JPH0776052A - Laminated structure and interior material - Google Patents

Abstract

PURPOSE:To provide a material which can be effectively used as a laminated structure, especially an interior material for an automobile or a house, with an outstanding adhesion to various types of other material, while having its retained characteristics such as light-weight, hardness, and adiabatic and shaping properties which are originally peculiar to a polystyrene foam. CONSTITUTION:This laminated structure is composed of a sheet-like material 1 obtained by integrally interlacing a composite fiber containing polystyrene with a fiber not containing polystyrene, and a polystyrene foam 2, to the surface of which the sheet-like material 1 is fused. In addition, this interior material is composed of the laminated structure obtained by fusion-bonding a short fiber unwoven cloth sheet-like material which consists of the composite fiber interlaced integrally with the fiber not containing polystyrene, laminated to the surface of a constituent member.

Description

Detailed Description of the Invention

[0001]

The present invention relates to light weight, hardness, heat insulation,
The present invention relates to a laminated structure and an interior material which have excellent shapeability and can be laminated.

[0002]

2. Description of the Related Art Conventionally, polystyrene foam is preferably used as a heat insulating material for cooler boxes, building materials, etc. due to its characteristics such as light weight, hardness, heat insulating property and shape forming property, and as a packaging material for food and household products. Has been done. However, polystyrene foam is extremely brittle against external stress and has the drawback of cracking or chipping. In order to make up for these drawbacks, there is a method of reinforcing the surface with a resin plate or a cardboard plate, but they are heavy and thick, and not only the adhesion is difficult but also the shapeability is deteriorated. As a method for improving the drawbacks, for example, Japanese Patent Publication No. 47-28097 and Japanese Patent Application Laid-Open No. 48-100471 propose a method of reinforcing fibers by mixing them.

As conventional ceiling materials, recycled cotton felt impregnated with phenol resin, cardboard paper impregnated with phenol resin, or glass fiber impregnated with phenol resin has been used. In recent years, a method of impregnating an inorganic fiber with a thermoplastic resin has been proposed as a method for reducing the weight and improving the moldability. For example, JP-A-1-156562 discloses that an inorganic fiber mat-like material is impregnated with a thermoplastic resin to partially bind the inorganic fibers.

[0004]

However, in these prior arts, since the reinforcing fibers and the foam are poorly integrated, a substantial reinforcing effect is not obtained, and further, flame retardancy and other properties are not obtained. There are problems such as adhesiveness with materials and deformation due to heat, and their applications were limited to applications such as packaging materials and heat insulating materials. The latter ceiling material is heavy and poor in moldability, and the ceiling material using glass fiber is bad for the health of the manufacturing operator, and improvement is desired. The present invention is
The original characteristics of polystyrene foam: light weight, hardness,
The purpose of the present invention is to provide a laminated structure that retains characteristics such as heat insulation and shapeability, but has excellent adhesiveness to various materials, and in particular, can be effectively used as an interior material for automobiles and houses. is there.

[0005]

The present invention takes the following means in order to solve the above problems. That is,
The laminated structure of the present invention is formed by intertwining and integrating a composite fiber containing polystyrene and a fiber not containing polystyrene into a sheet-like product, and then fusing the sheet-like product to the surface of the polystyrene foam. In addition, the interior material of the present invention, a short fiber nonwoven sheet-like material obtained by entangled and integrating a composite fiber and a fiber not containing polystyrene, is fused to a polystyrene foam sheet. The laminated structure is formed on the surface of the constituent member.

[0006]

The term "polystyrene-containing composite fiber" as used in the present invention means a fiber containing a polystyrene component, for example, a core / sheath type composite fiber such as polyester for the core component and polystyrene for the sheath component, or polyester on one side. , The other side is a bimetal type composite fiber such as polystyrene, even if it is a multi-core / sheath type,
It may be a multilayer bimetal type. Such composite fibers are
In order to facilitate fusion bonding with the foam and firmly fuse it, it is preferable that the single fiber contains 10 to 95% by weight of polystyrene. If it is less than 10% by weight, the fusion-bonding property with the polystyrene foam becomes poor, and if it is 96% by weight or more, the reinforcing effect of other fibers becomes poor.

Any other mating material other than the styrene component may be used. For composite with styrene, the thermoplastic synthetic polymer can be easily fiberized. For example, polyester, polypropylene, polyethylene, nylon, vinylon, etc. can be used. The styrene component becomes a fusion bonding component, and the other material with which it is a partner becomes a strong (reinforcing) component. The fiber used in the present invention needs to be a short fiber because of its moldability. Furthermore, by doing so, it is possible to prevent the generation of wrinkles and to facilitate the entanglement and integration with other fibers.

That is, the sheet material of the present invention is one or more selected from polyester short fibers, polyethylene short fibers, polypropylene short fibers, polyacrylonitrile short fibers, cellulose short fibers and animal fibers. And a short fiber of a composite fiber containing polystyrene, which is a short fiber non-woven fabric.

Since the laminated material of the present invention is used by laminating the laminated structure of the present invention on the surfaces of the constituent members of various structures,
It is preferable to further adhere a surface material to the surface. In this case, it is preferable that the material of the surface material is the same as the above-mentioned fiber because the adhesion becomes stronger. When used as a ceiling material for vehicles, it is preferable to use polyacrylic fibers, cellulosic fibers and animal fibers which are non-thermosoftening fibers from the viewpoint of dimensional stability.

The mixed fiber ratio (weight) of fibers containing polystyrene and fibers not containing polystyrene is 10: 9.
It is preferably in the range of 0 to 90:10. By making each of the two kinds of short fibers 10% by weight or more,
It is possible to improve the fusion bond between the polystyrene foam and other materials, and to supplement heat resistance and brittleness. The entanglement and integration of the short fibers may be performed by a method of heat bonding with a low melting point fiber or a method of entanglement by needle punching. The basis weight of such a short fiber non-woven fabric is preferably 30 to 300 g / m ² , and more preferably 50.
Those having a range of up to 150 g / m ² are used because of their reinforcing property and adhesiveness. In the case of a short fiber non-woven fabric with a weight of less than 30 g / m ² , not only is it difficult to manufacture, but also the reinforcing property tends to be poor, and the adhesiveness and brittleness are difficult to compensate. Again 300 g
When it exceeds / m ² , it becomes too heavy and it is difficult to effectively utilize the advantages of the polystyrene foam.

The polystyrene foam used in the present invention is
The expansion ratio is preferably 5 to 30 times, more preferably 1
It is 0 to 20 times, preferably 2 to 10 mm, and more preferably 4 to 8 mm. Expansion ratio is 5
If it is less than twice, it is heavy and inferior in heat insulating property and moldability, and if it exceeds 30 times, it becomes strong and weak, and is easily broken or broken. If the thickness is less than 2 mm, the bending strength becomes weak, and if it exceeds 10 mm, the moldability is deteriorated, which is not preferable.

INDUSTRIAL APPLICABILITY The laminated structure of the present invention can be effectively used as an interior material, and is laminated on the surface of constituent members of vehicles such as automobiles, airplanes, ships, trains and spacecraft, particularly preferably on the ceiling portion. Can be used.

When used as such an interior material, it is preferable to further laminate a fiber cloth, a synthetic resin sheet, or leather as a surface material on the surface of the laminated structure, or electro-implant short fibers.

As the surface material, raised tricot, TP
Synthetic resin sheets such as O to which leather grain is applied, or genuine leather, or to which short fibers or the like are electrically flocked are preferably used from the viewpoint of imparting surface aesthetics and soundproofing safety. Cushioning properties may be imparted to the polystyrene foam itself, in which case it can be easily obtained by subjecting the polystyrene foam to compression treatment.

Further, it is preferable to stack a resin foam or a fiber entangled body as a cushioning material between the laminated structure and the surface material because safety, sound absorption and vibration isolation are imparted. The density of such cushioning material is preferably 0.01
It is preferably in the range of 0.1 g / cm ³ . 0.01 g
If it is less than / cm ³ , the surface material may be broken or peeled off by a small external force, and if it exceeds 0.1 g / cm ³ , the cushioning property is reduced, which is not preferable. The thickness of this cushion material is 1
It is preferably about 3 mm. The fiber entangled body used as the cushioning material may be a needle punched product or a product in which fibers are fused with a low melting point fiber or the like, and a combination product of this fiber entangled body and resin foam is used. May be.

Next, the laminated structure of the present invention will be described with reference to the drawings.

FIG. 1 shows a polystyrene foam 2 which is a short fiber nonwoven sheet material 1 obtained by intertwining and integrating a composite fiber containing polystyrene and a fiber not containing polystyrene.
2 is a laminated structure in which the surface material 4 is laminated on one surface, and FIG. 2 is a laminated structure in which the surface material 4 is further laminated on one surface. FIG. 3 is a sheet-like cushion material 3 is laminated on the inner surface of the surface material 4. It is a laminated structure. Such a laminated structure can be used by laminating it on the surfaces of the constituent members of various structures, but can also be used as a structure itself.

[0018]

EXAMPLES The present invention will be further described below with reference to examples.

Example 1 As a composite fiber containing polystyrene, a multi-core / sheath type short fiber having a core component of polyester and a sheath component of polystyrene (36 cores, fineness 4 denier, fiber length 51 mm, polystyrene content 28) %) And short fibers made of polyester (2 denier, 51 mm) as fibers not containing polystyrene at a mixing ratio of 1: 1 to produce a nonwoven fabric with a basis weight of 70 g / m ² by a needle punching method. did. On the other hand, a plate having a foaming ratio of 15 times and a thickness of 5 mm was manufactured from a polystyrene resin mixed with a foaming agent using a foam molding machine.

Next, the non-woven fabric prepared above is laminated on both sides of the expanded polystyrene plate, and the surface temperature of the iron plate is 105.
Use a hot press machine at ℃ 30 to make the thickness 5 mm.
After pressing for fusion for 2 seconds and cooling, a laminate was manufactured. The weight of the plate was 498 g / m ² , which was an extremely lightweight plate.

The three-point bending strength set to a width of 50 mm and a span distance of 100 mm is 3.07K for both vertical and horizontal.
The laminated structure had a weight of 2.0 g and a weight of 2.01 kg, was not broken and was not broken, and was lightweight and sufficiently strong.

As a comparative example, the polystyrene content is 9.6.
Using multi-core / sheath type short fibers (36 and 16 cores, respectively) in weight% and 96% by weight, and the same short fiber made of polyester, with the same mixing ratio and method, manufacture of two levels of non-woven fabric Tried. When the basis weight was less than 30 g / m ² , the sheet could not be formed by the needle punching method. In addition, unevenness became noticeable and could not be used to reinforce the expanded polystyrene plate. Weight is 50
At about g / m ^{2, the} nonwoven fabric sheet became stable and had good quality.

Two levels of non-woven fabric having a basis weight of 70 g / m ² were laminated on the same polystyrene plate by the same method. The one having a polystyrene content of 9.6% by weight has a weak adhesive force with the expanded polystyrene plate, while the one having a polystyrene content of 96% by weight has a weak core component polyester. The reinforcing effect was poor and it was not practical. Further, when the basis weight of the nonwoven fabric sheet is 300 g / m ² or more, it is not preferable because it is difficult to control the thickness of the laminated structure, heat transfer is deteriorated, and adhesion failure occurs.

Example 2 As a composite fiber containing polystyrene, a multi-core / sheath type short fiber having a core component of polyester and a sheath component of styrene (16 cores, fineness 3 denier, fiber length 51 mm, polystyrene content 43) %) And polystyrene-free fibers with polyester core / sheath type low melting point fibers (4 denier, 51 mm) at a mixing ratio of 1: 1 and having a basis weight of 100 g / m ² by a needle punching method. A non-woven fabric was produced.

On the other hand, a plate having a foaming ratio of 18 times and a thickness of 5 mm was produced from a polystyrene resin mixed with a foam material using a foam molding machine.

Next, the nonwoven fabric manufactured in Example 1 is press-formed on one surface of the expanded polystyrene plate and the nonwoven fabric manufactured this time on the other surface of the expanded polystyrene plate by a heating press machine while heating to a thickness of 9 mm. did.

The molded product had a unit weight of 520 g / m ^{2 and} was of good quality. Also, width 50 mm, span distance 10
The three-point bending strength of the flat plate set to 0 mm was 4.25 kg on average in the vertical and horizontal directions, and was a lightweight and extremely strong laminated structure and interior material.

As a comparative example, the same composite fiber containing polystyrene and the same polyester low melting point fiber were used to produce a two-level nonwoven fabric (each having a basis weight of 100 g / m ² ) in which each fiber was 9% by weight. did. Using the non-woven fabric,
A laminated structure having the same method and the same thickness as in Example 2 was manufactured. However, in the case where 9% by weight of the composite fiber containing polystyrene was used, there was a portion where the adhesion to the expanded polystyrene plate was poor, and the laminated structure It was hard to say. Further, when 9% by weight of the low-melting point fiber was used, the adhesive strength between the surface material and the polyester knitted fabric was weak, and the effect of mixing fibers containing no polystyrene was lost.

Example 3 As a composite fiber containing polystyrene, the same short fiber as that used in Example 2 was used, and as a fiber containing no polystyrene, polyacrylonitrile fiber having a denier of 2 mm and 51 mm and a fiber length of 60 mm were cut. The resulting wool fibers were mixed at a mixing ratio of 2: 1: 1, respectively, to produce a nonwoven fabric having a basis weight of 90 g / m ² by the needle punching method.

Next, the non-woven fabric was pressed on both sides of the polystyrene foam plate produced in Example 2 by a hot press machine at a surface temperature of 120 ° C. for 30 seconds so as to have a thickness of 5 mm, and heat-bonded. The laminate has a good surface feel and a combustion test (JIS D
In 1201), the interior material was excellent at 65 mm / min.

As a comparative example, a polystyrene foam was produced such that the expansion ratio was 4.5 times and 32 times, and the thickness was less than 2 mm and 10 mm or more, and the same fiber material and non-woven fabric were prepared. A laminated board was produced in the same manner as above.

A polystyrene foam having an expansion ratio of 4.5 times is hard but heavy, and conversely, a polystyrene foam having an expansion ratio of 32 times is
When it was light but poor in rigidity, and the thickness was less than 2 mm, the laminated plate was warped and the thickness was uneven, resulting in poor quality. Further, when the thickness is 10 mm or more, it becomes unsuitable as an interior material for automobiles and the like, and it is not enough to carry out a combustion test.

Example 4 Using the laminated structure manufactured in Example 1, both sides were heated to 105 ° C. by an infrared heater and then molded by a stamping press machine. The molded product had a smooth surface despite deep drawing. Cut the flat part, width 50m
When measuring the three-point bending strength in a 90 ° C atmosphere with m and span distance set to 100 mm, the vertical and horizontal strengths are 2.0 each.
It was excellent at 8 kg and 1.67 kg.

Next, 1 mm short fibers of 1 denier dyed in a light brown color made of nylon fiber were electro-implanted on the inner surface of the molded article. The four-layer laminated structure was an interior material having excellent quality and quality.

On the other hand, a long fiber non-woven fabric made of polyester (thickness: 5 denier, basis weight: 40 g / m ² ) was used as a fiber not containing polystyrene, and the fiber used in Example 1 as a composite fiber containing polystyrene. A non-woven fabric having a basis weight of 80 g / m ² was produced by the needle punching method, and a laminated structure was produced by the same method.

Next, similarly, under the same conditions, it was molded by a stamping press machine, but wrinkles were generated in the deep drawn portion, and the interior material was extremely poor in quality.

Example 5 A dyed tricot knitted fabric composed of polyester filaments and a polyester low melting point web sheet (area weight 40 g /
m ² ) and the laminated surface side of the laminated structure manufactured in Example 2 containing the polyester low melting point fiber,
The temperature of the knitted fabric side was 120 ° C. and the temperature on the other side was set to 105 ° C. A heat press molding machine was integrally molded at the same time as fusion so as to have a thickness of 7 mm to obtain a car ceiling. The peel strength of the tricot knitted fabric of the laminated molded product is 423 g / vertical / horizontal
The molded ceiling had an extremely high adhesive strength of 25 mm and 385 g / 25 mm.

On the other hand, a tricot knitted fabric was laminated under the same conditions using a laminated structure produced in the same manner by using 9% by weight of low melting point fiber, but the adhesive force was extremely weak and fibers containing no polystyrene were mixed. The effect of doing was gone.

Example 6 As a composite fiber containing polystyrene, the same short fibers as used in Example 1 and a fiber not containing polystyrene were mixed with 1.5 denier and 44 mm polyethylene short fibers. A web produced by mixing fibers at a ratio of 1: 1 and a card machine was temporarily adhered with a heat calender roller to produce a nonwoven fabric having a basis weight of 60 g / m ² .

On the other hand, a polyethylene sheet having a foaming ratio of 30 times and a thickness of 2 mm and a textured polyethylene resin sheet were heat laminated.

Next, the non-woven fabric prepared above was pasted on both sides of a polystyrene plate having an expansion ratio of 18 times and a thickness of 6 mm by a hot press machine, and the polyethylene foam side of the laminate sheet prepared separately. And were laminated and integrated. The thus produced leather-like laminate having a leather-like surface was a lightweight and rigid interior material having an excellent surface elasticity.

On the other hand, for the purpose of imparting cushioning properties, a laminated structure is manufactured by the same method using a polyethylene sheet having a foaming ratio of 8 times and an apparent density of 0.13 g / cm ³ and a thickness of 2 mm. did. The structure had no surface elasticity and was not effective as a cushion material. Also, a non-woven fabric made of polyethylene fiber (1.5 denier, 44 mm) and having an apparent density of 0.008 g / cm ³ and a thickness of 1 mm was used as a cushioning material, but it was not elastic,
The adhesive strength with the polyethylene resin sheet, which is the surface material, was weak, and the nonwoven fabric was broken by a weak force, which was not practical.

[0043]

The laminated structure of the present invention is extremely lightweight,
Moreover, in addition to the basic property of excellent bending rigidity, cloths and sheets made of various materials can be bonded easily and firmly.

It can be effectively used as an automobile ceiling material by taking advantage of its lightness, rigidity and heat insulation, and as an interior room material, furniture and bags by taking advantage of its lightness, rigidity and adhesiveness with a surface material.

[Brief description of drawings]

FIG. 1 is a schematic sectional view of a three-layer laminated structure of the present invention.

FIG. 2 is a schematic cross-sectional view of a four-layer laminated structure of the present invention.

FIG. 3 is a schematic cross-sectional view of a 5-layer laminated structure of the present invention.

[Explanation of symbols]

 1: Short fiber non-woven sheet material 2: Polystyrene foam 3: Cushion material 4: Surface material

Claims (13)

[Claims] 1. A laminated structure comprising a polystyrene foam and a surface of a polystyrene foam, which is fused with a short fiber non-woven fabric sheet in which woven fibers containing polystyrene and fibers not containing polystyrene are entangled and integrated with each other. 2. The laminated structure according to claim 1, wherein the composite fiber contains 10 to 95% by weight of a polystyrene component. 3. The sheet material has a basis weight of 30 to 300 g / m 2.
Layered structure of claim 1 wherein the ^2. 4. The laminated structure according to claim 1, wherein the mixed fiber ratio of the composite fiber and the fiber not containing polystyrene is 10:90 to 90: 10% by weight. 5. The fiber containing no polystyrene is one or more fibers selected from polyester fiber, polyethylene fiber, polypropylene fiber, polyacrylonitrile fiber, cellulose fiber and animal fiber. 1. The laminated structure according to 1. 6. The laminated structure according to claim 1, wherein the conjugate fiber is a core / sheath type or bimetal type conjugate fiber. 7. The laminated structure according to claim 6, wherein the core / sheath type composite fiber is a multi-core type composite fiber. 8. The laminated structure according to claim 1, wherein the polystyrene foam has an expansion ratio of 5 to 30 times and a thickness of 2 to 10 mm. 9. A short-fiber non-woven sheet-shaped product obtained by entangled and integrating a composite fiber and a fiber not containing polystyrene.
An interior material, wherein a laminated structure formed by fusion bonding to a polystyrene foam sheet is laminated on the surfaces of constituent members. 10. An interior material, characterized in that the interior material is, at least on its surface, a laminated structure made of at least one selected from fiber cloth, synthetic resin sheet, leather or flock. 11. The interior material has an apparent density of 0.01 to 0.
The interior material according to any one of claims 9 to 10, which is obtained by laminating sheet-like cushion materials in the range of 1 g / cm. 12. The interior material according to claim 9, wherein the interior material is attached to a surface of a constituent member of one kind of vehicle selected from automobiles, airplanes, ships, trains and spacecraft. 13. The interior material according to claim 9, wherein the interior material is attached to a ceiling portion.