JPH0536531B2 - - Google Patents
Info
- Publication number
- JPH0536531B2 JPH0536531B2 JP59247663A JP24766384A JPH0536531B2 JP H0536531 B2 JPH0536531 B2 JP H0536531B2 JP 59247663 A JP59247663 A JP 59247663A JP 24766384 A JP24766384 A JP 24766384A JP H0536531 B2 JPH0536531 B2 JP H0536531B2
- Authority
- JP
- Japan
- Prior art keywords
- needle
- fibers
- punched
- heat
- woven fabric
- 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.)
- Expired - Fee Related
Links
- 239000000463 material Substances 0.000 claims description 31
- 239000000835 fiber Substances 0.000 claims description 22
- 239000004745 nonwoven fabric Substances 0.000 claims description 19
- 238000000034 method Methods 0.000 claims description 8
- 238000004519 manufacturing process Methods 0.000 claims description 7
- 238000002844 melting Methods 0.000 claims description 4
- 230000008018 melting Effects 0.000 claims description 4
- 238000010438 heat treatment Methods 0.000 claims description 3
- 239000000126 substance Substances 0.000 claims description 2
- 239000004952 Polyamide Substances 0.000 description 7
- 229920002647 polyamide Polymers 0.000 description 7
- 239000010410 layer Substances 0.000 description 4
- 229920000728 polyester Polymers 0.000 description 4
- 238000005299 abrasion Methods 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- -1 polypropylene Polymers 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- 239000002759 woven fabric Substances 0.000 description 2
- 229920002972 Acrylic fiber Polymers 0.000 description 1
- OAKJQQAXSVQMHS-UHFFFAOYSA-N Hydrazine Chemical compound NN OAKJQQAXSVQMHS-UHFFFAOYSA-N 0.000 description 1
- 229920002821 Modacrylic Polymers 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 229920001328 Polyvinylidene chloride Polymers 0.000 description 1
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000002313 adhesive film Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 229920006248 expandable polystyrene Polymers 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000002648 laminated material Substances 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 239000005033 polyvinylidene chloride Substances 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 238000007666 vacuum forming Methods 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Landscapes
- Laminated Bodies (AREA)
- Nonwoven Fabrics (AREA)
Description
【発明の詳細な説明】
（産業上の利用分野）
本発明は自動車の天井材、リヤパツケージ、ト
ランクルーム、ドアトリムや建物の壁材等の内装
に用いられる内装材の製造方法に関するものであ
る。DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for producing interior materials used for interiors such as automobile ceiling materials, rear passenger compartments, trunk rooms, door trims, and building wall materials.
（従来の技術及びその問題点）
従来、この種の内装材としては、シボ付ポリ塩
化ビニールシートとポリウレタンスポンジとの積
層材、繊維編織布或いはその起毛布、塩化ビニー
ルシート他各種樹脂シートへ短繊維を植毛したフ
ロツキー加工品等が使用されている。しかし、近
年自動車等の用途に於いては、軽量化、低価格
化、繊維化指向が高まり、不織布基材が多く用い
られるようになつて来た。特に天井材、トランク
ルーム、リヤパツケージ、ドアトリム等は加熱プ
レス機による成型加工が通常行なわれ、その加工
適応性の良さから不織布使用の傾向がますます高
まつている。さらに従来より比較的上級車の天井
用表装材用途に用いられて来た編織布の表面を起
毛処理することにより得られる、いわゆるベロア
調起毛布は豪華であるが、通常多くの加工工程を
要するため、安価に供給することが不可能で、こ
のベロア調起毛布の代替を不織布に求める動きが
活発となつて来た。また、フロツキー加工にみら
れる、毛足のそろつた均一な表面を有する精度感
のある成型加工可能な内装材も併せて求められる
ようになつて来た。このように背景から不織布に
於いても起毛処理することにより、ベロア調起毛
布を得ようとする試みがなされたり、不織布基材
へのフロツキー加工の試みがなされたりしている
が、毛足が不ぞろいで、均一度・精度感が不足で
あつたり、耐摩耗性に問題を生じたり、起毛工
程、フロツキー工程の付加によるコスト高等多く
の問題があつた。(Prior art and its problems) Conventionally, this type of interior material has been made of laminated materials of textured polyvinyl chloride sheets and polyurethane sponges, fiber woven fabrics or raised fabrics, vinyl chloride sheets and other various resin sheets. Flotsky processed products made of flocked fibers are used. However, in recent years, in applications such as automobiles, there has been an increasing trend toward weight reduction, cost reduction, and fiberization, and nonwoven fabric base materials have come to be used more frequently. In particular, ceiling materials, trunk rooms, rear passenger compartments, door trims, etc. are usually molded using a hot press machine, and the use of nonwoven fabrics is becoming more and more popular due to its good processing adaptability. Furthermore, so-called velour-like raised blankets, which are obtained by raising the surface of knitted and woven fabrics that have traditionally been used as ceiling covering materials for relatively high-end cars, are luxurious, but usually require many processing steps. Therefore, it is impossible to supply velor blankets at a low price, and there has been an active movement to find nonwoven fabrics as a substitute for velor upholstered blankets. In addition, there has also been a demand for interior materials that can be molded with precision and have a uniform surface with even piles, as seen in Frotzky processing. In this way, attempts have been made to obtain velour-adjusted blankets by applying napping to non-woven fabrics, and attempts have been made to apply frotsky processing to non-woven fabric base materials, but the nap There were many problems such as unevenness, lack of uniformity and precision, problems with abrasion resistance, and high cost due to the addition of a napping process and a frotting process.
（問題点を解決するための手段）
本発明は、このような現況に鑑み、摩擦に対し
て堅牢で、表面が均一な立毛状態のベロア調で、
豪華なしかも軽量で成型加工性に富む内装材を簡
単な工程で安価に製造しうる内装材の製造方法を
提供することを目的とする。(Means for Solving the Problems) In view of the current situation, the present invention provides a velour-like material that is strong against friction and has a uniform raised surface.
To provide a method for manufacturing an interior material that is luxurious, lightweight, and highly moldable at a low cost through a simple process.
本発明は熱収縮性繊維を一部混入した不織布繊
維層を素材として使用し、ニードルパンチング加
工した後、不織布基材両面に直火ガスバーナーを
直接接触させることにより、不織布の構成繊維を
収縮させ緻密化すると共に、一部溶融接着させ、
さらにこの基材を厚み方向に対し水平方向に二層
にスライスして、分割することを特徴とする。 The present invention uses a non-woven fiber layer partially mixed with heat-shrinkable fibers as a material, and after needle punching, a direct gas burner is brought into direct contact with both sides of the non-woven fabric base material, thereby shrinking the constituent fibers of the non-woven fabric. At the same time as densification, some parts are melted and bonded,
Furthermore, this base material is divided into two layers by slicing it horizontally to the thickness direction.
（実施例） 以下本発明を実施例に基づき詳しく説明する。(Example) The present invention will be explained in detail below based on examples.
予め所要の色例えばオフホワイト色に染色され
たポリエステル繊維3d×51mm70％と、同色に染
色された熱収縮性ポリエステル繊維1.5d×38mm
（ユニチカエステルtype143）30％よりなる、均一
に開繊、積層された繊維マツトを、ニードルパン
チマシーンにより、打込み深さ10mmで上下方向よ
り均等に各々250パンチ／cm2のニードルパンチ加
工を施して、目付350ｇ／m2、厚さ3.2mmの不織布
基材１を得た。 3D x 51mm 70% polyester fiber pre-dyed in the desired color, for example off-white, and 1.5D x 38mm heat-shrinkable polyester fiber dyed in the same color.
(Unitika ester type 143) 30% uniformly opened and laminated fiber mat is needle punched evenly from above and below at a depth of 10mm using a needle punch machine at 250 punches/cm 2 each. A nonwoven fabric base material 1 having a basis weight of 350 g/m 2 and a thickness of 3.2 mm was obtained.
尚上記繊維マツトに用いる化学繊維はポリエス
テルの他のポリアミド、ポリプロピレン、アクリ
ル、ポリエチレン、ポリ塩化ビニリデン、モダア
クリル等の市販繊維が使用できまた熱収縮性繊維
としてはポリエステル系の他、ポリアミド系、ア
クリル系、ポリオレフイン系等の繊維を用いるこ
とができる。 The chemical fibers used for the fiber mats mentioned above can be commercially available fibers other than polyester, such as polyamide, polypropylene, acrylic, polyethylene, polyvinylidene chloride, modacrylic, etc. Heat-shrinkable fibers include polyester, polyamide, and acrylic fibers. , polyolefin fibers, etc. can be used.
次に、この不織布基材１を第１図に示す概略工
程図に従つて直火ガスバーナー加熱溶融装置６を
有するラミネート装置に導入し、不織布の両表面
を瞬間的に加熱収縮溶融させると同時に熱融着性
ポリアミドフイルム２（ダイアミド＃3100、厚さ
30μ；ダイセル化学(株)製）を、夫々冷却ロール
３，４，５で押圧して一体にラミネートした。こ
の時の直火ガスバーナー加熱溶融装置のバーナー
温度は約950℃に調整されており、このバーナー
の炎を直接受けた不織布基材の表面温度は、瞬間
的に約300℃の高温になるため、不織布は瞬時に
して収縮をおこし密度は緻密化され、その表面層
は溶融状態となる。従つて冷却ロール３，４，５
で熱融着性ポリアミドフイルム２と圧着一体化さ
れたニードルパンチ不織布の表層界面８は充分に
溶融接着されており、容易に剥離を生じるもので
はない。このようにして得られたニードルパンチ
加工不織布−ポリアミドフイルムの三層複合体７
のトータル目付は450ｇ／m2、厚さ3.0mmであり、
その断面図を第２図に示す。ついで、この三層複
合体をＡ−Ｂ線で示す水平方向に均等にスライス
して本発明の内装材を形成した。 Next, this nonwoven fabric base material 1 is introduced into a laminating apparatus having a direct flame gas burner heating and melting device 6 according to the schematic process diagram shown in FIG. Heat-adhesive polyamide film 2 (Diamide #3100, thickness
30 μm (manufactured by Daicel Chemical Co., Ltd.) were pressed together with cooling rolls 3, 4, and 5 and laminated together. At this time, the burner temperature of the direct gas burner heating and melting device is adjusted to approximately 950℃, and the surface temperature of the nonwoven fabric base material that is directly exposed to the flame of this burner instantly becomes a high temperature of approximately 300℃. , the nonwoven fabric instantly shrinks and becomes denser, and its surface layer becomes molten. Therefore, the cooling rolls 3, 4, 5
The surface layer interface 8 of the needle-punched nonwoven fabric, which is integrally bonded with the heat-fusible polyamide film 2, is sufficiently melt-bonded and does not easily peel off. Needle punched nonwoven fabric-polyamide film three-layer composite 7 thus obtained
The total area weight is 450g/m 2 and the thickness is 3.0mm.
A sectional view thereof is shown in FIG. Next, this three-layer composite was sliced evenly in the horizontal direction indicated by line A-B to form the interior material of the present invention.
得られた内装材は、第３図に示す如くスライス
面９が均一で、立毛状態を呈し精度感に富む軽量
な不織布内装材を同時に２枚得ることが出来た。
こうして得られた内装材は、加熱収縮及び、繊維
溶融結合固着により密度は緻密化され、さらには
熱融着性フイルムにより強固に接着されているた
め耐摩擦堅牢度は非常に優れており、テーパー式
ロータリーブレツサーによる試験結果は４〜５級
とこの種の内装材と比較すると非常に優秀であつ
た。 As shown in FIG. 3, the obtained interior material had a uniform slice surface 9 and a raised state, making it possible to simultaneously obtain two lightweight nonwoven fabric interior materials with a high sense of precision.
The interior material obtained in this way has a denser density due to heat shrinkage and fiber melt bonding, and is also strongly bonded with a heat-fusible film, so it has excellent abrasion resistance and has excellent abrasion resistance. The test results using the type rotary breather were 4 to 5 grade, which was very excellent compared to this type of interior material.
試験条件 摩耗輪；CS＃
10
荷 重；500ｇ
回 数；150回
表面外観はスライスしているため非常に均一で
精度感に優れ、繊維固着剤を全く使用していない
ため、表面風合いは非常にソフトで成型加工性に
富む、特に自動車用天井表皮材やドアトリム表皮
材として好適の高級内装材となつた。尚この内装
材は熱融着性フイルムをラミネートしているた
め、成型基材例えば、発泡ポリエチレン、発泡ポ
リスチレン、フエノール含浸フエルト、ダンボー
ル等との直接成型接着加工が可能であり、特に通
気性を有しない構造となつているため、真空成型
接着加工に於いて優れた性能を示した。 Test conditions Wear ring: CS#10 Load: 500g Number of times: 150 times The surface appearance is very uniform and has a good sense of precision because it is sliced, and the surface texture is very good because no fiber fixing agent is used. It has become a high-grade interior material that is soft and has excellent moldability, making it particularly suitable for automobile ceiling skin materials and door trim skin materials. Since this interior material is laminated with a heat-adhesive film, it can be directly molded and bonded to molding substrates such as foamed polyethylene, foamed polystyrene, phenol-impregnated felt, cardboard, etc., and is particularly breathable. Because of its structure, it showed excellent performance in vacuum forming adhesive processing.
（発明の効果）
本発明によるときは、製造工程が簡単であるば
かりか、高級内装材を安価に大量生産できるとい
う効果がある。(Effects of the Invention) According to the present invention, not only the manufacturing process is simple, but also high quality interior materials can be mass-produced at low cost.
第１図は本発明の１実施例を示す内装材製造方
法を示す概略工程図、第２図は同製造方法により
得られた内装材のスライス前の概略断面図、第３
図は同第２図のＡ−Ｂ線スライス後の概略断面図
である。
１…ニードルパンチ加工上り不織布、２…熱融
着性ポリアミドフイルム、３，４，５…水冷式冷
却ロール、６…直火式ガスバーナー、７…不織布
−フイルムラミネート体、８…熱融着性ポリアミ
ドフイルム、９…繊維溶融結合部。
FIG. 1 is a schematic process diagram showing a method for manufacturing an interior material according to an embodiment of the present invention, FIG. 2 is a schematic cross-sectional view of the interior material obtained by the manufacturing method before slicing, and FIG.
The figure is a schematic cross-sectional view taken along the line A-B in FIG. 2. 1... Needle-punched nonwoven fabric, 2... Heat-fusible polyamide film, 3, 4, 5... Water-cooled cooling roll, 6... Direct-fired gas burner, 7... Non-woven fabric-film laminate, 8... Heat-fusible Polyamide film, 9...Fiber melt bonding part.
Claims (1)
性繊維を少なくとも10％以上含有する化学繊維を
主体として構成する繊維マツトを、上下方向から
ニードルパンチング加工により繊維相互を絡合せ
しめて形成したニードルパンチ加工不織布を加熱
溶融装置に導入し、該ニードルパンチ加工不織布
の両表面を直火ガスバーナーの炎で直接接触させ
ることにより、該ニードルパンチ加工不織布に含
まれる熱収縮性繊維を熱収縮させて緻密化すると
共に、該ニードルパンチ加工不織布の両表面の表
層繊維を溶融固着化した後、上記ニードルパンチ
不織布を厚み方向に対し水平な方向に二層にスラ
イスすることを特徴とする内装材の製造方法。 ２ 直火ガス溶融面に夫々フイルム状シートを圧
着ラミネートしたことを特徴とする特許請求の範
囲第１項記載の内装材の製造方法。[Scope of Claims] 1. A fiber mat mainly composed of chemical fibers containing at least 10% of heat-shrinkable fibers that cause heat shrinkage at relatively low temperatures is needle-punched from above and below to entangle the fibers with each other. The needle-punched non-woven fabric thus formed is introduced into a heating melting device, and both surfaces of the needle-punched non-woven fabric are brought into direct contact with the flame of an open gas burner, thereby reducing the heat shrinkage contained in the needle-punched non-woven fabric. The fibers are heat-shrinked to make them dense, and the surface fibers on both surfaces of the needle-punched nonwoven fabric are melted and fixed, and then the needle-punched nonwoven fabric is sliced into two layers in a direction horizontal to the thickness direction. A manufacturing method for interior materials. 2. The method for manufacturing an interior material according to claim 1, wherein a film-like sheet is pressure-bonded and laminated on each of the open flame gas melting surfaces.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP59247663A JPS61124668A (en) | 1984-11-22 | 1984-11-22 | Production of interior material |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP59247663A JPS61124668A (en) | 1984-11-22 | 1984-11-22 | Production of interior material |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS61124668A JPS61124668A (en) | 1986-06-12 |
| JPH0536531B2 true JPH0536531B2 (en) | 1993-05-31 |
Family
ID=17166813
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP59247663A Granted JPS61124668A (en) | 1984-11-22 | 1984-11-22 | Production of interior material |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS61124668A (en) |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS4954501A (en) * | 1972-09-30 | 1974-05-27 |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5414081U (en) * | 1977-06-20 | 1979-01-29 |
-
1984
- 1984-11-22 JP JP59247663A patent/JPS61124668A/en active Granted
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS4954501A (en) * | 1972-09-30 | 1974-05-27 |
Also Published As
| Publication number | Publication date |
|---|---|
| JPS61124668A (en) | 1986-06-12 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| LAPS | Cancellation because of no payment of annual fees |