JP7286181B2 - Automotive interior fabric - Google Patents

Description

TECHNICAL FIELD The present invention relates to an automobile interior fabric that is suitably used for, for example, automobile seats, door coverings, and the like, as well as the skin of automobile interior materials.

In the claims of the present application and in this specification, T is used as a tex, and dT and dtex are used as decitex as units of the thickness (number) of fibers and yarns.

BACKGROUND ART Conventionally, the hue of interior fabrics for automobiles is overwhelmingly black, and black interiors exist in any type of vehicle. Black interiors are often used because dirt such as dirt from hands and dust is less noticeable and gives a calm impression. On the other hand, in the interior fabric used as the seat upholstery, the fibers on the fabric surface become fibrillated due to repeated wear and tear caused by the human body when getting in and out of the vehicle over a long period of time. In the present application, this phenomenon is called bleaching phenomenon. The whitening phenomenon is particularly likely to occur when the fabric of the seat side portion is rubbed when getting on and off, and is often seen in vehicles with high hip points such as SUV vehicles, which have become popular in recent years. In cars with a high hip point, whitening of the fabric has been a problem due to the large load caused by friction when getting on and off.

In polyester fibers, which are widely used as interior fabrics for automobiles, when expressing black or dark colors, the problem is that the color development is inferior to natural fibers and nylon fibers mainly composed of polyamide, and depth cannot be obtained. there were. For example, Patent Document 1 proposes a dark-colored fabric that satisfies the friction physical properties of automotive interior fabrics. Insufficient to suppress later whitening phenomenon.

If the single yarn fineness is increased by a general method to solve this problem, the dyeability will be improved, the color will be easier to darken, and the abrasion resistance will be improved, but the touch will be poor and the luster peculiar to synthetic fibers will be reduced. The feeling becomes strong, and the quality as the interior fabric for automobiles is impaired.

In addition, it is known to fix the fiber surface of the fabric with resin to improve abrasion resistance. It is required to avoid this processing because it causes an increase in CO ₂ emissions during the manufacturing process of the product and hinders the easy recyclability of the product itself. In other words, there is a demand for products with less environmental impact.

Furthermore, due to the increasing need for car sharing, automobiles are required to be public, and automobiles used by an unspecified number of people are required to have fabrics that do not change in appearance even after long-term use.

Patent No. 6504752

The present invention has been made in view of the above technical background, and is not only excellent in environmental performance evaluation based on the usage rate of products with less environmental load, that is, recycled materials, but also improved abrasion resistance as in the past. Therefore, there is no need to apply a process to fix the fiber surface of the fabric with resin. To provide an automobile interior fabric which does not cause wrinkles.

As a result of intensive studies on measures to prevent the whitening phenomenon after abrasion of interior fabrics for automobiles with relatively low lightness, the present inventor limited the thickness and raw materials of the polyester long fibers protruding to the outermost surface of the fabric to specific ones. By the way, it was discovered that the above problems can be solved at once. That is, the inventors have found that it is possible to obtain an automobile interior fabric which is excellent in abrasion resistance and does not cause whitening after abrasion, and thus arrived at the present invention. The present invention provides the following means.

[1] A fabric comprising polyester long fibers,
In the yarns constituting the fabric, the ratio of yarns that simultaneously satisfy the following conditions (1) to (3) is in the range of 30 to 70% by weight, and the L measured in accordance with JIS Z8722-2009 of the fabric The value of * is 17 or less,
Abrasion resistance test using No. 6 cotton canvas specified in JIS L3102 (pressing load 9.81 N, 10,000 times reciprocation) is grade 4 or higher, and the color difference before and after abrasion in the abrasion resistance test ▲Δ▼ E is less than 2.65 .
(1) The thickness of the polyester filament yarn protruding from the outermost surface of the fabric is 2.5 dtex or more in single fineness and 1,000 dtex or more in total fineness. 50 to 75% by weight of the pulverized product and virgin polyester resin pellets (3) The yarn of the polyester long fiber is a three-color mixed fiber yarn colour)

[ 2 ] The automotive interior fabric according to the preceding item 1, wherein the three-color mixed fiber base-dyed yarn is a yarn obtained by mixing three types of fibers in which 0.3 to 1.5% by weight of different pigments are mixed.

In the invention [1], even in a fabric with a relatively low lightness suitable for black interiors, which is the mainstream in automotive interiors, that is, a fabric with an L* value of 17 or less, the yarn of the polyester long fibers is a three-color mixed fiber. Because it is a spun-dyed yarn, whitening due to abrasion does not occur, and it has the advantage of being excellent in abrasion resistance over a long period of time and making changes in appearance less noticeable. is less than 2.65 , it is possible to provide an automobile interior fabric with even less change in appearance.

In the invention [ 2 ], suitability for automotive interiors can be enhanced in terms of color shade of the fabric. Furthermore, by mixing different pigments, there is an advantage that the whitening phenomenon and appearance change due to abrasion become less noticeable.

1 is a photograph of a fabric surface (a non-worn portion and a worn portion) of an example of a fabric in which a whitening phenomenon has occurred due to wear.

Next, one embodiment of the automotive interior fabric according to the present invention will be described in detail.

The automotive interior fabric of the present invention is a fabric comprising polyester long fibers, and in the yarns constituting the fabric, the ratio of yarns satisfying the following conditions (1) to (3) at the same time is 30 to 70. % range by weight, and the value of L * measured in accordance with JIS Z8722-2009 of the fabric is 17 or less, and the wear resistance test (pressing load 9.81 N, 10,000 reciprocating cycles), grade 4 or higher, and the color difference (ΔE) before and after abrasion in the abrasion resistance test is less than 2.65 . (1) The thickness of the polyester filament yarn protruding from the outermost surface of the fabric is 2.5 dtex or more in single fineness and 1,000 dtex or more in total fineness. 50 to 75% by weight of the pulverized product and virgin polyester resin pellets (3) The yarn of the polyester long fiber is a three-color mixed fiber yarn colour)

By adopting such a structure, not only is it excellent in environmental performance due to the use of recycled materials, but it is also necessary to apply processing to fix the fiber surface of the fabric with resin in order to improve abrasion resistance as in the past. Even if it is a fabric with a relatively low lightness, that is, a fabric with an L* value of 17 or less, the yarn of the polyester long fiber is a three-color mixed yarn (a color close to black) . , There is no whitening phenomenon due to abrasion, it has excellent abrasion resistance over a long period of time, and it has the advantage that the change in appearance is less noticeable . Therefore, it is possible to provide an automobile interior fabric with less change in appearance. In addition, since no resin agent is used, the manufacturing cost does not increase due to an increase in the number of processes and man-hours in the manufacturing process or an increase in material costs, and the fabric does not lose its attractiveness in terms of texture. Furthermore, as a fabric for automotive interiors, it is suitable for mainstream black interiors, and there is an advantage that by selecting an arbitrary pigment color, it is possible to enhance the design and match it with the interior color.

By setting the thickness of the polyester long fibers protruding to the outermost surface of the fabric to a single fineness of 2.5 dtex or more and a total fineness of 1,000 dtex or more, the whitening phenomenon due to single fiber breakage and fibrillation after abrasion. Also, the relative wear strength can be increased. More preferably, the single fineness is in the range of 2.5dtex to 4.5dtex and the total fineness is in the range of 1,000dtex to 1,500dtex.

Since the yarn of the polyester long fiber is a yarn obtained by spinning a raw material containing 50 to 75% by weight of pulverized resin molding waste and virgin polyester resin pellets, it can contribute to reduction of environmental load. If it is less than 50% by weight, the effect of reducing the environmental load is reduced.

The polyester filament yarn is a three-color mixed filament dyed yarn (a color close to black) . By adopting this configuration, changes in appearance after wear become less noticeable. The spun-dyed yarn of the three-color mixed fiber is preferably a yarn obtained by mixing three kinds of fibers in which 0.3 to 1.5% by weight of different pigments are mixed. In this way, it is possible to further improve suitability for automotive interiors in terms of color shade of the fabric. That is, even if the brightness is low, whitening after abrasion does not occur, and changes in appearance are less noticeable, so it is suitable for use in mainstream black interiors. By mixing fibers with different pigments, there is an advantage that changes in appearance after abrasion become less noticeable.

In the present invention, the spun-dyed yarn is obtained, for example, by melt-spinning polyester resin pellets kneaded with a pigment. , obtained by combining each fiber melt-spun through a twin-screw extruder of the original dyed yarn 3).

Examples of pigments for dope-dyed yarns include organic pigments such as phthalocyanine-based, anthraquinone-based, and perinone-based pigments, and inorganic pigments such as titanium oxide, iron oxide, ultramarine, and carbon black.

The resin molding waste material is not particularly limited as long as it is mainly composed of polyester resin. It is preferable that the main body is a bottle. Since fibers of stable quality are readily available through separate collection, the fineness of the polyester long fibers can be stabilized. Furthermore, from the perspective of sustainability, using waste materials has the advantage of being a product that can be green procured.

The fiber material constituting the automotive interior fabric of the present invention contains polyester long fibers, and the ratio of the yarn that simultaneously satisfies the above conditions (1) to (3) is in the range of 30 to 70% by weight. Other than that, there are no particular restrictions, and for example, fibers such as polyamide fibers and acrylic fibers may be combined with mixed fibers, mixed spinning, twisted yarns, and the like.

Although the form of the automotive interior fabric of the present invention is not particularly limited, woven fabrics and knitted fabrics are preferred. In addition, in order to make specific polyester long fibers protrude from the outermost surface of the fabric, it is sufficient to increase the count difference of the fibers constituting the fabric by 3 times or more. One of them may be used as a warp thread and the other as a weft thread. There are no particular restrictions. If the ratio of count yarns of 1000 dtex or more is set to 30 to 70% by weight, the deterioration of the texture is suppressed and it becomes a range that can be used as an interior material for automobiles. In addition, regarding the hue and lightness of count yarns other than 1000 dtexi in the present invention, it is sufficient that the value of L* at first glance in the finished fabric is in the range of 17 or less. The mixed weaves were evaluated based on the hue and brightness of similar colors. Also, in the case of knitted fabrics, yarns having a count difference of 3 times or more may be mixed and knitted in the same manner as in the above-mentioned woven fabrics.

Further, in the present invention, it is preferable to provide a backing layer on the back side of the woven or knitted fabric. By providing a backing layer on the back side, dimensional stability can be improved and functionality such as flame retardancy can be imparted. The backing layer is not particularly limited. For example, a resin composition such as an acrylic resin, a urethane resin, a polyvinyl chloride resin, an ethylene-vinyl acetate copolymer (EVA) resin, and a known flame retardant are blended. can be mentioned. In order to laminate the backing layer, a flame retardant or the like may be added to the emulsion of the resin composition, coated with a known roll coater, comma coater, knife coater or the like, and dried.

The fabric has an L* value of 17 or less measured in accordance with JIS Z8722-2009, grade 3 or higher in both the vertical and horizontal directions in a planar abrasion test of the fabric, and a color difference before and after abrasion in an abrasion resistance test. Since ▲Δ▼ E is less than 2.65 , whitening after abrasion does not occur and the appearance change is small over a long period of time. If the value of L* is 25 or more, it is not possible to match the color to the bright, black interior.

Next, specific examples of the present invention will be described, but the present invention is not particularly limited to these examples. Table 1 shows examples and comparative examples, and Table 2 shows the results of wear resistance test, color difference, texture evaluation, and environmental performance evaluation.

<Preparation of polyester filament yarn>
(A) 70% by weight of resin molding waste and virgin (commercially available) polyester resin pellets; 0.66% by weight of pigments containing black, titanium oxide, and blue are contained, and the spun-dyed yarn 3 contains 0.79% by weight of pigments containing carbon black, titanium oxide, and blue. A method of obtaining a three-color mixed yarn by combining the original-dyed yarn 1, the original-dyed yarn 2, and the original-dyed yarn 3 melt-spun through an extruder. A three-color mixed filament dope-dyed yarn of each kind was obtained. At first glance, this spun-dyed yarn was black.
1220dtex/432f (single yarn fineness 2.8dtex) BK1
1100dtex/288f (single yarn fineness 3.8dtex) BK2
660dtex/288f (single yarn fineness 2.3dtex) BK3
250dtex/216f (single filament fineness 1.1dtex) BK4
(B) 50% by weight of resin molding waste and virgin (commercially available) polyester resin pellets;
The dope-dyed yarn 2 contains 0.48% by weight of the same pigment as the dope-dyed yarn 1,
The dope-dyed yarn 3 contains 0.48% by weight of the pigment of the same composition as the dope-dyed yarn 1, and is melt-spun through three twin-screw extruders. The following one-color mixed fiber base-dyed yarn was obtained by the method of obtaining a single-color mixed fiber base-dyed yarn by doubling the dyed yarn 3. At first glance, this spun-dyed yarn was black.
1100dtex/288f (single yarn fineness 3.8dtex) BK5
Here, an example of black color, which tends to cause whitening phenomenon, is shown, but if the value of L* is 25 or less, dark blue color, dark brown color, etc. can also be used. can be applied in

The above-described three-color mixed fiber dope-dyed yarn BK1 and 167 dtex/48 f polyester long fibers (black) were mixed and woven so that the composition ratio of BK1 was 60% by weight. (See Table 1 for the weave structure.) Regarding the hue and brightness of the mixed 167dtex/48f raw yarn, it is difficult to appear on the surface due to the thickness of the three-color mixed yarn, but at first glance the hue and brightness The brightness was adjusted to be similar to BK1. Subsequently, the woven gray fabric is scouring with a jet dyeing machine and dried, then an acrylic resin emulsion is applied to the back side of the gray fabric, dried at a temperature of 150 ° C. for 5 minutes with a hot air dryer, and set for tentering and warp density. An automobile interior fabric having an L* value of 16 and a weft density of 69 lines/inch and a weft density of 57 lines/inch was obtained. The result of the abrasion resistance test of the fabric was Grade 4 in the vertical direction and Grade 4 in the horizontal direction, both passing. In addition, the color difference ΔE of the fabric before and after abrasion was 1.65 in the vertical direction and 1.38 in the horizontal direction. The texture evaluation was grade 3, and the environmental performance evaluation was "O", both of which were acceptable.

In Example 1, the same procedure as in Example 1 was performed except that the three-color mixed fiber dope-dyed yarn BK2 was used in place of the three-color mixed fiber dope-dyed yarn BK1, and the composition ratio of BK2 was 60% by weight. , L* of 15 was obtained. The result of the abrasion resistance test of the fabric was grade 4 in the vertical direction and grade 4 in the horizontal direction, both of which passed. In addition, the color difference ΔE of the fabric before and after abrasion was 1.55 in the vertical direction and 1.26 in the horizontal direction. The texture evaluation was grade 3, and the environmental performance evaluation was "O", both of which were acceptable.
<Reference example>

In Example 1, a single mixed fiber dope-dyed yarn BK5 was used in place of the three-color mixed fiber dope-dyed yarn BK1. An automobile interior fabric having an L* value of 12 was obtained in the same manner as in Example 1, except that the fabric was finished to have a weft density of 70 lines/inch and a weft density of 56 lines/inch. The result of the abrasion resistance test of the fabric was grade 4 in the vertical direction and grade 4 in the horizontal direction, both of which passed. In addition, the color difference ΔE of the fabric before and after abrasion was 2.65 in the vertical direction and 3.18 in the horizontal direction. The texture evaluation was grade 3, and the environmental performance evaluation was "O", both of which were acceptable.

<Comparative Example 1>
In Example 1, instead of the three-color mixed fiber dope-dyed yarn BK1, the three-color mixed fiber dope-dyed yarn BK3 was used. A fabric having an L* value of 16 was obtained in the same manner as in Example 1, except that the weft density was 80 lines/inch and the weft density was 60 lines/inch. The result of the abrasion resistance test of the fabric was grade 3 in the vertical direction and grade 3 in the horizontal direction, and both failed. In addition, the color difference ΔE of the fabric before and after abrasion was 5.34 in the vertical direction and 5.55 in the horizontal direction. The texture evaluation was grade 3, and the environmental performance evaluation was "O", both of which were acceptable.

<Comparative Example 2>
In Example 1, instead of the three-color mixed fiber dope-dyed yarn BK1, the three-color mixed fiber dope-dyed yarn BK4 was used, weaving was performed so that the composition ratio of BK4 was 50% by weight, tenter setting was performed, and the warp density A fabric having an L* value of 17 was obtained in the same manner as in Example 1, except that the weft density was 180 lines/inch and the weft density was 85 lines/inch. The result of the abrasion resistance test of the fabric was grade 3 in the vertical direction and grade 3 in the horizontal direction, and both failed. In addition, the color difference ΔE of the fabric before and after abrasion was 6.55 in the vertical direction and 6.34 in the horizontal direction. The texture evaluation was grade 4, and the environmental performance evaluation was "O", both of which were acceptable.

<Comparative Example 3>
In Example 1, the three-color mixed fiber dope-dyed yarn BK2 was used instead of the three-color mixed fiber dope-dyed yarn BK1. A fabric having an L* value of 16 was obtained in the same manner as in Example 1, except that the weft density was 70 lines/inch and the weft density was 56 lines/inch. The result of the abrasion resistance test of the fabric was grade 3 in the vertical direction and grade 3 in the horizontal direction, and both failed. In addition, the color difference ΔE of the fabric before and after abrasion was 5.85 in the vertical direction and 5.94 in the horizontal direction. The texture evaluation was grade 4 and passed, but the environmental performance evaluation was "x" and failed.

<Comparative Example 4>
In Example 1, the three-color mixed fiber dope-dyed yarn BK2 was used instead of the three-color mixed fiber dope-dyed yarn BK1. A fabric having an L* value of 17 was obtained in the same manner as in Example 1, except that the weft density was 50 lines/inch and the weft density was 40 lines/inch. The result of the abrasion resistance test of the fabric was grade 4 in the vertical direction and grade 4 in the horizontal direction, both of which passed. In addition, the color difference ΔE of the fabric before and after abrasion was 2.54 in the vertical direction and 2.56 in the horizontal direction. The texture evaluation was grade 2 and failed, but the environmental performance evaluation was "○" and passed.

As can be seen from Tables 1 and 2, the automotive interior fabrics of Examples 1 and 2 have little change in appearance over a long period of time, have excellent abrasion resistance, and are automotive interior fabrics that do not cause whitening after abrasion. there were.

On the other hand, the fabrics of Comparative Examples 1 to 4 did not satisfy all of the abrasion resistance test, evaluation of whitening after abrasion, evaluation of texture, and evaluation of environmental performance at the same time.

<Brightness L*>
The lightness L* value of the fabric was measured using a spectral color difference meter (product number NF555) manufactured by Nippon Denshoku Industries Co., Ltd. in accordance with JIS Z8722-2009.

<Abrasion resistance test>
It was evaluated by a wear resistance test using a plane wear tester (type: AR-2S, manufactured by Intec Co., Ltd.). For measurement, a test piece with a width of 70 mm and a length of 300 mm is taken one by one from the vertical direction and the horizontal direction, and the thickness is 10 ± 1 mm on the flat abrasion table of the flat abrasion tester, and the 20% compressive stress is 0.79 to 1. The test piece was placed on a urethane foam of .08 N/cm ² and fixed with a clamp. Next, a friction element attached with No. 6 cotton canvas specified in JIS L3102 (cotton canvas) is placed on the test piece, and the pressing load including the friction element is 9.81 N, the stroke is 140 mm, and the speed is 60 m ± 10 A test was conducted with 10,000 reciprocations per minute. The degree of wear in the central portion of the test piece was visually observed and evaluated according to the following five grades. Grade 4 or higher was regarded as passing.
(grade)
Grade 5: No change observed Grade 4: Change slightly observed, but hardly noticeable Grade 3: Change clearly observed, but not noticeable Grade 2: Change somewhat remarkable 1st grade: Significant change

<Evaluation of whitening after abrasion (color difference ▲Δ▼E measurement)>
The color difference ΔΔE of the test piece before and after the abrasion resistance test was measured to evaluate the degree of whitening. That is, the color difference between the central portion of the test piece after the abrasion resistance test and the test piece before the test was measured, and the color difference ΔE of 5 or less was regarded as acceptable.

<Texture evaluation>
The texture of the interior fabrics for automobiles was sensory-evaluated by tactile sensation, and evaluated in the following 4 stages. In addition, grade 3 or higher was regarded as a pass.
(grade)
Grade 4: The surface is smooth and not rough Grade 3: The surface is slightly rough, but it is not noticeable Grade 2: The surface is slightly rough Grade 1: The surface is extremely rough

<Environmental performance evaluation>
It was evaluated by the ratio of the recycled material to the total weight of the automotive interior fabric. That is, when the recycled material is 25% by weight or more of the total weight, it is subject to green procurement, so it is judged as acceptable and marked as "○", and when it is less than 25% by weight, it is judged as unacceptable and marked as "X".

The automobile interior fabric of the present invention is suitable for applications such as automobile seat seats, door coverings, and the like, as well as the skins of automobile interior materials.

Claims (2)

A fabric comprising polyester long fibers,
In the yarns constituting the fabric, the ratio of yarns that simultaneously satisfy the following conditions (1) to (3) is in the range of 30 to 70% by weight, and the L measured in accordance with JIS Z8722-2009 of the fabric The value of * is 17 or less,
Abrasion resistance test using No. 6 cotton canvas specified in JIS L3102 (pressing load 9.81 N, 10,000 times reciprocation) is grade 4 or higher, and the color difference before and after abrasion in the abrasion resistance test ▲Δ▼ E is less than 2.65 .
(1) The thickness of the polyester filament yarn protruding from the outermost surface of the fabric is 2.5 dtex or more in single fineness and 1,000 dtex or more in total fineness. 50 to 75% by weight of the pulverized product and virgin polyester resin pellets (3) The yarn of the polyester long fiber is a three-color mixed fiber yarn colour) 2. The interior fabric for automobiles according to claim 1, wherein the three-color mixed yarn is a yarn obtained by mixing three kinds of fibers mixed with 0.3 to 1.5% by weight of different pigments.

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