JPH01174658A - Production of interior substrate for automobile - Google Patents

Abstract

PURPOSE:To obtain the subject substrate good in raised state and appearance, outstanding in wear resistance, by needle punching, thermal calendering and raising of a laminated short fiber mat of unilayered structure with its one side layer incorporated with undrawn short fiber. CONSTITUTION:(A) a short fiber mat A and (B) a second short fiber mat B incorporated with undrawn short fiber are laminated followed by needle punching 2 to form an interlaced fiber mat. Thence, a unified fiber mat C having a contact-bonded plate 3 where said undrawn short fiber has been fused is formed by thermal calendering with the roll temperature on the B-layer side increased, followed by raising the surface of the A-layer side.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for manufacturing an automobile interior base material used for automobile ceiling materials, rear packages, door trims, etc.

[Conventional technology and its problems]

Conventionally, as this type of automotive interior base material, a textured polyvinyl chloride sheet and a polyurethane sponge are laminated together, or a raised fabric thereof is used. However, in recent years, automotive applications have become lighter and cheaper.

The trend toward fiberization has increased, and there has been a demand for nonwoven fabrics as constituent elements of interior materials.In particular, the so-called pear-like raised fabrics obtained by raising the surface of knitted and woven fabrics are luxurious. However, although the fabrics obtained by brushing knitted fabrics are luxurious, they usually require many processing steps. However, there is a problem that it is impossible to provide it at a low price, and it is disadvantageous from an economic point of view.

On the other hand, with regard to nonwoven fabrics used as interior material, there have been unsuccessful attempts to obtain velour-like fabrics by brushing, but there are no results for nonwoven fabrics. To process, apply 1. It is necessary to have sufficient strength to prevent the width of the cloth from shrinking excessively.To obtain that strength, the raising process cannot be done satisfactorily unless it is impregnated or coated with resin. However, if impregnated or coated with resin, the elongation of the fibers will be limited, so the resin attached to the fibers will be pulled out together with the fibers during raising, resulting in an unfavorable appearance. There were many problems such as insufficient wear resistance.

[Means for solving problems]

However, the present invention solves the above-mentioned problem by using as a material an interlaced fiber mat made by blending unstretched short fibers into one layer of a laminated fiber mat made of short fibers with a two-layer structure of Km. Then, by heat calendering, the fibers of the undrawn short fiber-containing fiber layer are bonded together by the fusion of the Isamitsuta drawn short fibers to form a plate-like layer, and the surface of the other layer is subjected to a raising process. After the treatment, heat treatment is performed to solve the problem, and to provide an automotive interior base material with good napping, good appearance, and excellent abrasion resistance.

(Example〕 ``One embodiment of the present invention will now be described in accordance with the diagram.

As shown in Figs. 1 and 8, the short fibers are, for example, short fiber mats (A
);- and undrawn polyester fiber (t) 5 d X
88' and 50% of the same polyester fiber as the (A) layer, uniformly spread and laminated with a fabric weight of 100.
40-7G'% by overlapping F with the short fiber mat (B) layer.
A laminated mat of 5116 P is formed from the t33+ layer side using a needle punch machine.
/a11" needle punch processing, layer (A) and I
B) form an intertwined fiber mat with integrated layers. Next, this interlaced fiber mat (roll temperature on the N layer side is 160°C,
(B) The undrawn polyester fibers are passed through a heated calender roll adjusted to have a roll temperature of sso'e on the layer side and calendered to melt the undrawn polyester fibers into a film as shown in Figure 3'. Polyester fibers and undrawn polyester fibers are bonded to other polyester fibers and then needle punched (punched) to form (
A) Partially unstretched polyester fibers penetrating the layer side and 1B) A plate-like layer (3) with the 4 sides crimped together.
), the surface of this integrated fiber mart) OoA layer side is brushed with sandpaper to make the brushed fibers (4) protrude from the (A) layer side as shown in Figure 4. Thereafter, the undrawn polyester fibers were passed through a hot air dryer to condense and stabilize the fibers, thereby obtaining an automobile interior material. The (B) layer of the automobile interior material obtained and leaked in this way is extremely dense due to the formation of a film of unstretched polyester fibers, and is mechanically entangled and unstretched by needle punching. Because it is obtained by forming a film from polyester fiber, it has a high friction resistance and shows excellent results in wear tests using a taper m rotary compressor, and as shown in the table below, it is also excellent in 10-moji and lath. It showed excellent results and was able to fully withstand the napping treatment, and was able to withstand use as an automotive interior base material such as automotive ceiling materials, rear packages, and door trims.

By the way, in the above example, (A) layer, IB) J'
Polyester fibers were used as short fibers other than the undrawn polyester fibers used in fJ, and the +4) layer.

LB) Both layers are made of boria ζ fiber, polypropylene fiber,
Polyacrylonitrile fiber, 4-da acrylic fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, polyethylene fiber, polycrethane fiber.

Synthetic fibers such as polyvinyl alcohol fibers, semi-synthetic fibers such as a7tate fibers and triacetate fibers, recycled fibers such as viscose lace ln, copper annular 4sL array laminate, and inorganic fibers such as glass fibers, metal fibers, rock fibers, etc. In addition to chemical fibers such as, it is also possible to use one or more types of natural fibers alone or in combination.◎ In addition, in order to obtain sufficient strength to withstand the lifting and studying, K is made of undrawn short fibers. If the mixing ratio is less than 10% of the total weight, it will elongate and shrink in width, which is undesirable. If it exceeds 5 ozb, the fill-hatched fibers will increase and the texture will become hard, which is not desirable. Although sandpaper was used in this process, the raising process can also be performed using a raising machine equipped with a raising needle cloth.

〔Effect of the invention〕

Since the present invention has the above-mentioned structure, it has sufficient strength to withstand the raising process, and no width shrinkage occurs. front,
This invention has excellent effects such as being able to obtain a velour-like interior material for automobiles that is more vertical and luxurious than the conventional material IIIK.

[Brief explanation of the drawing]

Fig. 1 is a block diagram showing the manufacturing process of the present invention, Fig. 8 is a schematic cross-sectional view of the laminated mat of staple fiber web used in carrying out the present invention, and Fig. 3 is a schematic diagram of the same after needling and thermal calendering. Fig. 4 is a schematic cross-sectional view of the structure of an automobile interior base material which has been subjected to the same napping treatment. mouth)...undrawn polyester fiber (ri...needle punch processing +31...crimped plate layer (4)...raised fiber

Claims (1)

[Claims] A fibrous web (A) layer made of 100% short fibers and a fibrous web (B) layer made of a mixture of 90 to 50% of the above short fibers and 10 to 50% of unstretched short fibers are laminated, and the (B) layer is laminated. An intertwined fiber mat is formed by needle punching from the side, and is passed through a thermal calendar roll to thermally fuse the unstretched short fibers on the (B) layer side to fix the surrounding fibers to each other, and then ( A) A method for producing an automotive interior base material, in which the layer side surface is raised and then heat treated to crystallize the undrawn short fibers.