JPH0321443A - Car interior material - Google Patents

Abstract

PURPOSE:To enhance the abrasion resistance by forming a web composed of a high m.p. fiber or natural fiber and a low m.p. fiber as an upper layer while forming a web composed of a high m.p. fiber reclaimed cotton or natural fiber reclaimed cotton and the low m.p. fiber or a fibrous material as a lower layer to interlace both layers by needle punching and melting the low m.p. fiber or fibrous material to integrate both web layers by pressing. CONSTITUTION:An upper layer web consisting of 60-90wt.% of a high m.p. fiber or natural fiber and 10-40wt.% of a low m.p. fiber and a lower layer web consisting of 40-80wt.% of high m.p. fiber reclaimed cotton or natural fiber reclaimed cotton and 20-60wt.% of the low m.p. fiber or an analogous shape material thereof are laminated to form a laminate wherein the wt. of the lower layer web is 1.5 times or more that of the upper layer web on a wt. basis and this laminate is subjected to needle punching on the surface side thereof to interlace both webs with each other and the low m.p. fiber is melted to integrate and mold both webs by pressing. As the high m.p. fiber, a polyester or polyamide fiber is used and, as the low m.p. fiber, a fiber composed of polypropylene, polyethylene or an ethylene/propylene copolymer can be used. By this method, surface abrasion resistance can be enhanced by compounding and using the low m.p. fiber even in a surface layer.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to automobile interior materials such as trunk interior materials made of composite layers of fiber webs. <Prior art> As an automobile interior material made of a fiber web composite layer, (A
) A web made from polyester cotton and shaped by the carding method is double-drilled to form the skin layer, while a web made from inexpensive cotton is double-drilled to form the lower layer, and both are laminated and double-drilled from the surface side. There is one that is made into one piece, then coated with an emulsion binder from the back side and dried. (B) Another method is to form a web using a card method using polyester cotton as a raw material and then double-drilling it, then layer a reticulated thermosensitive fiber on the back side and double-drill it from the front side to form a skin layer. There is a method in which a web made of cotton is nidried, coated with the binder, etc., dried, and the back side of the skin layer is laminated, heated in a heating furnace, and integrated with a press between rolls.

(C) As an improved product of the above method, JP-A-64-14359
No. 64-22647. This allows the upper layer fiber amount to be less than 200g/♂ by laminating the upper layer web and the lower layer web and integrating them by needle punching from the upper layer side, and the lower layer contains low melting point fibers and thermoplastics if necessary. There is also one that imparts moldability by coating and impregnating an emulsion and melting the low melting point fiber and thermoplastic emulsion when heated.

(D) There is one shown in Utility Model Application Publication No. 63-162892. The outer skin is a fiber layer mainly composed of synthetic fibers containing 3 to 50% low melting point fibers, and the lower layer is a felt layer that is made of a mixture of natural fibers and synthetic fibers and is larger than the above fiber layer. Both are polymerized and punched from the skin fiber side to form the skin fiber structure IJj containing low melting point fibers.
．． It is made by transferring some of the fibers to the lower felt side and heating the above polymer to melt and fuse the low melting point fibers. <Problems to be solved by the invention> Conventional automobile interior materials (A) and (B) have complicated manufacturing processes, and each layer requires at least 200 g/r to make a nonwoven fabric by needle punching.
It requires a cotton amount of n', which poses problems in terms of productivity and cost. (C) has improved productivity, but the surface abrasion strength is lower than that of (A) and (B), which is problematic. (D) has no problems in surface abrasion strength, but has almost no formability and is limited to flat objects. Means for Solving the Problems> In order to solve the above problems, an upper layer web consisting of 60 to 90% by weight of high melting point fibers and/or natural fibers and 10 to 40% by weight of low melting point fibers and high melting point fibers or/and waste cotton wool. and 40 to 80% by weight of natural fiber recycled cotton and 20 to 60% by weight of low melting point fibers and/or fiber-like materials, with a wire web as the lower layer, and the two layers are intertwined by needle punching, and the low melting point fibers and/or fiber-like materials are melted. By pressing, we were able to produce interior materials with improved surface abrasion strength with high productivity.

Typical high melting point fibers include polyester and polyamide. Polypropylene, polyethylene, ethylene/propylene copolymer fiber, etc. can be used as the low melting point fiber, and the blending ratio of the low melting point fiber in the surface layer is 1.
If it is less than 0% by weight, there is little effect on improving the abrasion strength of the surface. If it exceeds <40% by weight, molten matter will partially appear on the surface, resulting in an unfavorable appearance. If the proportion of low melting point fibers in the lower layer is less than 20% by weight, the rigidity as an interior material will be insufficient, and if it is more than 60% by weight, there will be little improvement in rigidity and the cost will increase, which is not preferable.

In addition to fibers, the low-melting point fibers to be blended into the lower layer web may be those having a similar shape, i.e. reticular fibers, which have been processed through a rewinding machine, uniaxially stretched films that have been cut to a predetermined length and then run through a rewinding machine or a crusher, or multifilaments, which have been cut. You can use fiber-like materials such as Effects> The low melting point fibers and/or fiber-like materials in the raw materials are melted in a heat furnace, and other fibers are welded in a press to impart rigidity and formability.

The upper layer also has the effect of imparting wear strength. The 21-drilling process entangles and integrates the upper and lower layer fibers.

Example 1> Polyester waste cotton 60% by weight, 10 denier (de
) 40% by weight of polypropylene fibers were blended through a blender, opened through a cylinder opener, and the cotton was stacked on a conveyor to produce a 70og/m web, while 15% recycled polyester stock solution colored cotton 45% was mixed from a direction perpendicular to the flow. % polyester white cotton 25% lo
30% by weight of recycled polypropylene cotton is mixed, passed through a feeder mixer and cylinder opener, carded with a card machine, folded and laminated in an amount of 20og/m on the lower layer using a cross layer, and then passed through a 21 dollar loom from the upper layer surface.
0 times / crri' 21 times to integrate the upper and lower layers, then grasp both ends and 200'
The polypropylene fibers were melted by passing the hot air of C through a suction, and the fiber contacts were welded through a press roll at the exit of the heating furnace, and then the unheated air was forced to pass through with a suction to cool it, and then punched into the shape of a trunk floor. The surface abrasion strength of the product whose outer periphery was overlocked using a sewing machine was grade 3.5 as measured by the following test method. The one that did not use low melting point fibers in the upper layer was grade 2.5. Further, the results of a thermal cycle test of this material under the conditions shown below showed that there was almost no change in shape.

The surface abrasion strength was measured using a Taber abrasion tester using a worn wheel H-38.
In the test, the surface condition after a load of Ikg and 1000 rotations is evaluated in five grades, with grade 5 being the best and grade 1 being the worst.

Thermal cycle test is 80'C 4 hours room temperature 1 hour -4
This is a test in which changes in shape are checked by performing 4 cycles of 0'02 hours.

<Example 2> A laminated web having the same structure as Example 1 except that the lower layer web was 500 g/♂ was cut after the needling process, and the cut web was heated for 60 seconds with upper and lower heating plates at 200'C. Trunk side parts were manufactured by melting polypropylene fibers and pressing between upper and lower dies. The surface abrasion strength of this product was grade 3.5, and there was almost no change in shape in the thermal cycle test.

Example 3 1 manufactured from polyester film scraps as upper M fibers
5de recycled polyester black stock solution 90% by weight of colored cotton and 10% by weight of polypropylene uncolored cotton, 200g/mL
For the lower layer, 350 parts by weight of polyester recycled cotton and 150 parts by weight of recycled knitted fibers from polypropylene miscellaneous recycled chips passed through a recycling machine were mixed and used, and laminated, heated and press-molded in the same manner as in Example 2. This was done to create a trunk side part. The surface abrasion strength of this product is 3R. The thermal cycle test showed almost no change in shape and was satisfactory.

<Example 4> As the upper WI fiber, 60% by weight of 15de polyester blue dyed cotton produced from polyester film waste and 40% by weight of polypropylene non-colored cotton were blended, and the lower layer was 40% by weight of polyester waste cotton, In Example 2, a 20 micron uniaxially stretched film was made from polypropylene miscellaneous recycled chips as a raw material, cut into 4 cm pieces, and made into a fibrous material using a curling machine.60% by weight was used to make a 500 g/m web. Laminating, heating,
It was molded into trunk rear wall material. The surface abrasion strength of this product was 4.5 grade, and there was almost no change in shape in the thermal cycle test.

Sharp Example 5 The heated web of Example 2 was set on a mold with a number of suction holes in the lower mold, and then press-formed in the upper mold, and after opening the upper mold, outside air was forcibly penetrated by suction. By doing this, the molded product was cooled and trunk side material was obtained. The surface abrasion strength of this product was determined by a 3.5 class thermal cycle test, with almost no change in shape.

<Example 6> 40% by weight of cotton waste. 10de high density polyethylene 6
15 on the bottom layer of 500g/rri' using 0wt%
Trunk mats and trunk side materials were manufactured from a web consisting of 200 g/n {of scraps using a blend of 90% by weight of da polyester stock solution colored fibers and 10% by weight of high-density polyethylene fibers by the methods of Examples 1, 2, and 3. .

A product with good surface abrasion strength and shape stability was obtained through thermal cycle tests.

Effects of the Invention In the present invention, the abrasion strength of the surface could be improved by blending and using low melting point fibers in the surface layer as well.

In particular, as a result of devising ways to use inexpensive materials for the high-melting point fibers on the surface and the low-melting point fibers and/or fiber-like materials in the lower layer, we were able to significantly reduce the cost of the product compared to conventional products.

Claims (2)

[Claims] (1) High melting point fiber or/and natural fiber 60-90% by weight
, an upper layer web consisting of 10 to 40% by weight of low melting point fibers, and 40 to 8% by weight of high melting point fibers or/and natural fibers.
0% by weight low melting point fiber or/and its similar shape 20-6
A web consisting of 0% by weight is used as the lower layer, and the lower layer web is at least 1.5 times as heavy as the upper layer web. Both layers are intertwined by needle punching from the surface side of the laminate, and the low melting point fibers are melted and integrated by pressing, if necessary. Molded automotive interior material (2) An automobile interior material according to claim 1, characterized in that the high melting point fiber is recycled polyester solution colored cotton.