 1 to 20. That is, the 50% compressive strength of the fiber material is more than 0.26/100 and less than 25/100 (1/4) of the 50% compressive strength of the foamed elastic foam, preferably 100/100. It is 0.5 (1/200) or more and less than 25/100 (1/4), more preferably 1/100 to 20/100 (1/5).
When the ratio of the 50% compressive strength of the fibrous material is excessively small when the 50% compressive strength of the foamed elastic foam is set to 100, the reinforcing layer 12 made of the fibrous material in the compressed state is elastic made of the foamed elastic foam. The layer 11 cannot be sufficiently reinforced. Further, when the ratio of the 50% compressive strength of the fiber material is excessively large when the 50% compressive strength of the foamed elastic foam is set to 100, the elastic layer 11 made of the foamed elastic foam in the compressed state has a suitable feel. Can no longer be demonstrated.

From the viewpoint of setting the ratio of the 50% compressive strength of the fiber material and the foamed elastic foam to the above range, for example, when the fiber used for the fiber material is glass wool and the material used for the foamed elastic foam is a combination of polyurethane. The fiber material preferably has a thickness of 15 ± 5 mm and a unit area mass of 300 ± 50 g / m ² , and the foamed elastic foam preferably has a thickness of 15 ± 5 mm and a unit area mass of 300 ± 50 g / m ² .
When the fiber used for the fiber material is glass wool and the material used for the foam elastic foam is a combination of melamine resin, the fiber material has a thickness of 15 ± 5 mm and a unit area mass of 300 ± 50 g / m ^2, and has foam elasticity. The body foam preferably has a thickness of 15 ± 5 mm and a unit area mass of 160 ± 50 g / m ² .
When the fiber used for the fiber material is polyester fiber and the material used for the foam elastic foam is a combination of polyurethane, the fiber material has a thickness of 20 ± 5 mm and a unit area mass of 300 ± 50 g / m ^2, and has foam elasticity. The body foam preferably has a thickness of 15 ± 5 mm and a unit area mass of 300 ± 50 g / m ² .
When the fiber used for the fiber material is polyester fiber and the material used for the foamed elastic foam is a combination of melamine resin, the fiber material has a thickness of 20 ± 5 mm and a unit area mass of 300 ± 50 g / m ^2, and is foamed. The elastic foam preferably has a thickness of 15 ± 5 mm and a unit area mass of 160 ± 50 g / m ² .

In the interior base material 10, the foamed elastic foam and the fiber material are joined to each other. This joining method is not particularly limited.
As a specific example of the joining method, a liquid foam precursor made of a synthetic resin is applied to the surface of a fiber material to a predetermined thickness and dried by heating to form a foamed elastic foam from the foam precursor and foamed. Examples thereof include a method of joining an elastic foam and a fiber material.
Another method is to join the fiber materials produced in different steps and the foamed elastic foam to each other using an adhesive. Examples of this adhesive include hot melt adhesives, acrylic resin adhesives, acrylic resin adhesives, synthetic rubber adhesives, synthetic rubber adhesives and the like.

As shown in FIG. 2, the interior material 20 has the interior base material 10 and a skin material 21 laminated on the surface of the elastic layer 11 which is one side of the interior base material 10. As shown in FIG. 3, the skin material 21 may be laminated on both sides of the interior base material 10.
The skin material 21 covers the surface of the elastic layer 11, or the surfaces of the elastic layer 11 and the reinforcing layer 12, so that the elastic layer 11 and the like are not visible from the outside, so that the appearance of the interior material 20 is designed. To improve.

As the skin material 21, a non-woven fabric made of fibers is used. This fiber is not particularly limited.
Specific examples of the fibers include synthetic fibers such as polyester fiber, polyethylene fiber, polypropylene fiber, polyamide fiber, acrylic fiber, urethane fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, and acetate fiber, and extracted from plants such as corn and sugar cane. Biodegradable fibers (polylactic acid fibers) made of starch, natural fibers such as pulp, cotton, palm fiber, hemp fiber, bamboo fiber, and kenaf fiber, or scraps of textile products using these fibers are defibrated. Examples thereof include the obtained regenerated fibers. For the skin material 21, one or more of these fibers are used.
Further, from the viewpoint of improving the heat resistance or the binding property between the fibers, the fiber is a heat-resistant synthetic fiber having a melting point of 250 ° C. or higher, or a melting point of 180, which is mentioned in the fiber material. Low melting point thermoplastic fibers below ° C. may be mixed.

Nonwoven fabrics include the spunbond method, in which synthetic resin, which is the material of synthetic fibers, is discharged into long fibers to form a sheet, the melt blow method, in which synthetic resin is blown out into a sheet with a high-speed, high-temperature air flow, and fibers. The spunlacing method in which a web sheet or mat made of fibers is entangled by a high-pressure water stream, the chemical bond method in which a synthetic resin binder is impregnated or mixed with a web sheet or mat made of fibers and bonded, or a web made of fibers Those manufactured by a thermal bond method in which fibers are bonded to each other by heating and softening a sheet or mat, or a needle punching method in which a web sheet or mat made of fibers is entangled by needle punching are used. Among these, the non-woven fabric produced by the spunbond method is easy to manufacture and can be reduced in thickness, so that the influence of the compression of the skin material 21 on the elastic layer 11 and the reinforcing layer 12 is suppressed. From the viewpoint that it is possible, the skin material 21 is preferable.

The skin material 21 can be impregnated with a thermosetting resin from the viewpoint of imparting heat resistance, improving rigidity, and improving moldability and shape retention.
Thermosetting resins include resole-type phenol-based resins, urethane-based resins, melamine-based resins, thermosetting-type acrylic resins (particularly those that cure by forming ester bonds by heating), urea-based resins, and epoxy-based resins. Examples include thermosetting polyester resins. In addition, urethane-based resin prepolymer, urea-based resin prepolymer (initial condensate), phenol-based resin prepolymer (initial condensate), diallyl phthalate prepolymer, acrylic oligomer, polyvalent isocyanate, methacrylic ester monomer, diallyl phthalate monomer. Such as prepolymers, oligomers, monomers and other synthetic resin precursors are exemplified. As the thermosetting resins exemplified above, it is preferable to use an aqueous solution, an aqueous emulsion, or an aqueous dispersion from the viewpoint of easy handling, but those in the form of an organic solvent solution may also be used. Further, two or more kinds may be mixed and used for the thermosetting resin or the synthetic resin precursor.

Among the illustrated thermosetting resins, the resole-type phenolic resin is desirable as the one to be impregnated in the skin material 21 from the viewpoints of being easily available, easy to handle, and having high heat resistance. Resol-type phenolic resins are obtained by reacting phenolic compounds with excess formaldehyde and in an alkali catalyst, consisting of a mixture of phenol and various phenolic alcohols with formaldehyde added, usually provided in aqueous solution. To.
As the resorcinol-type phenolic resin, a phenol-alkylresorcin cocondensate is more desirable, and in particular, a polyhydric phenol mixture obtained by carbonization of an Estonian oil shale has a long pot life, is inexpensive, and is composed of 5-methylresorcin. In addition, it is useful because it contains a large amount of various highly reactive alkylresorcins.
A catalyst or a pH adjuster may be mixed with the resole-type phenolic resin, if necessary, and a curing agent such as formaldehyde or an alkylolated triazine derivative may be added and mixed. In addition, the water-soluble resole-type phenolic resin may be sulfomethylated and / or sulfimylated for the purpose of improving stability. Details regarding the sulfomethylated and / or sulfimethylated resin are described in, for example, Japanese Patent No. 3393927 and Japanese Patent No. 3339959.

When the skin material 21 is impregnated with a thermosetting resin, the thermosetting resin squeezed out from the skin material 21 during heat press molding and exuded to the surface creates a plastic texture such as gloss peculiar to the resin. As a result, the appearance quality of the fibers of the skin material 21 may be deteriorated. In order to suppress such deterioration of appearance quality, it is necessary to make the amount of the thermosetting resin impregnated into the skin material 21 appropriate.
The impregnation amount of the thermosetting resin can be adjusted by setting the application amount to the skin material 21. The coating amount in terms of solid content, preferably ^{10g / m 2 ~50g / m 2} , more preferably ^{10g / m 2 ~45g / m 2} , more preferably ^{10g / m 2 ~40g / m 2} . If the amount of coating is excessively small, the thermosetting resin does not spread sufficiently over the entire surface of the skin material 21, and it becomes difficult to uniformly impregnate the resin. If the amount of coating is excessively large, the thermosetting resin tends to exude from the skin material 21 to the surface, and the appearance quality is deteriorated.

The impregnation amount of the thermosetting resin can also be adjusted by setting the ventilation resistance of the skin material 21. This ventilation resistance indicates the resistance when air passes through the skin material 21, and is measured by a ventilation tester (product name: KES-F8-AP1, manufactured by Kato Tech Co., Ltd., steady flow differential pressure measurement method). It shall refer to the measured value.
From the viewpoint of suppressing deterioration of appearance quality, the ventilation resistance of the skin material 21 is preferably 0.01 to 0.1 kPa · s / m, more preferably 0.015 to 0.08 kPa · s / m. More preferably, it is 0.015 to 0.04 kPa · s / m. If the ventilation resistance is excessively low, the thermosetting resin soaks in more than necessary, which tends to cause deterioration of the appearance quality. If the ventilation resistance is excessively high, the thermosetting resin does not easily soak into the skin. The material 21 cannot be uniformly impregnated with the thermosetting resin.

Mass per unit area of the skin material 21 is not particularly limited, the ventilation resistance from the viewpoint of the above ^range, it is preferable to ^{10g / m 2 ~120g / m 2} , 15g / m 2 ~110g / m 2 it is more preferable ^that, it is more preferable to ^{15g / m 2 ~100g / m 2} . If the unit area mass is excessively small, the ventilation resistance may be excessively low, and if the unit area mass is excessively large, the ventilation resistance may be excessively high.
The setting of the ventilation resistance in the skin material 21 is particularly useful when the sound absorbing performance is imparted by using a foam having an open cell structure for the foamed elastic foam.

In the interior material 20, the skin material 21 and the interior base material 10 are joined to each other. For this bonding, when the skin material 21 is impregnated with a thermosetting resin, the thermosetting resin can be used as an adhesive. Further, for joining the skin material 21 and the interior base material 10, an adhesive such as a hot melt adhesive, an acrylic resin adhesive, an acrylic resin adhesive, a synthetic rubber adhesive, or a synthetic rubber adhesive is used. You can also do it.
When sound absorbing performance is imparted to the foamed elastic foam by using a foam having an open cell structure, powder is used from the viewpoint of maintaining air permeability between the elastic layer 11 made of the foamed elastic foam and the skin material 21. It is desirable to use a shape-like adhesive and disperse it in dots. This powdered adhesive, from the viewpoint of ensuring air permeability, is preferably in the range of 80~500μm an average particle size by sieving method, spraying amount and ^2g / ^{m 2 ~40g} / m 2 it is preferable ^to, and more preferably to ^{5g / m 2 ~30g / m 2} .
When the interior material 20 is provided with sound absorbing performance, the total ventilation resistance of the skin material 21 and the interior base material 10 is set to 0.2 to 5.0 kPa from the viewpoint of making the sound absorbing performance suitable. -It is preferably set to s / m, more preferably set to 0.25 to 4.5 kPa · s / m, and even more preferably set to 0.3 to 4.0 kPa · s / m.

The fiber material and / or the skin material 21 contains higher fatty acids such as stearic acid and palmitic acid, higher alcohols such as palmityl alcohol and stearyl alcohol, and esters of fatty acids such as butyryl stearate and glycerin monostearate. , Fatty acid amides, carnauba wax, paraffins, paraffin oil, etc., waxes and lubricants, fluororesin, silicone resin, polyvinyl alcohol, grease, etc., water and oil repellents, phosphorus compounds, nitrogen compounds, sulfur Flame-retardant agents and flame-retardants such as based compounds, boron-based compounds, bromine-based compounds, guanidine-based compounds, phosphate-based compounds, phosphate ester-based compounds, amino-based resins, etc., or pigments, dyes, antioxidants, antioxidants, etc. Various agents such as crystallization accelerators, insect repellents, preservatives, surfactants, antiaging agents, ultraviolet absorbers and the like may be added.

As shown in FIG. 4, the interior material 30 has an elastic layer 11 made of a foamed elastic foam, a reinforcing layer 12 made of a fiber material, and a skin material 21 covering the surface of the elastic layer 11. .. The interior material 30 is obtained by heat-press molding the interior material 20 into a predetermined shape.
When the skin material 21 is touched on the surface of the interior material 30, a suitable feel is given by the flexibility of the elastic layer 11 in the compressed state, and when the interior material 30 is transported or the like, the compressed state is provided. The rigidity of the reinforcing layer 12 suppresses bending and deformation of the elastic layer 11.

At the time of heat press molding, the interior material 30 is formed to have a predetermined thickness, so that the reinforcing layer 12 made of the fiber material and the elastic layer 11 made of the foamed elastic foam are each compressed and have a predetermined thickness. It is formed on the elasticity.
The ratio of the thickness of the reinforcing layer 12 to the elastic layer 11 (reinforcing layer / elastic layer) is more than 1/100 and less than 55/100, preferably 2/100 to 50/100, and more preferably 2 It is / 100 to 46/100.
In other words, when the thickness of the elastic layer 11 is 100, the ratio of the thickness of the reinforcing layer 12 is in the range of more than 1 and less than 55, preferably in the range of 2 to 50, and more preferably in the range of 2 to 50. It is in the range of 46. That is, the thickness of the reinforcing layer 12 exceeds 1/100 of the thickness of the elastic layer 11 and is less than 55/100, preferably 2/100 (1/50) to 50/100 (2 minutes). 1), more preferably 2/100 (1/50) to 46/100.
When the thickness ratio of the reinforcing layer 12 is excessively small when the thickness of the elastic layer 11 is 100, the reinforcing layer 12 cannot sufficiently reinforce the elastic layer 11, and the interior material is inferior in rigidity. Become. Further, when the thickness of the elastic layer 11 is 100, if the ratio of the thickness of the reinforcing layer 12 is excessively large, the flexibility of the elastic layer 11 is lost and the feel is inferior.

The thickness of the interior material 30 after heat press molding is preferably 1 mm to 30 mm, more preferably 3 mm to 20 mm, and even more preferably 5 mm to 15 mm.
If the thickness of the interior material after heat press molding is excessively small, the elastic layer 11 does not have a sufficient thickness to exhibit flexibility, and the interior material is likely to be inferior in tactile sensation. If the thickness of the interior material 30 after heat press molding is excessively large, the reinforcing layer 12 is not compressed to a thickness sufficient to exhibit rigidity, and there is a high possibility that the rigidity will be inferior.
From the viewpoint of setting the ratio of the thickness of the reinforcing layer 12 to the elastic layer 11 in the above range, for example, the fiber used for the fiber material of the reinforcing layer 12 is glass wool, and is used for the foamed elastic foam of the elastic layer 11. When the material is a combination of polyurethane or melamine resin, the thickness of the interior material is preferably 5 mm to 15 mm.
When the fiber used for the fiber material of the reinforcing layer 12 is polyester fiber and the material used for the foamed elastic foam of the elastic layer 11 is a combination of polyurethane or melamine resin, the thickness of the interior material is 11 mm to 20 mm. Is preferable.

Hereinafter, examples in which the present invention is further embodied will be described, but the present invention is not limited to these examples.

[Example 1]
Reinforcing layer: The materials and performance fiber materials shown in Table 1 were used.
Elastic layer: Foamed elastic foam with the materials and performance shown in Table 1 was used.
Skin material: Polyester spunbonded non-woven fabric (unit area mass: 30 g / m ² ) is semi-cured by applying and impregnating an uncured solution of resole-type phenol resin so that the coating amount is 15 g / m ^2. The one pre-cured to the state (B state) was used.
Preparation of sample: After laminating the fiber material (reinforcing layer), the foamed elastic foam (elastic layer) and the skin material so that the fiber material and the foamed elastic foam are a combination of the materials shown in Table 2, the mold temperature Sample 1 (thickness: 5 mm), by performing heat press molding using a heat press molding machine at 180 ° C. and interposing a spacer between the upper and lower dies of the mold during this heat press molding. Sample 2 (thickness: 10 mm) and sample 3 (thickness: 15 mm) were prepared.
50% compression strength ratio: For Samples 1 to 3, 50% compression strength A (N) of foamed elastic foam and 50% compression strength B (N) of fiber material, respectively, 50% compression of foamed elastic foam The ratio (= (B × 100) / A) to the 50% compressive strength of the fiber material when the strength was 100 was calculated. The results are shown in Table 2.
Ratio of thickness between reinforcing layer and elastic layer: For samples 1 to 3, the thickness A (mm) of the elastic layer and the thickness B (mm) of the reinforcing layer were measured, respectively, and the thickness of the elastic layer was set to 100. The ratio to the thickness of the reinforcing layer (= (B × 100) / A) was calculated. The results are shown in Table 2.

[Comparative Example 1] and [Comparative Example 2]
Reinforcing layer: The materials and performance fiber materials shown in Table 1 were used.
Elastic layer: Foamed elastic foam with the materials and performance shown in Table 1 was used.
Skin material: The same material as in Example 1 was used.
Preparation of sample: After laminating the fiber material (reinforcing layer), the foamed elastic foam (elastic layer) and the skin material so that the fiber material and the foamed elastic foam have the combination shown in Table 2, the same as in Example 1. In the same manner, Sample 1 (thickness: 5 mm), Sample 2 (thickness: 10 mm), and Sample 3 (thickness: 15 mm) were prepared.
50% compression strength ratio: The 50% compression strength ratio was calculated for Samples 1 to 3 in the same manner as in Example 1. The results are shown in Table 2.
Reinforcement layer / elastic layer thickness ratio: The thickness ratio was calculated for Samples 1 to 3 in the same manner as in Example 1. The results are shown in Table 2.

[Tactile test]
With respect to Samples 1 to 3 of Example 1 and Samples 1 to 3 of Comparative Example 1, the tactile sensation of the elastic layer when the surface of each skin material was touched with a finger was evaluated in the following five stages. The results are shown in Table 3.
⊚: The elastic layer has sufficient flexibility, and the hardness of the reinforcing layer is not felt even if it is pressed a little strongly.
◯: The elastic layer has sufficient flexibility, and when pressed slightly strongly, the hardness of the reinforcing layer is felt.
Δ: The elastic layer has flexibility, but when pressed slightly strongly, the elastic layer feels hardness.
×: When pressed a little hard, the elasticity of the elastic layer is lost, and the texture is stiff and uncomfortable.
XX: There is no effect of the reinforcing layer, it is very flexible and the molded shape cannot be maintained.

From the results in Table 3, the evaluation of Example 1 was ◯ or ⊚, and the tactile sensation was good. According to this Example 1, when the 50% compression strength ratio of the reinforcing layer (fiber material) and the elastic layer (foamed elastic foam) before compression is the reinforcing layer / elastic layer = 0.5 to 20/100, The ratio of the thickness after compression is the reinforcing layer / elastic layer = 2 to 50/100, and the elastic layer is surely thicker than the reinforcing layer. Therefore, it was found that the hard tactile sensation due to the reinforcing layer was reduced, and the elastic and flexible texture due to the elastic layer was obtained as the tactile sensation.
On the other hand, in Comparative Example 1, the evaluation was × or Δ, and the tactile sensation was poor. According to this Comparative Example 1, when the 50% compression strength ratio (fiber material / foam elastic foam) of the reinforcing layer (fiber material) before compression and the elastic layer (foam elastic foam) is 25/100 or more, The ratio of the thickness after compression (reinforcing layer / elastic layer) is 55/100 to 120/100, and the reinforcing layer exceeds half the thickness of the elastic layer, and in some cases, the reinforcing layer exceeds the thickness of the elastic layer. .. For this reason, it was found that the hard tactile sensation of the reinforcing layer was transmitted rather than the flexibility of the elastic layer, and the texture became worse.
Further, in Comparative Example 2, all the evaluations were XX, and there was no rigidity. According to this Comparative Example 2, the 50% compression strength ratio (fiber material / foam elastic foam) of the reinforcing layer (fiber material) before compression and the elastic layer (foam elastic foam) is 0.26 / 100 or less. In this case, the ratio of the thickness after compression (reinforcing layer / elastic layer) becomes 0.5 / 100 to 1.0 / 100, and the thickness of the reinforcing layer becomes excessively thin compared to the thickness of the elastic layer. .. Therefore, it has been found that the reinforcing layer cannot sufficiently reinforce the elastic layer and bends, bends, or the like, so that the shape after molding cannot be maintained.

According to the present invention, it is an object of the present invention to provide an interior base material and an interior material capable of exhibiting suitable rigidity and tactile sensation when compressed by heat press molding, and also to provide tactile sensation while maintaining rigidity. Since it is possible to provide an interior material that can be improved, it can be industrially used.

10 Interior base material 11 Elastic layer 12 Reinforcing layer 20 Interior material 21 Skin material 30 Interior material

Claims (4)

An interior base material having an elastic layer made of a foamed elastic foam and a reinforcing layer made of a fiber material.
An interior base material characterized in that the ratio of 50% compressive strength (fiber material / foam elastic foam) between the fiber material and the foamed elastic foam is more than 0.26 / 100 and less than 25/100. .. The interior base material according to claim 1, wherein the material used for the foamed elastic foam is melamine resin or polyurethane. An interior material comprising the interior base material according to claim 1 or 2, and a non-woven fabric skin material laminated on one side or both sides of the interior base material. The interior material according to claim 3 is obtained by heat-press molding into a predetermined shape, and the ratio of the thickness of the reinforcing layer made of the fiber material to the elastic layer made of the foamed elastic foam (reinforcing layer / elastic layer) is 1. An interior material characterized by exceeding / 100 and less than 55/100.

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