JPH0255131A - Molding sheet - Google Patents
Molding sheetInfo
- Publication number
- JPH0255131A JPH0255131A JP20659988A JP20659988A JPH0255131A JP H0255131 A JPH0255131 A JP H0255131A JP 20659988 A JP20659988 A JP 20659988A JP 20659988 A JP20659988 A JP 20659988A JP H0255131 A JPH0255131 A JP H0255131A
- Authority
- JP
- Japan
- Prior art keywords
- fiber
- nonwoven fabric
- layer
- resin
- denier
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000000465 moulding Methods 0.000 title claims abstract description 5
- 239000000835 fiber Substances 0.000 claims abstract description 36
- 239000010410 layer Substances 0.000 claims abstract description 29
- 229920005989 resin Polymers 0.000 claims abstract description 25
- 239000011347 resin Substances 0.000 claims abstract description 25
- 239000004745 nonwoven fabric Substances 0.000 claims abstract description 17
- 229920000728 polyester Polymers 0.000 claims abstract description 9
- 239000002344 surface layer Substances 0.000 claims abstract description 7
- 229920006379 extruded polypropylene Polymers 0.000 claims abstract description 3
- 229920002994 synthetic fiber Polymers 0.000 claims description 2
- 239000012209 synthetic fiber Substances 0.000 claims description 2
- 230000008595 infiltration Effects 0.000 claims 1
- 238000001764 infiltration Methods 0.000 claims 1
- 239000003063 flame retardant Substances 0.000 abstract description 7
- 238000002485 combustion reaction Methods 0.000 abstract description 6
- 239000011248 coating agent Substances 0.000 abstract description 5
- 238000000576 coating method Methods 0.000 abstract description 5
- 238000005299 abrasion Methods 0.000 abstract description 4
- 229920003002 synthetic resin Polymers 0.000 abstract description 4
- 239000000057 synthetic resin Substances 0.000 abstract description 4
- 238000002156 mixing Methods 0.000 abstract description 3
- 238000004080 punching Methods 0.000 abstract description 2
- 239000000203 mixture Substances 0.000 abstract 1
- 239000004743 Polypropylene Substances 0.000 description 13
- -1 polypropylene Polymers 0.000 description 13
- 229920001155 polypropylene Polymers 0.000 description 13
- 239000000463 material Substances 0.000 description 9
- 239000011162 core material Substances 0.000 description 7
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 5
- 238000001125 extrusion Methods 0.000 description 3
- 229920000297 Rayon Polymers 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 239000002964 rayon Substances 0.000 description 2
- 230000002542 deteriorative effect Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 239000004088 foaming agent Substances 0.000 description 1
- 239000012943 hotmelt Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000012778 molding material Substances 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 1
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000004834 spray adhesive Substances 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
Landscapes
- Laminated Bodies (AREA)
Abstract
Description
【発明の詳細な説明】
（産業上の利用分野）
本発明は自ｖＩ車内装用成形シートの改良に関するもの
であり、芯材とする発泡又は非発泡の熱可塑性樹脂シー
トとのラミネートが容易であり、深絞り成形ができる安
価な内装成形品を得るためになされたものである。Detailed Description of the Invention (Field of Industrial Application) The present invention relates to an improvement in a molded sheet for the interior of a private vehicle, which can be easily laminated with a foamed or non-foamed thermoplastic resin sheet as a core material. This was done in order to obtain an inexpensive interior molded product that can be deep drawn.
（従来の技術）
従来、自動車用内装用成形材としては、表面の外観上、
天井以外のリヤーパッケージ、トランク等の内装部材は
表皮材として６デニール以上のポリエステル、ポリプロ
ピレン等の合成繊維より形成したニードルパンチ不織布
に′Ｒ燃性合成樹脂を片面にコーティングしたもの、或
は細デニールの繊維（６デニール以下）を用いた不織布
にホ／［・メルトフィルムをラミネートしたものが見ら
れる。(Prior art) Conventionally, molding materials for automobile interiors have been
For interior parts such as rear packages and trunks other than the ceiling, the skin material is needle-punched nonwoven fabric made of synthetic fibers such as polyester or polypropylene of 6 denier or more, coated on one side with 'R' flammable synthetic resin, or fine denier. Nonwoven fabrics made of fibers (6 denier or less) are laminated with a melt film.
（発明が解決しようとする課題）
しかるに前者は芯材とするレジンフェルト、樹脂シート
、発泡シートとの接着に際しては新たにラミネートする
層間に接着剤を散布し一体に接着を行わねばならず、手
数を要する上高価になるという課題がある。また後者は
、ｆｌ燃性、表面耐摩耗性付与の為、合成樹脂で片面を
コーティングする必要があり、コスト高となる上に、ポ
リプロピレン樹脂を芯材として使用した時は所定の剥離
強度が得られないという課題がある。従ってポリプロピ
レン樹脂芯材とのラミネートは溶融押し出しと同時に不
織布表皮材とラミネートし、ポリプロピレン樹脂を不織
布繊維間隙に充填させ物理的に絡合させるしかなく、６
デニール以下の細デニルの繊維を用いる天井材で実用化
されている。しかるに６デニール以上の大デニールの繊
維を表皮材として要求される部品については繊維充填密
度を上げることは困難であり、ポリプロピレン樹脂が表
面にまで滲み出し、外観上好ましくなく、製品化できな
いという欠点がある。(Problem to be Solved by the Invention) However, in the case of the former, when adhering resin felt, resin sheet, or foam sheet as a core material, it is necessary to spray adhesive between the newly laminated layers and bond them together, which is time-consuming. The problem is that it requires a lot of time and is expensive. In addition, the latter requires coating one side with synthetic resin in order to provide fl flammability and surface abrasion resistance, which increases the cost, and when polypropylene resin is used as the core material, it is not possible to achieve the specified peel strength. The problem is that it cannot be done. Therefore, the only way to laminate with a polypropylene resin core material is to melt-extrude it and simultaneously laminate it with a nonwoven skin material, fill the gaps between the nonwoven fibers with the polypropylene resin, and physically entangle them.
It has been put into practical use as a ceiling material using fine denier fibers. However, it is difficult to increase the fiber packing density for parts that require large denier fibers of 6 deniers or more as the skin material, and the problem is that the polypropylene resin oozes out to the surface, which is unfavorable in appearance and cannot be commercialized. be.
（課題を解決する為の手段）
本発明は上記課題を解決する為、芯材とするポリプロピ
レン樹脂フィルム押出し成形時にラミネートする不織布
表皮材として、現状の製品外観、重量を維持し、コスト
を高めることなく、難燃樹脂加工、ホットメルト樹脂加
工を省力化し、大巾なコストダウンを実現したものであ
る。(Means for Solving the Problems) In order to solve the above problems, the present invention provides a nonwoven skin material to be laminated during extrusion molding of a polypropylene resin film used as a core material, while maintaining the current product appearance and weight and increasing costs. This technology saves labor in flame-retardant resin processing and hot-melt resin processing, resulting in significant cost reductions.
即ち表皮材を構成する基材不織布を２層構造とし表面側
は６デニール以上の太デニール中心の繊維構成となし、
裏面のラミネート面は燃焼炭化繊維を混入させた６デニ
ール以下の細デニール繊維で構成することにより繊維密
度を高めると共に裏面層側よりニードルパンチ加工によ
り一体となし、該裏面層側表面より２−区の深さで溶融
押出しポリプロピレン樹脂の浸透によるフィルム層を形
成することによって、裏面に芯材とする合成樹脂のコー
ティング又は貼合わせを不要とした成形用シートを提供
するものである。In other words, the base nonwoven fabric constituting the skin material has a two-layer structure, and the surface side has a fiber structure mainly consisting of thick deniers of 6 deniers or more,
The back laminate surface is made of fine denier fibers of 6 deniers or less mixed with combustion carbonized fibers to increase the fiber density, and is made into one piece by needle punching from the back layer side. By forming a film layer by infiltrating the melt-extruded polypropylene resin at a depth of 100 mL, it is possible to provide a moldable sheet that does not require coating or lamination of a synthetic resin as a core material on the back surface.
（作用）
本発明は表裏二層の繊維層より構成し、裏面層側に１〜
１０重量％の燃焼炭化繊維を混在せしめたことにより、
不織布の燃焼収縮をなくし、安定難燃状態を維持するこ
とができる。従って難燃性樹脂のコーティングが不要と
なる。また裏面層の繊維間隙に充填されたポリプロピレ
ン樹脂の固着により表面層の耐摩耗性が向上する。また
裏面層側の繊維密度を高めたから溶融プロピレン樹脂が
密度の低い表面層に浸透して表面に滲み出し外観を悪化
させることもない。(Function) The present invention is composed of two fiber layers, the front and back, and the back layer has 1 to 2 fiber layers.
By mixing 10% by weight of combustion carbonized fiber,
It is possible to eliminate combustion shrinkage of the nonwoven fabric and maintain a stable flame retardant state. Therefore, coating with flame retardant resin becomes unnecessary. Furthermore, the abrasion resistance of the surface layer is improved due to the adhesion of the polypropylene resin filled in the fiber gaps of the back layer. Furthermore, since the fiber density on the back layer side is increased, the molten propylene resin will not penetrate into the low density surface layer and ooze out onto the surface, thereby deteriorating the appearance.
（実施例） 以下本発明の１実施例を図面に従って詳細に説明する。(Example) An embodiment of the present invention will be described in detail below with reference to the drawings.
第１図は本発明に用いる基材不繊布概略構成断面図であ
り、（１）は表面層であり第１のカード機とクロスラッ
パーにより形成された６デニール×５１胴の原着ポリエ
ステル繊維９５重量％と３デニールＸ５１ｍｍの後染め
レーヨン繊維５重量％との混合繊維よりなる目付１００
ｇ／＋１？のクロスウェブであり、（２）は裏面層であ
り第２のカード機とクロスランパーにより形成した３デ
ニール×５１１ＩＩｆｆｌの原着ポリエステル繊維９５
重量％と３デニールＸ５１ｍｍの後染めレーヨン繊維５
重量％との混合繊維よりなる目付５０ｇ／ ｒｒｒのク
ロスウェブとの積層体よりなり、主として裏面層側より
４００〜５００Ｐ／２５．４ｍｊのニードルパンチ加工
（３）が施されて一体に交絡させた目付１５０ｇ／ ｒ
ｄ、厚さ１ 、３ ｍｍの基材不織布（４）を得る。第
２図は本発明の実施の１例を示す成形用シートの概略構
成断面図であり、上記基材不織布（４）の裏面層側（２
）の表面に押し出し成形機により押し出された溶融ポリ
プロピレン樹脂のシートがラミネートされ、該ポリプロ
ピレン樹脂のフィルム層（５）は繊維間隙に浸透し、基
材不織布の表面より深さ％〜Ａの範囲で且つ、裏面層内
で完全に止まり、表面層側への滲み出しは全く発生せず
、層間の剥離強度も、材料破壊状態となり強固に一体化
した成形用シートを構成する。FIG. 1 is a schematic cross-sectional view of the nonwoven base fabric used in the present invention, and (1) is a surface layer of 6 denier x 51 body spun-dyed polyester fibers 95 formed by the first card machine and cross wrapper. % by weight and 5% by weight of piece-dyed rayon fiber of 3 denier x 51 mm, fabric weight 100
g/+1? (2) is the back layer, which is a 3 denier x 511 Iffl spun-dyed polyester fiber 95 formed by a second card machine and a cross lumper.
Weight% and 3 denier x 51mm piece-dyed rayon fiber 5
It is made of a laminate with a cross web with a basis weight of 50 g/rrr made of mixed fibers with % by weight, and is needle punched (3) of 400 to 500 P/25.4 mj mainly from the back layer side to be intertwined together. Weight 150g/r
d, a base nonwoven fabric (4) with a thickness of 1.3 mm is obtained. FIG. 2 is a schematic cross-sectional view of a molding sheet showing an example of the implementation of the present invention, and shows the back layer side (2) of the base nonwoven fabric (4).
) is laminated with a sheet of molten polypropylene resin extruded by an extrusion molding machine, and the film layer (5) of the polypropylene resin penetrates into the fiber gaps to a depth of % to A from the surface of the base nonwoven fabric. In addition, it completely stops within the back layer, no oozing to the surface layer side occurs, and the peel strength between the layers is also in a state of material failure, forming a strongly integrated molding sheet.
向上記実施例に施で基材不織布の表、裏面層を構成する
繊維に主にポリエステル繊維を用いたのは嵩高性、弾撥
性にすぐれ、比較的軟化溶融点が高く、自然性がなく、
難燃性材料としてすぐれているからであるが、このよう
な性質を有するものであれば使用しても差し支えなくポ
リエステルに限定されるものではない。又ラミネートさ
れるポリプロピレン樹脂は発泡剤を含む発泡性樹脂も使
用できる。In the above examples, polyester fibers were mainly used as the fibers constituting the front and back layers of the base nonwoven fabric, which has excellent bulk and elasticity, has a relatively high softening melting point, and has no natural properties. ,
This is because it is an excellent flame-retardant material, but it is not limited to polyester, and any material having such properties may be used. Further, as the polypropylene resin to be laminated, a foamable resin containing a foaming agent can also be used.
（発明の効果）
本発明は上記の如く基材不織布を粗、密二層構造とする
ことにより、従来品と同一目付で、ポリプロピレン樹脂
の溶融押し出し成形ラミネート加工が可能となり、細デ
ニールの密度を高めた裏面層の範囲即ち基材不織布の％
〜２の深さに上記ポリプロピレン樹脂を浸透固着させる
ことによって、表裏面の耐摩耗性が向上させることが出
来る。また裏面層に燃焼炭化繊維を混在させることによ
り、基材不織布の燃焼収縮を防止し安定した難燃性を付
与することができ難燃性樹脂のコーティングが不要とな
り、また芯材としてのポリプロピレン樹脂シートを別個
に貼り合わせる必要もなくなる等の工数が大巾に低域し
、経済的である等の優れた効果を有する発明である。(Effects of the Invention) As described above, the present invention makes it possible to perform melt extrusion lamination processing of polypropylene resin with the same basis weight as conventional products by making the base nonwoven fabric have a coarse and dense two-layer structure, and the density of fine denier can be reduced. Increased back layer range i.e. % of base non-woven fabric
By penetrating and fixing the polypropylene resin to a depth of ~2, the abrasion resistance of the front and back surfaces can be improved. In addition, by mixing combustion carbonized fibers in the back layer, it is possible to prevent combustion shrinkage of the base nonwoven fabric and provide stable flame retardancy, eliminating the need for coating with flame retardant resin, and polypropylene resin as a core material. This invention has excellent effects such as being economical and reducing the number of man-hours by a large margin, such as eliminating the need to bond sheets together separately.
第１図は本発明に用いる基材不織布の概略構成断面図、
第２図は同実施の１例を示す概略構成断面図である。FIG. 1 is a schematic cross-sectional view of the base nonwoven fabric used in the present invention,
FIG. 2 is a schematic cross-sectional view showing an example of the same implementation.
Claims (1)
ニール以下の合成繊維ウェブ、表面層が少なくとも６デ
ニール以上のポリエステル繊維又は該ポリエステル繊維
と他の繊維との混合繊維よりなるウェブとの積層体で、
主に裏面層側よりニードルパンチ加工が施された一体化
基材不織布を形成し、上記基材不織布の裏面層側表面よ
り、深さ略１／２〜１／３程度に溶融押出しポリプロピ
レン樹脂のフィルム層を浸透形成させたことを特徴とす
る成形用シート。A synthetic fiber web with a back layer of 6 denier or less containing 1 to 10% by weight of burnt carbonized fibers, a web with a surface layer consisting of polyester fibers of at least 6 denier or a mixed fiber of the polyester fibers and other fibers. With a laminate,
An integrated base nonwoven fabric is formed which is needle-punched mainly from the back layer side, and melt-extruded polypropylene resin is applied to a depth of about 1/2 to 1/3 from the back layer side surface of the base nonwoven fabric. A molding sheet characterized by having a film layer formed by infiltration.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP20659988A JPH0255131A (en) | 1988-08-19 | 1988-08-19 | Molding sheet |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP20659988A JPH0255131A (en) | 1988-08-19 | 1988-08-19 | Molding sheet |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH0255131A true JPH0255131A (en) | 1990-02-23 |
Family
ID=16526061
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP20659988A Pending JPH0255131A (en) | 1988-08-19 | 1988-08-19 | Molding sheet |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH0255131A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2000013894A1 (en) * | 1998-09-03 | 2000-03-16 | Stefan Kraft | Anti-abrasion device mainly for protecting edges against abrasion |
| US6042221A (en) * | 1995-06-30 | 2000-03-28 | Canon Kabushiki Kaisha | Ink-jet recording head and ink-jet recording apparatus |
-
1988
- 1988-08-19 JP JP20659988A patent/JPH0255131A/en active Pending
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6042221A (en) * | 1995-06-30 | 2000-03-28 | Canon Kabushiki Kaisha | Ink-jet recording head and ink-jet recording apparatus |
| WO2000013894A1 (en) * | 1998-09-03 | 2000-03-16 | Stefan Kraft | Anti-abrasion device mainly for protecting edges against abrasion |
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