JPH0611530B2 - Skin material for interior materials - Google Patents

Description

TECHNICAL FIELD The present invention relates to a skin material for interior materials. More specifically, it relates to a skin material for interior materials used as a skin material for automobile interior materials such as automobile ceiling materials and sun visors.

[Prior Art] Conventionally, a non-woven fabric or a woven fabric having a soft texture is used as a skin material for an automobile interior material such as an automobile ceiling material and a sun visor, and the skin material and resin felt, cardboard, foamed plastic, etc. For example, a material that is bonded to a base material is used.

Nonwoven fabrics used as automobile interior materials include those obtained by impregnating one side of a needle-punched non-woven fabric with a binder, but the non-woven fabric itself has excellent breathability, and is used as a ceiling material for automobiles. When the humidity in the interior is high, water vapor easily permeates through the nonwoven fabric, and as a result of the condensation of water vapor on the back surface of the ceiling material, the nonwoven fabric is moistened and air remains in the space between the roof of the automobile and the ceiling material. Since it is easy, mold may be generated on the back surface of the ceiling material, and water droplets generated by dew condensation may ooze on the ceiling material surface with dirt.

Further, when producing an interior material made by adhering the skin material and the base material, there is a case where a welder process is performed,
In order to perform such a welding process, it was necessary to interpose a welder film or the like.

Furthermore, when the non-woven fabric is used as the ceiling material or the skin material of the ceiling material as described above, the non-woven fabric has air permeability,
Moreover, since it has a large void inside, dust may enter the inside and become dirty.

Therefore, in order to solve the above problems,
Various studies have been carried out, and a non-breathable film is placed between the nonwoven fabric and the substrate on the back surface of the ceiling material to prevent condensation of water vapor, and dust is retained inside the nonwoven fabric. In order to prevent this, it has been proposed to increase the amount of binder impregnated in the non-woven fabric.

[Problems to be Solved by the Invention] However, when a non-breathable film is interposed between the non-woven fabric and the substrate as described above, the production process becomes complicated, leading to a decrease in mass productivity, Further, when the amount of the binder impregnated into the nonwoven fabric is increased, the texture becomes hard and the weight of the nonwoven fabric is increased, and further, when the nonwoven fabric is molded into a predetermined shape, such moldability becomes extremely poor.

Therefore, in view of the above problems, the present inventor has been diligently researched to obtain a skin material for an interior material, which has no air permeability and is excellent in stain resistance, as a result of which the fibrous base material can be solved. When an impregnated layer of a synthetic resin emulsion containing a micro hollow body is provided on one side of and the material in which the impregnated layer is densified is used as a skin material, the occurrence of mold and the air permeability as described above are eliminated. Moreover, they have found a completely new skin material for interior materials, which is not easily soiled, has an excellent texture, and has an extremely simple manufacturing process, and has completed the present invention.

[Means for Solving Problems] That is, the present invention provides an interior material in which an impregnated layer of a synthetic resin emulsion containing a micro hollow body is provided on one surface of a fibrous base material, and the impregnated layer is densified. For skin materials for use.

[Operations and Examples] The skin material for an interior material of the present invention is provided with an impregnated layer of a synthetic resin emulsion containing micro hollow bodies on one surface of a fibrous base material,
And it is obtained by densifying the impregnated layer.

As the fibrous base material used in the present invention, a material having a flexible fiber itself, such as a non-woven fabric, a felt or a fibrous web, is used. The thickness of these materials cannot be unconditionally determined because it depends on the strength and thickness of the intended skin material and the type of material used, but it is usually 0.5 to 4.0 mm, especially 1.0 to 3.0 mm. Is used. Among the above fibrous base materials, a needle-punched non-woven fabric whose thickness can be easily adjusted according to the purpose and which is excellent in moldability and strength can be preferably used.

The micro hollow body contained in the synthetic resin emulsion used in the present invention refers to a hollow body whose outer wall is made of a thermoplastic resin and whose inside is made of a heat-expandable substance. In the present invention, the average particle diameter of the above composition is 5 It is preferable to use microspheres having a size of up to 50 μm that have already been subjected to heat treatment during the manufacturing process of the skin material to expand the thermally expandable substance inside the microspheres.

As a specific example of the micro hollow body, the outer wall is a vinylidene chloride copolymer, the inside is a low boiling point hydrocarbon such as isobutane Microsphere F-30 (Matsumoto Yushi-Seiyaku Co., Ltd., before heat treatment) Average particle size of microspheres: 10 to 20μ
m) and the like. It is preferable that the mixing ratio of the micro hollow body is 5 to 50% by weight, especially 10 to 30% by weight based on the total solid content of the emulsion. The blending ratio is 5
When it is less than 50% by weight, air permeability is present, and when it exceeds 50% by weight, the durability of the skin material decreases.

Examples of the synthetic resin emulsion include vinylidene chloride-based, ethylene-vinyl acetate-based, ethylene-vinyl chloride-based, acryl-styrene-based, acryl-vinyl chloride-based, and polyester-based synthetic resin emulsions. Synthetic resin emulsion containing 20 to 100% by weight of synthetic resin having a welder property such as vinyl chloride, acrylic-vinyl chloride, polyester, etc., especially 40 to 70% by weight is a film having a welder property. Since the welder processing can be performed without interposing, it can be used particularly preferably. If necessary, the synthetic resin emulsion contains a thickener, a flame retardant, a dispersant, a pH adjuster, a wetting agent, etc., in an amount of 5 to 35% by weight, particularly 10 to 30% by weight, based on the total solid content in the synthetic resin emulsion. You may add in the range of%.

Thickeners that can be added to the synthetic resin emulsion used in the present invention include cellulose-based, alginic acid-based, or polyacrylic acid-based compounds, and flame retardants include phosphoric acid-based, oxalic-based, chlorine-based compounds, and trioxide. Dispersants such as antimony and ammonium hydroxide are pigments, inorganic compounds such as aluminum hydroxide, pH adjusters are ammonia water, acetic acid, oxalic acid, etc., and wetting agents are nonionic or anionic interfaces. Activators, ethylene glycol, etc. may be mentioned, but these components may be used alone, and various components may be mixed as long as they can be added to the total solid content in the synthetic resin emulsion. You may use it.

The ratio of the weight of the fibrous base material (hereinafter referred to as F) to the total solid content of the synthetic resin emulsion (hereinafter referred to as B) (hereinafter referred to as F / B) is 60/40 to 95/5. ,Preferably
The synthetic resin emulsion is attached to the fibrous base material by adjusting it to 70/30 to 90/10. Such F / B is 60/4
If it is smaller than 0, the texture of the obtained skin material is hard,
If the moldability is poor and if it is more than 95/5, the durability such as abrasion resistance and strength elongation is deteriorated, and the desired non-permeability cannot be obtained.

After providing an impregnating layer of a synthetic resin emulsion containing micro hollow bodies on one side of a fibrous base material, the impregnating layer is densified. Usually, a calender or the like is used to perform densification. The impregnated surface of the emulsion is pressed or heated and pressed. The densification is performed to such an extent that the normally obtained skin material does not exhibit air permeability.

The thickness of the impregnated layer densified as described above is about 10 to 50%, especially 25 to 30% of the total thickness of the obtained skin material.
It is preferably about the same.

This is because when the thickness of the impregnated layer is less than 10%, the air permeability cannot be lost, while when it exceeds 50%, the texture becomes hard and the resin is likely to seep out, which is preferable in terms of appearance. Because there is no.

Thus, although the skin material is formed, a resin print may be applied to the surface of the skin material opposite to the synthetic resin emulsion impregnated layer in order to enhance abrasion resistance and impart a decorative effect. Examples of this resin print include acrylic resin and polyester resin, and the amount of adhesion is 5 to 5.
It is used after being adjusted to 15 g / m ² .

In addition, it is desirable that the obtained skin material has a thickness of 3.0 mm or less, a basis weight of 300 m / m or less, and a basis weight of 300 g / m ² or less from the viewpoint of workability such as weight reduction and molding. The thickness is 1.0mm or more and the basis weight is 120g from the viewpoints of properties and strength.
/ M ² or more is preferable.

Next, the skin material of the present invention will be described in more detail based on examples, but the present invention is not limited to these examples.

Example 1 Polyester fiber (fineness: 3 denier, fiber length: 64 mm)
After forming a web consisting of, a punched felt non-woven fabric (weight per unit area: 184 g / m ² , thickness:
3 mm).

The resulting non-woven fabric contains isobutane and the outer shell is made of vinylidene chloride copolymer Microsphere Microsphere F-
One side of the non-woven fabric was impregnated with an acrylic-vinyl chloride resin emulsion containing 30 (Matsumoto Yushi-Seiyaku Co., Ltd.) in a solid content of 15% by weight by a bubble impregnation method.

After that, it was dried with a dryer at 150 ° C., and at the same time, the microspheres were foamed to form microhollow bodies, and then calendered.

The obtained skin material has a basis weight of 230 g / m ² , F / B of 80/20,
The thickness of the impregnated layer was about 1/3 of the total thickness of 2.0 mm.

When the air permeability of this skin material was measured, it was 0 cc / cm ² / sec.
It showed that there was no breathability at all.

In addition, when a ceiling material was produced using this skin material, the obtained ceiling material had a soft texture and cushioning property, dirt was less likely to adhere to it compared to the conventional one, and dew condensation including dirt was also present. There were no problems such as water seeping out.

In addition, when a sun visor was manufactured using this skin material, it showed good weldability and was easy to process.

The air permeability was measured according to the following method.

(Measurement of Air Permeability) JIS L-1079 5.20 is applied mutatis mutandis, after using a Flangedle type tester and attaching a test piece to one end of the cylinder, the tilt type barometer shows the pressure of 1.27 cm of water column by the adjusting resistor. The amount of air passing through the test piece (cc / cm ^{2) according} to the table attached to the tester based on the pressure indicated by the vertical barometer at that time and the type of air holes used. / sec)
Ask for. The measurement was performed 5 times and the average value is shown.

Comparative Example 1 The needle punched non-woven fabric obtained in Example 1 was mixed with acrylic.
-Vinyl chloride emulsion impregnated with 46 g / m ² (solid content).

Then, it was dried at 150 ° C. with a dryer and then calendered.

The obtained skin material has a basis weight of 230 g / m ² , F / B of 80/20,
The thickness of the impregnated layer was about 1/3 of the total thickness of 2.0 mm.

When the air permeability of this skin material was measured in the same manner as in Example 1, it showed air permeability at 100 cc / cm ² / sec, and when it was integrally molded with resin felt and used as a ceiling material, dust and dirt easily adhered. Also, a phenomenon such as dew condensation of water oozing on the surface occurred.

In addition, a film having a welder property must be interposed in order to manufacture this skin material on a sun visor, and its processing is complicated.

[Effects of the Invention] The skin material of the present invention has a dense synthetic resin emulsion impregnated layer containing minute hollow bodies and exhibits almost no air permeability, and therefore is used in combination with a base material such as resin felt. However, there is no condensation on the back side,
Therefore, water generated by dew condensation does not seep to the surface with dirt. Further, the skin material of the present invention densified with the synthetic resin emulsion has its internal voids closed, so that dust does not enter the skin material. Furthermore, the skin material of the present invention is lightweight and has a soft texture, and is excellent in moldability.

Moreover, if a synthetic resin emulsion having a welder property is used, it is not necessary to use a welder film, and the welder processing becomes extremely easy.

Claims (3)

[Claims] 1. A skin material for an interior material, which comprises an impregnated layer of a synthetic resin emulsion containing micro hollow bodies on one surface of a fibrous base material, and the impregnated layer is densified. 2. The skin material for an interior material according to claim 1, wherein the synthetic resin emulsion contains a synthetic resin having a welder property as a main component. 3. A synthetic resin emulsion impregnated layer having a thickness of
Claim 1 which is 10 to 50% of the thickness of the fibrous base material.
A skin material for an interior material according to the item.