JP6906989B2 - Interior surface material and its manufacturing method - Google Patents

Description

The present invention relates to an interior surface material and a method for producing the same. In particular, the present invention relates to an interior surface material suitable for a surface material of an automobile interior material such as a ceiling, a door side, a pillar garnish, and a rear package, and a method for manufacturing the same.

Nonwoven fabrics have been conventionally used as surface materials for automobile interiors. As such a non-woven fabric, the applicant of the present application stated, "One side of the fiber web is subjected to needle punching treatment, the surface subjected to the needle punching treatment is impregnated with a binder, and then a calendar treatment is performed, and then the needle punching treatment is performed. "Interior skin material impregnated with a binder with less tack on the opposite surface of the applied surface" (Patent Document 1), "The raising of one surface of the needle punched non-woven fabric is suppressed, and the surface where the raising is suppressed is impregnated with resin. We have proposed "a skin material for automobile interior materials" (Patent Document 2). However, these skin materials had insufficient tactile sensation. In addition, with the spread of navigation systems in recent years, quietness is required in the passenger compartment, but the above-mentioned skin material does not consider sound absorption, and it is not possible to sufficiently meet the demand for quietness. There wasn't.

Japanese Unexamined Patent Publication No. 62-257472 Japanese Unexamined Patent Publication No. 9-13372

The present invention has been made to solve such a problem, and an object of the present invention is to provide an interior surface material having excellent tactile sensation and sound absorption, particularly an automobile interior surface material, and a method for manufacturing the same. ..

According to the present invention, "a surface material for interior use made of a non-woven fabric, the fineness of the fibers constituting the non-woven fabric is 0.7 dtex or more, and the surface material for interior use is a surface measured by a surface tester (KES-FB4). It has a main surface having a roughness (SMD) of 2.5 or less, a variation of friction coefficient (MMD) of 0.011 or less, and an average dynamic friction coefficient (MIU) of 0.30 or more and 1.00 or less. It contains two non-woven fabric layers, a first non-woven fabric layer having a surface and a second non-woven fabric layer other than the first non-woven fabric layer, and the first non-woven fabric layer and the second non-woven fabric layer are bonded by an adhesive. The interior surface material is characterized in that the air permeability of the interior surface material is 40 cm ³ / cm ² · s or less. ”

Interior surface material of the present invention are preferably "the first nonwoven layer is a nonwoven layer composed mainly of fibers of fineness 0.8 ～2.0Dtex" a, "the thickness of the second nonwoven fabric layer 1 It is preferably 5.5 mm or more. "

Such an interior surface material of the present invention has a surface roughness (SMD) of 2.5 or less and a friction coefficient fluctuation (MMD) of 0.010 or less as measured by a surface tester (KES-FB4). And the first non-woven fabric having a main surface with an average coefficient of dynamic friction (MIU) of 0.15 or more, and the surface roughness (SMD) of 3.5 or less and the coefficient of friction measured by a surface tester (KES-FB4). After producing a second non-woven fabric having a main surface having a fluctuation (MMD) of 0.014 or less and an average coefficient of dynamic friction (MIU) of 0.25 or more, the first non-woven fabric and the second non-woven fabric are laminated and integrated. It can be manufactured by.

In the production method, it is preferable that "the first non-woven fabric is a non-woven fabric having a main surface smoothed by heating and pressurizing after forming a fiber web using fibers having a fineness of 0.7 to 2.0 dtex". , "The thickness of the second non-woven fabric is 1.5 mm or more" is preferable.

The interior surface material of the present invention has a surface roughness (SMD) of 2.5 or less, a friction coefficient fluctuation (MMD) of 0.011 or less, and an average dynamic friction coefficient (MIU) of 0.30 or more. A surface material for interior use, which is made of a non-woven fabric having a main surface having such surface roughness, fluctuation of friction coefficient, and average dynamic friction coefficient, has an excellent tactile sensation. That is, a small surface roughness means that the surface of the surface material is smooth, a small fluctuation of the friction coefficient means that the surface material surface is uniform, and a large average dynamic friction coefficient means that the surface material is flexible. It means that, when these conditions are satisfied, it is found that the tactile sensation is excellent.

It was also found that the air permeability of the interior surface material is 40 cm ³ / cm ² · s or less, and that such air permeability improves the sound absorption coefficient in the low frequency region due to resonance vibration.

Further, when two non-woven fabric layers, a first non-woven fabric layer and a second non-woven fabric layer having a main surface, are included, it is easy to satisfy the surface roughness, the fluctuation of the friction coefficient, and the average dynamic friction coefficient. That is, the first non-woven fabric layer having a large contribution to satisfy the surface roughness and the fluctuation of the friction coefficient as described above and the second non-woven fabric layer having a large contribution to satisfy the average dynamic friction coefficient as described above are included. By doing so, it is easy to satisfy the above physical properties.

Further, when the first non-woven fabric layer is a non-woven fabric layer mainly composed of fibers having a fineness of 0.5 to 2.0 dtex, it can be a non-woven fabric having fine voids, and it is easy to satisfy the above-mentioned air permeability.

Further, when the thickness of the second non-woven fabric layer is 1.5 mm or more, the average dynamic friction coefficient as described above can be easily satisfied.

Such interior surface materials having excellent tactile sensation and sound absorption have a first non-woven fabric having a uniform main surface with a small surface roughness and smoothness and a small variation in friction coefficient, and a large average dynamic friction coefficient and flexibility. It can be manufactured by laminating and integrating with a second non-woven fabric having an excellent main surface. That is, since both the first non-woven fabric and the second non-woven fabric are smoothed by heating and pressurizing after forming the fiber web, they have a smooth and uniform main surface, have low air permeability, and have excellent sound absorption. Can manufacture surface materials.

If the first non-woven fabric has a main surface smoothed by heating and pressurizing after forming a fiber web using fibers having a fineness of 0.5 to 2.0 dtex, the air permeability is further lowered. Because it is easy, it is easy to manufacture an interior surface material with excellent sound absorption.

Further, since the thickness of the second non-woven fabric is 1.5 mm or more, it is easy to manufacture an interior surface material that satisfies the average dynamic friction coefficient as described above and has excellent sound absorption.

The non-woven fabric constituting the interior surface material of the present invention (hereinafter, may be simply referred to as “surface material”) has a surface roughness (SMD) of 2.5 or less and a friction coefficient fluctuation (MMD) of 0. It has a main surface of 011 or less and an average coefficient of dynamic friction (MIU) of 0.30 or more. The present inventor has found that the tactile sensation is excellent by simultaneously satisfying such physical properties. The air permeability of the non-woven fabric constituting the surface material is 40 cm ³ / cm ² · s or less. The present inventor has also found that when the air permeability is 40 cm ³ / cm ² · s or less, the sound absorption coefficient in the low frequency region is improved by the resonance vibration, and the sound absorption property is excellent. The "main surface" in the present invention means the surface having the largest area among the surfaces of the non-woven fabric which is the surface material, and at least one main surface in the main surface satisfies the above physical characteristics. Hereinafter, the main surface satisfying the above physical characteristics may be referred to as a "smooth and flexible main surface".

This surface roughness is literally an index showing unevenness on the main surface, that is, smoothness, and according to the examination by the present inventors, if the surface roughness (SMD) is 2.5 or less, the tactile sensation is excellent. It was found that it can contribute to. A smaller surface roughness (SMD) value tends to be smoother and have a better tactile sensation. Therefore, the surface roughness (SMD) is preferably 2.3 or less, preferably 2.1 or less. Is more preferable, and 2.0 or less is further preferable. The lower limit of the surface roughness (SMD) is not particularly limited, but ideally, it is 0, which indicates a surface roughness without any unevenness. This surface roughness (SMD) is a value measured using a surface tester (KES-FB4), and a sample (20 cm square) of a surface material is set on the tester with a load of 400 g, and rough contact is made. A load of 10.0 g was applied to the child (0.5 mm wire, contact surface width: 5 mm) to bring it into contact with the sample, and the sample was brought into contact with the sample at 1 mm / sec. It means the mean deviation measured by moving at the speed of.

Further, the fluctuation of the coefficient of friction (MMD) is measured by using a surface tester (KES-FB4). By bringing the friction element into contact with the main surface of the surface material and moving the surface material, the friction element becomes the surface material. Since it is measured in a state of stroking, it means the uniformity of the main surface of the surface material, and according to the study of the present inventor, if the fluctuation of the friction coefficient (MMD) is 0.011 or less, it is an excellent tactile sensation. I found that I could contribute to that. The smaller the value of the coefficient of friction fluctuation (MMD), the more uniform the smooth and flexible main surface tends to be, and the better the tactile sensation tends to be. Therefore, the fluctuation of the coefficient of friction (MMD) is 0.010 or less. Is preferable. The lower limit of the fluctuation of the friction coefficient (MMD) is not particularly limited, but ideally, it is 0, which indicates that the friction coefficient is exactly the same and the smooth and flexible main surface is uniform. This variation in friction coefficient (MMD) is a value measured using a surface tester (KES-FB4), and a sample of surface material (20 cm square) is set on the tester with a load of 400 g and friction is applied. A 50 g load was applied to the child (10 mm × 10 mm) to bring it into contact with the sample, and the sample was placed at 1 mm / sec. It means the mean deviation measured by moving at the speed of.

Further, the average dynamic friction coefficient (MIU) means the flexibility of the surface material, and according to the study of the present inventor, if the average dynamic friction coefficient (MIU) is 0.30 or more, it can contribute to excellent tactile sensation. I found it. In other words, in the measurement of this average dynamic friction coefficient (MIU), the friction element is weighted and brought into contact with the surface material. If the surface material is soft, the friction element is in a state of being sunk in the surface material, and the surface material is moved in that state. Therefore, the average dynamic friction coefficient becomes large, but specifically, it was found that when the average dynamic friction coefficient (MIU) is 0.30 or more, it can contribute to the excellent tactile sensation. The larger the value of the average dynamic friction coefficient, the more flexible and the better the tactile sensation tends to be. Therefore, the average dynamic friction coefficient (MIU) is preferably 0.31 or more, and more preferably 0.32 or more. preferable. On the other hand, if the value of the average dynamic friction coefficient (MIU) is too large, the frictional resistance is too strong and the finger feels like it is caught, which may impair the tactile sensation. Therefore, it is preferably 1.00 or less. .. The average coefficient of dynamic friction (MIU) is a value measured using a surface tester (KES-FB4), and means an average value measured under the same conditions as the condition for measuring the fluctuation of the coefficient of friction (MMD).

Furthermore, the present inventor can be a non-woven fabric having fine voids when the air permeability of the non-woven fabric constituting the surface material is 40 cm ³ / cm ² · s or less, and the sound absorption property in the low frequency region is improved by resonance vibration. I found it to be excellent. The smaller the air permeability, the more a non-woven fabric having fine voids can be obtained, and the sound absorbing property tends to be excellent. Therefore, the air permeability ^{is preferably 35 cm 3} / cm ² · s or less, preferably 30 cm. ³ / cm and more preferably at ² · s or less, and even more preferably at 25 cm ³ / cm ² · s or less. The lower limit of the air permeability is a value exceeding ^{0 cm 3} / cm ^{2 · s.} If the air permeability is 0 cm ³ / cm ² · s, there is no ventilation at all and sound insulation is provided. Therefore, it is 5 cm ³ / cm ² · s or more so that the range of the frequency range where the sound absorption effect is expected is wide. Is preferable. This "air permeability" refers to a value measured by 6.8.1 (Frazier type method) specified in JIS L1913: 2010 "General non-woven fabric test method".

The surface material having a smooth and flexible main surface having such surface roughness, fluctuation of friction coefficient, and average dynamic friction coefficient and having low air permeability is made of a non-woven fabric, but preferably contains two non-woven fabric layers. That is, the first non-woven fabric layer constituting the smooth and flexible main surface of the surface material, which greatly contributes to satisfying the surface roughness and the fluctuation of the friction coefficient as described above, and the average dynamic friction coefficient as described above are satisfied. It is preferable to include a second non-woven fabric layer different from the first non-woven fabric layer, which has a large contribution to the above.

More specifically, the first non-woven fabric layer has a surface roughness (SMD) of 2.5 or less, a friction coefficient fluctuation (MMD) of 0.010 or less, is smooth and uniform, and has an average dynamic friction coefficient (MIU) of 0. It is preferably composed of a non-woven fabric having a main surface having a certain degree of softness (hereinafter, may be referred to as "smooth main surface") of 15 or more. More preferably, it is made of a non-woven fabric having a surface roughness (SMD) of 2.2 or less, a friction coefficient fluctuation (MMD) of 0.009 or less, and an average dynamic friction coefficient (MIU) of 0.16 or more. It is made of a non-woven fabric having a surface roughness (SMD) of 2.0 or less, a friction coefficient fluctuation (MMD) of 0.009 or less, and an average dynamic friction coefficient (MIU) of 0.18 or more.

On the other hand, the second non-woven fabric layer has a surface roughness (SMD) of 3.5 or less, a friction coefficient fluctuation (MMD) of 0.014 or less, is smooth and uniform, and has an average dynamic friction coefficient (MIU) of 0.25. It is preferably composed of a non-woven fabric having the above soft main surface (hereinafter, may be referred to as "flexible main surface"). More preferably, it is made of a non-woven fabric having a surface roughness (SMD) of 3.2 or less, a friction coefficient fluctuation (MMD) of 0.012 or less, and an average dynamic friction coefficient (MIU) of 0.28 or more. It is made of a non-woven fabric having a surface roughness (SMD) of 3.0 or less, a friction coefficient fluctuation (MMD) of 0.010 or less, and an average dynamic friction coefficient (MIU) of 0.30 or more. In this way, the second non-woven fabric layer also has a smooth and uniform flexible main surface to some extent, so that the influence of the first non-woven fabric layer on the originally smooth and uniform smooth main surface is minimized. preferable. Therefore, it is preferable that the flexible main surface of the second non-woven fabric layer is laminated and integrated in a state of facing the main surface of the first non-woven fabric layer facing the smooth main surface having the physical characteristics.

The non-woven fabric constituting the surface material of the present invention preferably contains a first non-woven fabric layer and a second non-woven fabric layer as described above, but includes a non-woven fabric layer other than the first non-woven fabric layer and the second non-woven fabric layer. Is also good. When such a third non-woven fabric layer is included, the third non-woven fabric layer has a surface roughness (SMD) of 3 so as not to impair the tactile sensation achieved by the first non-woven fabric layer and the second non-woven fabric layer. It is preferable that the friction coefficient fluctuation (MMD) is 0.014 or less and the average dynamic friction coefficient (MIU) is 0.15 or more. Even when such a third non-woven fabric layer is provided, the first non-woven fabric layer and the second non-woven fabric layer are in a state of being laminated and integrated adjacent to each other, and the smooth main surface of the first non-woven fabric layer is a surface. It is preferable to form a smooth and flexible main surface of the material.

The "nonwoven fabric layer" of the present invention means a layer of a non-woven fabric having morphological stability that can be handled by the layer itself. That is, it means that the layer itself is in the state of a non-woven fabric in which fibers are bonded to each other by entanglement, binder adhesion, and / or fiber fusion. Therefore, when the fibers are laminated in a fiber web state in which the fibers are not yet bonded to each other and then the fibers are bonded to each other to produce a non-woven fabric, the non-woven fabric layer is one layer and does not have two or more non-woven fabric layers. .. When laminated in the state of fiber webs in this way, the surface of the laminated fiber webs tends to be rough, and in order to improve this point, the surface is smoothed by heating and pressurizing the laminated fiber webs. The thickness becomes thin and the softness is impaired, and it is difficult to simultaneously satisfy the surface roughness, the fluctuation of the friction coefficient, and the average dynamic friction coefficient as in the surface material of the present invention.

The fineness of the fibers constituting the non-woven fabric (for example, the first non-woven fabric layer and the second non-woven fabric layer) of the present invention is not particularly limited, but it is smooth and uniform because it is thin to some extent and has excellent dispersibility. It is preferably 0.5 to 6.6 dtex, preferably 0.5 to 4.4 dtex, so that a flexible main surface can be easily formed and the air permeability can be easily 40 cm ³ / cm ^{2 · s or less.} It is more preferable to have it, and it is more preferable to have 0.7 to 3.3 dtex.

In particular, the fibers constituting the first non-woven fabric layer can have a smooth main surface that is smooth and uniform and has a certain degree of softness, and the air permeability of the surface material ^{tends to be 40 cm 3} / cm ² · s or less. As described above, it is preferable to mainly use 0.5 to 2.0 dtex fibers, more preferably 0.8 to 1.9 dtex fibers, and mainly 1.0 to 1.8 dtex fibers. It is more preferable to have. In addition, "mainly" means that it occupies 50 mass% or more of the fibers constituting the first non-woven fabric layer. Further, the "fineness" in the present invention means a value obtained by the method A specified in JIS L 1015 (2010) and 8.5.1 (positive amount fineness).

Further, the fiber length of the fibers constituting the non-woven fabric (for example, the first non-woven fabric layer and the second non-woven fabric layer) of the present invention is not particularly limited, but it is smooth and uniform smooth and flexible due to its excellent dispersibility. It is preferably 20 to 110 mm, more preferably 30 to 80 mm so that it can have a main surface. The "fiber length" refers to a value measured according to JIS L1015 (2010), 8.4.1c) direct method (C method).

The fibers constituting the non-woven fabric (for example, the first non-woven fabric layer and the second non-woven fabric layer) of the present invention are not particularly limited, but for example, polyester fiber, nylon fiber, acrylic fiber, vinylon fiber, vinylidene fiber, and polyvinyl chloride. Synthetic fibers such as fibers, polyethylene fibers, polypropylene fibers, polyurethane fibers; regenerated fibers such as rayon fibers; semi-synthetic fibers such as acetate fibers; plant fibers such as cotton and hemp; animal fibers such as wool; .. Among these, it is preferable to contain polyester fiber having excellent heat resistance, weather resistance, antifouling property and / or rayon fiber having excellent flame retardancy.

Further, the fibers constituting the non-woven fabric of the present invention (for example, the first non-woven fabric layer and the second non-woven fabric layer) may be white or colored in a color other than white, but the smooth and flexible main surface of the surface material. The non-woven fabric (for example, the first non-woven fabric layer) constituting the above is preferably colored in a color other than white so as to have excellent designability. The colored fibers can be prepared by incorporating a pigment by kneading or adhering it, or by dyeing it with a dye.

The fibers constituting the non-woven fabric of the present invention (for example, the first non-woven fabric layer and the second non-woven fabric layer) may be oriented in any manner, but the fibers are such that the non-woven fabric has a smooth and uniform smooth and flexible main surface. It is preferable that they are oriented so as to intersect each other. The non-woven fabric in such a state in which the fibers are oriented so as to intersect with each other can be produced, for example, by forming a cross raid web of unidirectional fiber webs with a cross layer or the like and bonding the fibers to each other.

The non-woven fabric of the present invention (for example, the first non-woven fabric layer and the second non-woven fabric layer) is preferably in a state in which fibers are entangled with each other so as to have excellent flexibility. The non-woven fabric in which the fibers are entangled with each other can be produced, for example, by subjecting the fiber web to a needle punching treatment or a water flow entanglement treatment. In particular, the needle punching process is suitable because it is more flexible.

Further, the non-woven fabric of the present invention (for example, the first non-woven fabric layer and the second non-woven fabric layer) is smooth and flexible so as to suppress fluffing of fibers so as to maintain surface smoothness and to have excellent wear resistance. It is preferable that the main surface is bonded with a binder. When such is the state of being bonded with the binder, if the binder amount is too large, there is a tendency that flexibility is impaired, it is preferable amount of binder is ^{1~20g / m 2, 1~10g / m} 2 Is more preferable, and 1 to 5 g / m ² is even more preferable. Further, even if the amount of the binder is within the above range, if the binder resin itself is hard, the flexibility of the non-woven fabric tends to be impaired. Therefore, the glass transition temperature of the binder resin is preferably 0 ° C. or lower. It is more preferably 10 ° C. or lower, further preferably −20 ° C. or lower, and further preferably −30 ° C. or lower. On the other hand, if the glass transition temperature of the binder resin is too low, the tactile sensation tends to deteriorate due to the adhesiveness, and when molding the surface material, the moldability tends to deteriorate. It is preferably −50 ° C. or higher. The binder can be composed of, for example, resins such as ethylene-vinyl chloride type, ethylene-vinyl acetate type, ethylene-vinyl acetate-vinyl chloride type, vinylidene chloride type, vinyl chloride type, polyester type, and acrylic acid ester type. The above-mentioned "glass transition temperature" means the intermediate point glass transition temperature (Tmg) read from the DSC curve drawn according to JIS K7121 (2012).

The texture of the non-woven fabric constituting the surface material of the present invention is not particularly limited as long as it satisfies the above-mentioned surface roughness, fluctuation of friction coefficient, and average dynamic friction coefficient, but it is not particularly limited so that see-through or tearing is unlikely to occur. It is preferably 150 g / m ² or more, and it is lightweight, and in the case of molding, it is preferably 500 g / m ² or less so as to have excellent moldability.

When the surface material contains the first non-woven fabric layer and the second non-woven fabric layer, the basis weight of the first non-woven fabric layer is such that the smooth main surface is smooth and uniform and has a certain degree of softness, and the surface material. of such air permeability is low, is preferably from 50 to 200 g / ^{m 2,} more preferably from 100 to 200 g / ^{m 2,} and even more preferably 150 to 200 g / ^{m 2.} On the other hand, the basis weight of the second non-woven fabric layer is preferably 100 to 300 g / m ² and more preferably ^{130 to 250 g / m 2 so as to impart flexibility to the non-woven fabric (surface material).} It is more preferably 150 to 200 g / m ^2.

The thickness of the non-woven fabric constituting the surface material of the present invention is not particularly limited, but is preferably 2.0 mm or more, preferably 2.1 mm or more so as to have excellent flexibility and tactile sensation. Is more preferable, 2.3 mm or more is further preferable, and 2.5 mm or more is further preferable. On the other hand, the upper limit of the thickness of the non-woven fabric is not particularly limited, but it is preferably 5.5 mm or less, more preferably 4.5 mm or less, and 4.0 mm or less so as to be lightweight. Is more preferable, and 3.0 mm or less is further preferable. When the surface material contains the first non-woven fabric layer and the second non-woven fabric layer, the thickness of the first non-woven fabric layer is 0.5 to 2.0 mm so as to have excellent flexibility to some extent. It is preferably 0.8 to 1.8 mm, more preferably 1.0 to 1.5 mm. On the other hand, the thickness of the second non-woven fabric layer is preferably 1.5 mm or more, and more preferably 1.6 mm or more so as to impart flexibility to the non-woven fabric (surface material). The thickness of the second non-woven fabric layer is not particularly limited, but is preferably 3.5 mm or less so as to be lightweight. This "thickness" refers to a value under a 2.0 kPa load, and when the surface material has a first non-woven fabric layer and a second non-woven fabric layer, the substance in the thickness direction cross section of the surface material under a 2.0 kPa load. It means the arithmetic mean of the thickness at 5 randomly selected points where micrographs are taken.

When two or more non-woven fabric layers are provided so that the non-woven fabric constituting the surface material of the present invention has a first non-woven fabric layer and a second non-woven fabric layer, the adjacent non-woven fabric layers may be bonded to each other in any state. It is good, but when the first non-woven fabric layer and the second non-woven fabric layer are provided, the surface condition of the smooth and uniform smooth main surface of the first non-woven fabric layer is not impaired, and the first non-woven fabric layer and the second non-woven fabric are not impaired. It is preferably bonded by an adhesive so as not to impair the flexibility of the layers. When bonded with an adhesive in this way, the amount of the adhesive is preferably 1 to 30 g / m ^{2 so that the surface material can be firmly bonded without impairing the flexibility of the surface material.} , 5 to 25 g / m ² , more preferably 10 to 20 g / m ² .

Examples of this adhesive include ethylene-based copolymers such as ethylene-vinyl chloride, ethylene-vinyl acetate, and ethylene-vinyl acetate-vinyl chloride; polyolefin resins such as polyethylene and polypropylene; polyamide-based copolymers and vinylidene chloride-based resins. It can be composed of a resin such as a resin, a vinyl chloride resin, a polyester resin, or an acrylic acid ester resin. The adhesive can be a hot melt type adhesive, an emulsion type, or a suspension type, but in the case of a hot melt type adhesive, when the adhesive action of the hot melt type adhesive is exhibited, the first non-woven fabric and the second non-woven fabric and the second adhesive are used. The melting point of the hot-melt adhesive is preferably lower than the melting point of the resin having the lowest melting point among the resins constituting the first non-woven fabric and the second non-woven fabric so that the surface condition of the non-woven fabric does not change. It is more preferable that the temperature is 30 ° C. or higher lower than the melting point of the resin.

Such a smooth and flexible main surface of the present invention has a surface roughness (SMD) of 2.5 or less, a friction coefficient fluctuation (MMD) of 0.011 or less, and an average dynamic friction coefficient (MIU) of 0.30 or more. A surface material made of a non-woven fabric having an air permeability of 40 cm ³ / cm ² · s or less has a surface roughness (SMD) of 2.5 or less (preferably) measured by, for example, a surface tester (KES-FB4). Is 2.2 or less, more preferably 2.0 or less), the coefficient of friction fluctuation (MMD) is 0.010 or less (preferably 0.009 or less), and the average coefficient of dynamic friction (MIU) is 0.15 or more (preferably). Has a smooth main surface of 0.16 or more, more preferably 0.18 or more), and the surface roughness (SMD) measured by a surface tester (KES-FB4) is 3.5 or less (SMD). The coefficient of friction (MMD) is 0.014 or less (preferably 0.012 or less, more preferably 0.010 or less), and the average coefficient of dynamic friction (MMD) is preferably 3.2 or less, more preferably 3.0 or less). After producing a second non-woven fabric having a flexible main surface having a MIU) of 0.25 or more (preferably 0.28 or more, more preferably 0.30 or more), the first non-woven fabric and the second non-woven fabric are laminated and integrated. It can be manufactured by converting.

Specifically, first, a first non-woven fabric having a smooth main surface that is smooth and uniform and has excellent flexibility to some extent is produced. As described above, the fineness is 0.5 to 2.0 dtex (preferably 0.8 to 1.9 dtex, more preferably 1.0 to 1.8 dtex) so as to facilitate the production of such a first non-woven fabric. It is preferable to prepare fibers having a fiber length of 20 to 110 mm (preferably 30 to 80 mm). Further, as described above, the fibers are preferably polyester fibers and / or rayon fibers. Further, the fibers are preferably colored fibers.

The prepared fibers are then used to form a fiber web. This fiber web is made of fibers with a fineness of 0.5 to 2.0 dtex (preferably 0.8 to 1.9 dtex, more preferably 1.0 to 1.8 dtex) so that a surface material having low air permeability can be produced. It is preferable to use it as the main body. The method for forming the fiber web is not particularly limited, but it is preferable to form the fiber web by a dry method such as a curd method, which is relatively bulky and can form a flexible fiber web. In addition, in order to easily form the first non-woven fabric having a smooth and uniform smooth main surface, the fibers are in a state of being crossed with each other on the main surface of the fiber web which is the source of the smooth main surface of the first non-woven fabric. Is preferably oriented. For example, it is preferable that the unidirectional fiber web is formed into a cross raid web by a cross layer or the like so that the fibers are crossed with each other.

Next, the fibers are bonded to each other to produce the first non-woven fabric. This bonding method is not particularly limited, but it is preferable to bond the first nonwoven fabric by needle punching treatment or water flow entanglement so that the first nonwoven fabric is excellent in flexibility to some extent, and the first nonwoven fabric having excellent flexibility is more preferably used. It is preferable to bond by needle punching, which is easy to manufacture.

Further, it is preferable to bond the main surface of the fiber web, which is the smooth main surface, with a binder so that the smoothness of the smooth surface can be maintained, the fluffing of the fibers is suppressed, and the wear resistance is excellent. As described above, such a binder is an emulsion composed of a resin such as, for example, ethylene-vinyl chloride type, ethylene-vinyl acetate type, ethylene-vinyl acetate-vinyl chloride type, vinylidene chloride type, vinyl chloride type, polyester type, acrylic acid ester type, etc. Alternatively, suspension can be used. Adhesion using such a binder can be carried out by impregnating, whipping, coating, or spraying one or both sides of a fiber web (preferably a needle punch web or a water flow entangled web) and drying. As described above, the amount of the binder is ^{preferably 1 to 20} g / m 2 (preferably 1 to 10 g / m ² , more preferably ^{1 to 5 g / m 2} ). The glass transition temperature of the binder resin is preferably 0 to −50 ° C. (preferably −10 to −50 ° C., more preferably −20 to −50 ° C., still more preferably −30 ° C. to −50 ° C.). ..

The non-woven fabric in which the fibers are bonded to each other in this way has insufficient smoothness and uniformity, and has a surface roughness (SMD) of 2.5 or less and a friction coefficient fluctuation (MMD) of 0.010 or less. It is preferable to produce the first non-woven fabric by heating and pressurizing the surface of the non-woven fabric to make it dense and smooth. The heating and pressurizing conditions are such that the smooth main surface has a surface roughness (SMD) of 2.5 or less, a friction coefficient fluctuation (MMD) of 0.010 or less, and an average dynamic friction coefficient (MIU) of 0.15 or more. It suffices as long as it is a condition for the first non-woven fabric to have, and it depends on the type of the first non-woven fabric constituent fiber, the binder, etc., so it is appropriately adjusted by experiment. In addition, heating and pressurization may be performed at the same time, or may be pressurized after heating. For example, if a heating roll is used, heating and pressurization can be performed at the same time, and if heating is performed by a pair of rolls having a temperature lower than the heating temperature after heating in an oven or the like, heating and pressurization are performed separately. be able to.

The thickness of the first nonwoven fabric can be adjusted to some extent by the heating and pressurizing, but in order to adjust the thickness, the thickness is adjusted after the heating and pressurizing treatment to reduce the thickness of the first nonwoven fabric to 0. It is preferably .5 to 2.0 mm (more preferably 0.8 to 1.8 mm, still more preferably 1.0 to 1.5 mm). This thickness adjustment can be performed, for example, by passing between a pair of rolls.

On the other hand, a second non-woven fabric having excellent flexibility, a certain degree of smoothness and a uniform flexible main surface is produced. As described above, the fineness is 0.5 to 6.6 dtex (preferably 0.5 to 4.4 dtex, more preferably 0.7 to 3.3 dtex) so as to facilitate the production of such a second non-woven fabric. It is preferable to prepare fibers having a fiber length of 20 to 110 mm (preferably 30 to 80 mm). Further, as described above, the fibers are preferably polyester fibers and / or rayon fibers. Further, the fibers may or may not be colored, but when molding the surface material, if the fibers are colored in the same color as the fibers constituting the first non-woven fabric layer, see-through during molding is prevented and the appearance is improved. It is preferable to prepare fibers colored in the same hue as the first non-woven fabric layer constituent fibers, because the fibers are not easily damaged.

The prepared fibers are then used to form a fiber web. The method for forming the fiber web is not particularly limited, but it is preferable to form the fiber web by a dry method such as a curd method, which is relatively bulky and can form a flexible fiber web. In addition, in order to facilitate the formation of the second non-woven fabric having a smooth and uniform flexible main surface to some extent, the fibers are in a state of intersecting with each other on the main surface of the fiber web which is the source of the flexible main surface of the second non-woven fabric. It is preferable to orient the fibers. For example, it is preferable that the unidirectional fiber web is formed into a cross raid web by a cross layer or the like so that the fibers are crossed with each other.

Next, the fibers are bonded to each other to produce a second non-woven fabric. This bonding method is not particularly limited, but it is preferable to bond by needle punching or water flow entanglement so that the second nonwoven fabric has excellent flexibility, and a second nonwoven fabric having more flexibility is produced. It is easy to bond by needle punching.

In addition, it is preferable to bond with a binder so that the smoothness of the flexible surface can be maintained. Such binder bonding can be carried out by the same method using the same binder as that of the first non-woven fabric. As described above, the amount of the binder is ^{preferably 1 to 20} g / m 2 (preferably 1 to 10 g / m ² , more preferably ^{1 to 5 g / m 2} ). The glass transition temperature of the binder resin is preferably 0 to −50 ° C. (preferably −10 to −50 ° C., more preferably −20 to −50 ° C., still more preferably −30 ° C. to −50 ° C.). ..

The non-woven fabric in which the fibers are bonded to each other in this way has insufficient smoothness and uniformity, and has a surface roughness (SMD) of 3.5 or less and a friction coefficient fluctuation (MMD) of 0.014 or less. It is preferable to produce the second non-woven fabric by heating and pressurizing the surface of the non-woven fabric to make it dense and smooth. The heating and pressurizing conditions are such that the flexible main surface has a surface roughness (SMD) of 3.5 or less, a friction coefficient fluctuation (MMD) of 0.014 or less, and an average dynamic friction coefficient (MIU) of 0.25 or more. It suffices as long as it is a condition for the second non-woven fabric to have, and it depends on the type of the second non-woven fabric constituent fiber, the binder, etc., so it is appropriately adjusted by experiment. The heating and pressurization may be performed at the same time as in the case of producing the first non-woven fabric, or may be pressurized after heating.

The thickness of the second non-woven fabric can be adjusted to some extent by the heat and pressure, but in order to adjust the thickness, the thickness is adjusted after the heat and pressure treatment to reduce the thickness of the second non-woven fabric to 1. It is preferably 5.5 mm or more (preferably 1.6 to 3.5 mm). With such a thickness, it is easy to manufacture a surface material having an average dynamic friction coefficient of 0.30 or more and having excellent flexibility. This thickness adjustment can be performed, for example, by passing between a pair of rolls.

Next, in order to laminate and integrate the first non-woven fabric and the second non-woven fabric formed as described above, an adhesive capable of adhering the first non-woven fabric and the second non-woven fabric is prepared. This adhesive may be any as long as it can bond the first non-woven fabric and the second non-woven fabric, and is not particularly limited. For example, polyethylene such as ethylene-vinyl chloride type, ethylene-vinyl acetate type, and ethylene-vinyl acetate-vinyl chloride type. The system copolymer; a polyolefin resin such as polyethylene and polypropylene; a polyamide copolymer, a vinylidene chloride resin, a vinyl chloride resin, a polyester resin, an acrylic acid ester resin and the like can be composed. The mode of the adhesive is not particularly limited, but it is easy to suppress the generation of volatile organic substances, and it is easy to laminate and integrate the first non-woven fabric and the second non-woven fabric while maintaining the smoothness and flexibility. It is preferably a hot melt type adhesive that can be fused by.

In the case of such a suitable hot melt type adhesive, the hot melt type adhesive is used so that the surface states of the first non-woven fabric layer and the second non-woven fabric layer do not change when the hot melt type adhesive exerts its adhesive action. The melting point of the non-woven fabric is preferably lower than the melting point of the resin having the lowest melting point among the resins constituting the first non-woven fabric and the second non-woven fabric constituent fiber, and more preferably 30 ° C. or more lower than the melting point of the resin. ..

Further, the first non-woven fabric and the second non-woven fabric are firmly adhered so as not to impair the smooth and uniform surface condition of the main surface of the first non-woven fabric (surface material) and without impairing the flexibility of the surface material. It is preferable to prepare an adhesive having an adhesive amount of 1 to 30 g / m ² (preferably 5 to 25 ^{g / m 2} , more preferably 10 to 20 g / m ² ) so that the adhesive can be bonded to. For example, in the case of a hot melt type adhesive, the above amount of fiber web, fiber, or powder is prepared, and in the case of an emulsion type or suspension type adhesive, the amount of solid content after drying is the above amount. Prepare to be.

Next, in order to laminate and integrate the first non-woven fabric and the second non-woven fabric, the surface roughness (SMD) of the second non-woven fabric is 3.5 or less, the coefficient of friction fluctuation (MMD) is 0.014 or less, and the average dynamic friction. The flexible main surface having a coefficient (MIU) of 0.25 or more, or the surface roughness (SMD) of the first non-woven fabric is 2.5 or less, the coefficient of friction fluctuation (MMD) is 0.010 or less, and the average dynamic friction coefficient (SMD). An adhesive is applied to the main surface facing the smooth main surface having MIU) of 0.15 or more. For example, if the adhesive is a fiber web, it is laminated, if it is a fiber or powder, it is sprayed, and if it is an emulsion type or suspension type, it is applied or sprayed.

Next, on the adhesive, in the former case, the flexible main surface of the second non-woven fabric is laminated so that the main surface facing the smooth main surface of the first non-woven fabric faces, and in the latter case, For example, the first non-woven fabric is laminated on the main surface facing the smooth main surface so that the flexible main surface of the second non-woven fabric faces.

Then, the surface material of the present invention can be produced by exerting the adhesive action of the adhesive and integrating the first non-woven fabric and the second non-woven fabric. For example, in the case of a hot melt type adhesive, it is heated at a temperature equal to or higher than the melting point at which the adhesive melts, and in the case of an emulsion type or suspension type adhesive, it is heated at a temperature at which the solvent volatilizes to bond. The first non-woven fabric and the second non-woven fabric are integrated by exerting the adhesive action of the agent.

It is preferable to heat and pressurize the adhesive so that the adhesive action can be sufficiently exerted. However, if the heating temperature is too high, the pressing force is too strong, and / or the heating and pressurizing time is long, Since the smoothness, uniformity, and / or flexibility of the first and second non-woven fabrics tends to be impaired, heat and pressure are applied under the minimum necessary conditions, and the surface roughness (SMD) of the surface material is 2.5. Hereinafter, the surface has a smooth and flexible main surface having a friction coefficient variation (MMD) of 0.011 or less and an average dynamic friction coefficient (MIU) of 0.30 or more. Since the heating and pressurizing conditions differ depending on the adhesive, they are appropriately adjusted by experiments.

Since the interior surface material of the present invention is not only excellent in tactile sensation but also excellent in sound absorption, it is used for automobiles such as ceilings, door sides, pillar garnishes, and rear packages; for interiors such as partitions; walls. It can be suitably used for building materials such as mounting materials.

Examples of the present invention will be described below, but the present invention is not limited to the following examples.

(Examples 1 and 2, Comparative Examples 1 and 4)
(Manufacturing of first non-woven fabric)
Using 100% of gray-colored polyester short fibers (fiber length: 51 mm, melting point: 260 ° C.) with a fineness of 1.1 dtex, 1.7 dtex, or 2.2 dtex, the fibers are opened by a card machine and unidirectional. After forming the fiber web, a cross layer was used to form a cross ray web in which the fibers were crossed with each other, and further needle punched to entangle the fibers to form a needle punch web with a basis weight shown in Table 1.

Next, one side of the needle punch web is whipped and impregnated with an emulsion binder solution as shown in Table 1, dried in a can dryer at a temperature of 150 ° C., and then between thermal calendar rolls under the conditions shown in Table 1. The first non-woven fabric having the physical properties as shown in Table 1 was produced, either by smoothing the main surface or without smoothing the main surface by carrying out heating and pressurizing by passing through.

(Manufacturing of second non-woven fabric)
After 100% of gray-colored polyester short fibers (fiber length: 51 mm, melting point: 260 ° C.) with a fineness of 2.2 dtex or 3.3 dtex are opened by a card machine to form a unidirectional fiber web. The cross layer was used to form a cross ray web in which the fibers were crossed with each other, and further needle punched to entangle the fibers to form a needle punch web with a grain as shown in Table 2.

Next, one side of the needle punch web is whipped and impregnated with an emulsion binder solution as shown in Table 2, dried with a can dryer at a temperature of 150 ° C., and then between thermal calendar rolls under the conditions shown in Table 2. The second non-woven fabric having the physical characteristics as shown in Table 2 was produced either by smoothing the main surface or without smoothing the main surface by carrying out heating and pressurizing by passing through.

(Preparation of adhesive non-woven fabric)
As the adhesive nonwoven fabric, a hot-melt adhesive nonwoven fabric having a ^{mesh size of 17 g / m 2 made} of polyethylene fibers (melting point: 110 ° C.) was prepared.

(Manufacturing of surface material)
The adhesive non-woven fabric is laminated on a flexible main surface having the physical properties as shown in Table 2 of the second non-woven fabric, and further, smooth having the physical properties as shown in Table 1 of the first non-woven fabric is further formed on the adhesive non-woven fabric. The first non-woven fabric is laminated so that the main surface facing the main surface is in contact with the adhesive non-woven fabric, and in that state, heating and pressurizing at a temperature of 130 ° C. and a pressing force of 9.8 N is performed for 10 seconds to form the first non-woven fabric. The second non-woven fabric was adhesively integrated to produce surface materials having the physical properties shown in Table 3.

(Tactile evaluation of surface material)
By having the monitor directly touch the smooth and flexible main surface of the surface material on the first non-woven fabric side, the tactile sensation (smoothness, uniformity, softness) was evaluated on a 5-point scale. If it was excellent, it was evaluated as "5", if it was inferior, it was evaluated as "1", and in the middle, it was evaluated as "2-4". The results are as shown in Table 3.

(Evaluation of sound absorption of surface material)
The surface material of Examples 1 and 2 or Comparative Examples 1 to 4 is applied ^{to a base material mat (grain: 500 g / m 2} ) in which a glass fiber mat and a rigid polyurethane foam resin sheet are composited, and the second non-woven fabric layer of the surface material is glass. The mats were laminated so as to be in contact with the fiber mats, and bonded by a flat plate heat press set at a temperature of 200 ° C. to prepare test mats having a thickness of 5.0 mm.

Then, the sound absorption coefficient of these test mats was measured by a vertical incident method sound absorption coefficient measuring device manufactured by Bruel Care Co., Ltd. by a measuring method based on JIS-A1405. Since the sound absorption coefficient in the vicinity of the frequency of 800 to 1600 Hz is emphasized so that clear conversation can be performed in the vehicle interior, the sound absorption coefficient at 1000 Hz, which is a typical frequency, was measured. These results are as shown in Table 3.

(Discussion)
From the comparison between Examples 1 and 2 and Comparative Example 1, ^{it was found that when the air permeability was 40 cm 3} / cm ² · s or less, the sound absorption coefficient was high and the sound absorption performance was excellent. Further, from the comparison between Example 1 and Example 2, ^{it was found that when the air permeability was 30 cm 3} / cm ² · s or less, the sound absorption coefficient was higher and the sound absorption performance was excellent.

Further, from the comparison between Examples 1 and 2 and Comparative Example 2, it was found that the flexibility is excellent by having a smooth and flexible main surface having an average dynamic friction coefficient (MIU) of 0.30 or more. It was also found that the glass transition temperature and amount of the binder affect the flexibility of the surface material.

Further, from the comparison between Examples 1 and 2 and Comparative Example 3, it has a smooth and flexible main surface having a surface roughness (SMD) of 2.5 or less and a friction coefficient fluctuation (MMD) of 0.011 or less. It was found that the smoothness and uniformity were excellent. Further, even if the second non-woven fabric layer is excellent in smoothness and uniformity, if the smoothness and uniformity of the first non-woven fabric layer constituting the smooth and flexible main surface of the surface material is insufficient, the smoothness is smooth. It was also found that the surface material was not excellent in uniformity, and that the smoothness and uniformity of the first non-woven fabric layer affected the smoothness and uniformity of the surface material.

Since the interior surface material of the present invention has excellent tactile sensation and sound absorption, it is suitably used for automobiles such as ceilings, door sides, pillar garnishes, and rear packages; for interiors such as partitions; and for building materials such as wall coverings. can do.

Claims (6)

It is an interior surface material made of a non-woven fabric, and the fineness of the fibers constituting the non-woven fabric is 0.7 dtex or more, and the interior surface material has a surface roughness (SMD) measured by a surface tester (KES-FB4). Is 2.5 or less, the variation of the friction coefficient (MMD) is 0.011 or less, and the average dynamic friction coefficient (MIU) is 0.30 or more and 1.00 or less. It contains two non-woven fabric layers, a non-woven fabric layer and a second non-woven fabric layer other than the first non-woven fabric layer, and the first non-woven fabric layer and the second non-woven fabric layer are bonded by an adhesive, and the interior surface material. A surface material for interior use, characterized in that the air permeability of the non-woven fabric is 40 cm ³ / cm ^{2 · s or less.} The interior surface material according to claim 1, wherein the first nonwoven fabric layer is a nonwoven fabric layer mainly composed of fibers having a fineness of 0.8 to 2.0 dtex. The interior surface material according to claim 1 or 2, wherein the thickness of the second non-woven fabric layer is 1.5 mm or more. When the surface roughness (SMD) is 2.5 or less, the coefficient of friction fluctuation (MMD) is 0.010 or less, and the average dynamic friction coefficient (MIU) is 0.15 or more, as measured by a surface tester (KES-FB4). The first non-woven fabric having a certain main surface, the surface roughness (SMD) measured by a surface tester (KES-FB4) is 3.5 or less, the coefficient of friction fluctuation (MMD) is 0.014 or less, and the average dynamic friction. The interior use according to claim 1, wherein the second non-woven fabric having a main surface having a coefficient (MIU) of 0.25 or more is produced, and then the first non-woven fabric and the second non-woven fabric are laminated and integrated. Surface material manufacturing method. 4. The non-woven fabric according to claim 4, wherein the first non-woven fabric is a non-woven fabric having a main surface smoothed by heating and pressurizing after forming a fiber web using fibers having a fineness of 0.7 to 2.0 dtex. How to manufacture interior surface materials. The method for producing an interior surface material according to claim 4 or 5, wherein the thickness of the second nonwoven fabric is 1.5 mm or more.