JPH0747627A - Interior material and production thereof - Google Patents

Abstract

PURPOSE:To obtain an excellent interior material rich in soundproof and heat insulating properties and generating no low-grade sound even by the rubbing with a car body by forming a corrugated core material from a nonwoven fabric containing a low m.p. fiber and bonding a surface material composed of a nonwoven fabric to the single surface or both surfaces of the core material. CONSTITUTION:10-70wt.% of low m.p. fibers, for example, polyester fibers with an m.p. of 13 deg.C are mixed with high m.p. fibers, for example, polyester fibers with an m.p. of 18 deg.C and the resulting mixture is subjected to needle punching to entangle the fibers and heated within the temp. range from the softening point of the low m.p. fibers to the softening point of the high m.p. fibers and the low m.p. fibers are softened to bond the high m.p. fibers to produce a nonwoven fabric 10. This nonwoven fabric 10 is heated in a heating oven 14 to soften the low m.p. fibers and subjected to cold molding by a toothed roll press 15 to produce a corrugated core material 12 and, after an acrylic adhesive is applied to both surfaces of the core material 12 by roll coaters 16, surface materials 13 each composed of the nonwoven fabric 10 are bonded to both surfaces of the core material under pressure to produce corrugated cardboard 11.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior material used for automobiles and the like and a method for manufacturing the same.

[0002]

BACKGROUND OF THE INVENTION Corrugated paper is used as a base material for interior materials such as ceiling materials and door trims in automobiles and the like.
As shown in FIG. 4, the corrugated cardboard (1) is composed of a corrugated core material (2) and a surface material (3) adhered to the core material (2). The surface material (3) is made of paper. However, cardboard made of paper (1)
Is poor in formability due to the small stretchability of the paper, wrinkles and cracks are generated in the deep-drawing forming part, and a low-grade sound is generated by rubbing the car body panel and the corrugated cardboard while the vehicle is running,
There are problems such as poor soundproofing and heavy weight.

[0003]

2. Description of the Related Art As a means for solving the problems of the above-mentioned paper-made cardboard, a cardboard in which a surface material made of a non-woven fabric is adhered to both surfaces of a paper-made core material is disclosed. 61-29532), surface material and /
Alternatively, corrugated cardboard (corresponding to No. 4-83742) using cork sheet as the core material, corrugated cardboard (corresponding to No. 4-72933) using laminated material of non-woven fabric and cork sheet as surface material are provided. There is.

[0004]

However, Japanese Unexamined Patent Application Publication No. Sho 6
In the cardboard of No. 1-29532, the surface material is made of non-woven fabric, but since the core material is made of paper, it cannot be said that the moldability is sufficient and there is a problem in soundproofing. With the corrugated cardboard of Japanese Patent Application No. 4-72933, the cork sheet does not have sufficient stretchability, good moldability cannot be obtained, and a low-grade sound may be generated due to rubbing with the vehicle body panel. There is a problem that it is not enough.

[0005]

Means for Solving the Problems As a means for solving the above-mentioned conventional problems, the present invention provides a corrugated core material (12) composed of a nonwoven fabric (10) and one or both surfaces of the core material (12). A corrugated cardboard composed of a surface material (13) made of a non-woven fabric (10) to be adhered, and at least the non-woven fabric (10) of the core material (12) contains a low melting point fiber in an amount of 10 to 70% by weight. (1
The present invention provides an interior material (11A), which is formed of 1) into a predetermined shape, and further contains 10 to 70% by weight of a low melting point fiber.
The non-woven fabric (10) contained in the ratio of the low melting point fiber is heat-molded at a temperature equal to or higher than the softening point to form a corrugated core material (12), and the non-woven fabric (10) is provided on both sides or one side of the core material (12). The present invention provides a method for manufacturing an interior material (11A), which comprises molding a cardboard (11) having a surface material (13) made of (1) attached thereto into a predetermined shape.

The non-woven fabric used as the material of the cardboard of the present invention is made of polyester fiber, polyamide fiber, acrylic fiber, acetate fiber, cotton fiber, wood fiber, organic fiber such as bamboo fiber, glass fiber, ceramic fiber, carbon fiber and the like. It is a non-woven fabric using one or more kinds of fibers such as inorganic fibers, and at least the non-woven fabric of the core material preferably has a low melting point such as low melting point polyester fiber, low melting point polyamide fiber, polyethylene fiber or polypropylene fiber. The low melting point fiber in the range of 150 ° C. is contained in the range of 10 to 70% by weight, preferably 30 to 60% by weight.
When the content of the low melting point fiber is less than 10% by weight, the thermoformability is insufficient, and when it exceeds 70% by weight, heat resistance becomes a problem. The non-woven fabric is obtained by binding the fibers with a synthetic resin binder, entangled by needle punching, or the like,
Alternatively, when the low melting point fiber is included, it is produced by heating the low melting point fiber to a temperature equal to or higher than the softening point to soften the low melting point fiber and binding the fiber. In the present invention, the non-woven fabric is usually 100 g / m ^{2 to} 2000 g.
The weight is / m ² , but the thickness can be partially changed if desired. The non-woven fabric includes synthetic resins such as acrylic resin, vinyl acetate resin, styrene resin, urethane resin, melamine resin, urea resin and phenol resin,
Alternatively, a precursor such as a monomer, a prepolymer or an oligomer of the above synthetic resin may be impregnated, or a plastic film such as a polyethylene film, a polypropylene film or a polyester film may be laminated. Furthermore, the above-mentioned non-woven fabric may be colored or embossed, and when such non-woven fabric is used as the surface material, the surface layer material becomes unnecessary.

In order to manufacture a cardboard from the above-mentioned non-woven fabric, the low-melting fiber containing the non-woven fabric as the core material is heated to a temperature above the softening point to soften the low-melting fiber and then cold-formed into a corrugated shape. Alternatively, hot forming is performed in a corrugated shape at a temperature above the above.

The non-woven fabric used as the surface material does not necessarily need to be mixed with the low-melting point fiber, but if desired, a material containing the low-melting point fiber may be used like the core material.

The core material and the surface material are adhered by using an ordinary adhesive, a hot melt adhesive or the like. When a synthetic resin or a nonwoven fabric impregnated with a synthetic resin precursor is used, the synthetic resin or the synthetic resin is used. Since the precursor functions as an adhesive, no adhesive is required.

[0010]

The cardboard (11) of the present invention uses a non-woven fabric for both the core material (12) and the surface material (13), and the non-woven fabric of the core material contains 10 to 70% by weight of low melting point fibers. Since the corrugated cardboard (11) as a whole is excellent in stretchability and thermoformability, the nonwoven fabric contains a large amount of air and is rich in sound insulation and heat insulation and cushioning. It produces no low-quality sound due to rubbing, and is extremely lightweight and highly breathable.

[0011]

EXAMPLE A high melting point fiber having a melting point exceeding 150 ° C. (for example, a polyester fiber having a melting point of 180 ° C.) has a melting point of 150 ° C.
A range of not less than the softening point of the low melting point fiber and not more than the softening point of the high melting point fiber after mixing 30% by weight of a low melting point fiber having the following melting point (for example, polyester fiber having a melting point of 130 ° C.) and entangled by needle punching. Temperature, eg 160 ℃
The high melting point fibers were bound by heating to low temperature to soften the low melting point fibers to produce a nonwoven fabric having a weight of 150 g / m ² .

As shown in FIG. 1, the nonwoven fabric (10) is heated in a heating furnace (1
The low melting point fiber of the non-woven fabric (10) is softened by heating to a temperature in the above range, for example, 160 ° C. by 4), and cold forming is performed by the tooth profile roll press (15) to obtain a corrugated core material.
(12) is produced. Alternatively, the non-woven fabric (10) may be formed into a corrugated core material (12) by hot forming with a tooth profile roll press heated to a temperature in the above range without being heated in a heating furnace.

A roll coater (16) is provided on both sides of the core material (12).
Acrylic adhesive is applied by and the core material (1
A surface material (13) made of a nonwoven fabric (10) is pressure-bonded to both surfaces of (2) to manufacture a cardboard (11) as shown in FIG. The weight of the cardboard (11) used as a ceiling material is 500 to
Was 600 g / m ^2, the weight of a conventional cardboard 800
~900g / m ^2, it is extremely light in comparison to the resin board 1.45 kg / m ^2. In the present invention, the surface material (13) may be bonded to only one surface of the core material (12).

The cardboard (11) is cold-pressed after heating to a temperature in the above range, for example, 160 ° C. to soften the low melting point fiber, or is formed by hot pressing to a temperature in the above range. By, for example, a ceiling shape as shown in FIG.
Used as (11A).

[0015]

Accordingly, the present invention provides an excellent interior material which is lightweight and has excellent moldability, and which is rich in sound insulation and heat insulation and does not generate low-grade sound even when rubbed against the vehicle body.

[Brief description of drawings]

 1 to 3 show an embodiment of the present invention.

[Figure 1] Cardboard manufacturing process diagram

FIG. 2 is a partial sectional view.

[Fig. 3] Perspective view of automobile ceiling material

FIG. 4 is a partial cross-sectional view of a conventional example.

[Explanation of symbols]

 10 Nonwoven fabric 11 Cardboard 12 Corrugated core material 13 Surface material 11A Interior material

Continuation of the front page (72) Inventor Tadao Asano 1511 Tsuya, Nanano-cho, Kaizu-gun, Gifu Prefecture Taishin Kogyo Co., Ltd.

Claims (2)

[Claims] 1. A corrugated core material made of a non-woven fabric and a surface material made of a non-woven fabric adhered to both sides or one side of the core material, and at least the non-woven fabric of the core material contains 10 to 70 low melting point fibers. Interior material characterized in that it is made of cardboard contained in a weight percentage and is molded into a predetermined shape 2. A non-woven fabric containing low melting point fibers in an amount of 10 to 70% by weight is heat-formed at a temperature equal to or higher than the softening point of the low melting point fibers to form a corrugated core material. A method of manufacturing an interior material, which comprises molding a cardboard having a surface material made of a non-woven fabric adhered on one side into a predetermined shape.