JPH08112816A - Thermoformable core meterial, its preparation and internal decorative material - Google Patents

Abstract

PURPOSE: To laminate a skin material without spoiling lightweight property, heat resistance, etc., and without application of an adhesive and drying process by laminating a sheet-like material with fine penetration holes consisting of a heat-resistant rigid resin layer and a heat-activated resin layer on one outside of a mat-like material wherein an inorg. fiber and a thermoplastic resin fiber are main materials so as to bring the rigid resin layer on the mat-like material side. CONSTITUTION: At least on one outer side of a mat-like material as a heat-formable core material wherein an inorg. fiber and a thermoplastic resin fiber are main materials, a sheet- like material consisting of a heat-resistant rigid resin layer with a m.p. being higher than that of the thermoplastic resin fiber and a heat-activated resin layer with only one peak of crystal m.p. is formed and as fine penetration holes are provided in the sheet-like material, there is no possibility of spoiling lightweight property, heat resistance and shielding properties of air permeability and as air retention is not generated during compression process, there exists no recessed part on the surface. In addition, it is possible to laminate the skin material without coating and drying processes of an adhesive for laminating the skin material and when the skin material is adhered with the core material, as the surface of the heat-activated resin layer can be brought into direct contact with the skin material, it is possible to laminate the skin material under a condition where adhesiveness is kept excellent.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a thermoformed composite material,
In particular, the present invention relates to a thermoformable core material used for a ceiling base material of a vehicle such as an automobile and an interior base material of a door, a manufacturing method thereof, and an interior material.

[0002]

2. Description of the Related Art Conventionally, a thermoformable core material used as an interior material for a vehicle such as an automobile, particularly as a base material for a thermoformed ceiling is lightweight,
It is required to have excellent properties such as rigidity, heat resistance, heat shaping properties, and non-breathability. As this kind of material, for example,
JP-A-1-56562 and JP-A-2-53948 disclose that the core material itself is completely heat-molded without impairing its lightness, heat resistance, heat shaping property, sound absorbing property, and the like. A thermoformable core material having a ventilation blocking property and a method for producing the same are disclosed.

[0003]

However, when a thermoformable core material of this kind is used as a base material for a molded ceiling of an automobile, for example, a skin material such as a skin material is formed on the surface of the thermoformable core material. In order to laminate a knit skin, a knit urethane skin, a non-woven skin, etc., after heat shaping of the thermoformable core material, the adhesive resin was dissolved in an organic solvent or dispersed in water on the surface on which the skin material should be laminated. A step of applying and drying an adhesive must be provided, and then a skin material must be laminated on the thermoformable core material. In this way, the conventional method requires an adhesive coating and drying step,
Moreover, it has a drawback that the working environment is polluted.

In view of the above-mentioned drawbacks, the object of the present invention is to apply an adhesive and dry the adhesive layer for laminating the skin material without impairing the lightness, heat resistance, heat shaping property, sound absorbing property and air-permeable property. The object is to provide a thermoformable core material, a method of manufacturing the same, and an interior material, which enable stacking of the skin material without providing the above.

[0005]

Means for Solving the Problems The first aspect of the present invention is to provide a heat-resistant rigidity having a melting temperature higher than that of the thermoplastic resin fiber on at least one outer side of a mat-like material formed mainly of inorganic fibers and thermoplastic resin fibers. A thermoformable core material is obtained by laminating a resin layer and a thermoactive resin layer having only one crystal melting temperature peak in this order.

In the first aspect of the present invention, the mat-like material is composed mainly of inorganic fibers and thermoplastic resin fibers. Examples of the inorganic fiber include glass fiber and rock wool. The length of the inorganic fiber is preferably 5 to 250 mm, more preferably 50, from the viewpoint of the moldability of the base layer.
Those having a thickness of up to 150 mm have a distribution of 70% by weight or more. The thickness of the inorganic fiber is preferably 5 to 20 μm, and more preferably 7 to 13 μm from the viewpoint of bending strength and thickness recovery of the thermoformable core material to be obtained.

The thermoplastic resin fiber is preferably a resin which is easily melted and bound to the inorganic fiber. Examples of such thermoplastic resin fibers include fibers made of resins such as polyethylene, polypropylene and polystyrene.
The length and thickness of the thermoplastic resin fiber are preferably such that the base layer can be easily formed by mixing with the inorganic fiber with good dispersibility.
Specifically, the length is preferably 5 to 200 mm, more preferably 20 to 100 mm. Thickness is 5-70 μm
Is preferable, and more preferably 15 to 40 μm.

The mat-like material may contain a thermoplastic resin, if necessary. It is preferable that the thermoplastic resin be easily impregnated between the inorganic fibers in the molten state and easily bound to the inorganic fibers. Examples of such a thermoplastic resin include thermoplastic resins such as polyethylene, polypropylene, polystyrene, ethylene-vinyl acetate copolymer, saturated polyester, and modified products thereof (for example, maleic anhydride-modified polyethylene).

The thermoformable core material of the present invention 1 comprises a heat-resistant and rigid resin layer having a melting temperature higher than that of the thermoplastic resin fiber and at least one crystal melting temperature peak on at least one outer side of the mat-like material. The active resin layer is laminated in this order.

The heat-resistant and rigid resin has a higher melting temperature than the thermoplastic resin fibers and the thermoplastic resin contained as necessary, and is 30 ° C. or higher than the melting temperature of the thermoplastic resin contained as necessary. , Preferably 50 ° C. or higher. As a result, the entire layer laminated on the mat-like material can be heated to melt the resin other than the heat-resistant and rigid resin. Examples of such heat-resistant and rigid resins include heat-resistant and rigid resins such as polybutylene terephthalate, polyethylene terephthalate, polycarbonate, polyamide and modified products thereof.

In order to obtain good thermoformability, the heat-resistant and rigid resin has a thermoforming drawing ratio (the thermoforming drawing ratio is a diameter D and a height when a plate-like object is drawn into a cylindrical shape by a vacuum forming machine). Ratio of H H /
Specified by D. ) Is preferably 0.5 or more.
When the thermoforming drawing ratio is 0.5 or less, the thermoforming performance of the core material,
That is, there is a problem in shapeability.

The thermoactive resin having only one crystal melting temperature peak has a thermal activity expression temperature which is preferably 20 ° C. or more lower than the melting temperature of the heat-resistant rigid resin, and the melting of the thermoplastic resin and the thermoplastic resin fiber. It is preferably about the same as the temperature. As a result, the entire laminated sheet can be heated to melt-activate the heat-activatable resin on the surface, without impairing the air permeability blocking performance of the heat-resistant and rigid resin layer, and without providing an adhesive coating / drying step. The skin material can be adhered to the thermoformable core material (in the prior application JP-A-5-93352, an adhesive coating and drying step was required).

The melt flow rate (referred to as MFR) as a measure of the fluidity of the heat activated resin is preferably 0.5 to.
20 and more preferably 2 to 15. When the MFR exceeds 20, the thermoactive resin is completely impregnated inside the skin material and the adhesive strength cannot be obtained. On the contrary, when it is less than 0.5, the thermoactive resin does not impregnate inside the skin material. The anchor effect cannot be obtained. Examples of such heat-activated resin include polyethylene, polypropylene, ethylene-vinyl acetate copolymer, maleic anhydride-modified polyethylene, saturated polyester-modified polyethylene, and copolymerized polyamide. Considering processability and price, Linear low density polyethylene is preferred.

Usually, heat resistance is required for adhesion of a skin material as an interior material, and the melting point of a heat activated resin is considered as a standard. For example, a conventional linear low-density polyethylene having a melting point of 125 ° C shows a crystal melting temperature peak near 125 ° C which is a melting point because it is a copolymer having an inhomogeneous monomer composition, and also has a crystal melting temperature around 105 ° C. This component impairs heat resistance because it exhibits a temperature peak. Therefore, as the thermoactive resin of the present invention, it is important to use a resin having only one crystal melting temperature peak, which is copolymerized so as to have a uniform monomer composition.

The thermoformable core material of the present invention 1 is expanded in the thickness direction. The degree of expansion depends on the porosity of the base layer being 50 to 9
The range is preferably 9%. Thereby, in the base layer, the inorganic fibers are bound to each other by the melt of the thermoplastic resin fiber and the thermoplastic resin at the intersection, and,
It has large voids throughout.

The size and density of the fine through-holes provided in the sheet-shaped article of the present invention 1 are such that no depressions can be formed on the surface of the obtained thermoformable core material, and the obtained thermoformable core material. It is necessary to be less than or equal to the level at which the air permeability is maintained. Specifically, the diameter of the fine through holes is 0.02 to
The range of 1 mm is preferable, and the density is 5,000 to
The range of 1,000,000 pieces / m ² is desirable.

More preferably, the porosity defined by the following formula: Porosity (%) = (average perforation area per fine through hole × density of fine through holes) × 100 It is in the range of 10%. The method of punching the fine through holes may be any method such as a needle hole or a punch hole, but it is said that the fine through hole having an arbitrary hole diameter can be stably opened by the thickness of the needle and the heating to the needle. For the reason, the mechanical needle hole method is preferably used.

The present invention 2 is an interior material in which a skin material is laminated on the thermoactive resin layer surface of the thermoformable core material of the present invention 1 and shaped.

In the present invention 2, as the skin material, for example, a natural fiber such as cotton, wool, or hemp, or a synthetic fiber such as polyester, polyamide, or polyurethane, which has a texture, flexibility, and design, is used. To be

As a method of laminating a skin material on the surface of the heat-active resin layer and shaping it, for example, a heat-activator comprising a polyamide-based copolymer, a polyester-based copolymer, an acid-modified polyolefin or the like on the heat-active resin layer surface. A method in which a skin material is laminated via a resin film or a synthetic fiber such as polyethylene, polypropylene, or polyurethane, and press molding is performed on the skin material can be adopted.

The third aspect of the present invention is to obtain a laminate by laminating a thermoplastic resin film on at least one outer side of a mat-like article formed mainly of inorganic fibers and thermoplastic resin fibers. A thermoplastic resin layer (a), a heat-resistant and rigid resin layer (b) having a melting temperature higher than those of the thermoplastic resin fiber and the thermoplastic resin film, and a thermal activity having only one crystal melting temperature peak, at least on one side. A multilayer material [(a) / (b) / (c)] made of a resin layer (c) and provided with fine through-holes is used as the thermoactive resin layer (c).
To obtain a laminated sheet, the laminated sheet is heated at a temperature equal to or lower than the melting temperature of the heat-resistant and rigid resin to melt and compress the thermoplastic resin fiber and the thermoplastic resin to obtain the heat-resistant rigidity. Thermoplastic resin is impregnated into the mat-like material without impregnating the mat-like material with the thermoactive resin that is not in contact with the resin and the mat-like material, and the thermoplastic resin fiber in the molten state and the inorganic fiber with the thermoplastic resin It is a method for producing a thermoformable core, which comprises the steps of binding each other, then expanding in the thickness direction, and curing the thermoplastic resin fibers and the thermoplastic resin in a molten state.

In the present invention 3, first, there is a step of obtaining a laminate. In the step of obtaining a laminate, a mat-like material mainly composed of inorganic fibers and thermoplastic resin fibers is used. The blending ratio of the matte inorganic fiber and the thermoplastic resin fiber is
When the proportion of the inorganic fibers is low, the heat resistance of the resulting thermoformable core material decreases, and when the proportion is high, the bonding strength between the inorganic fibers decreases and the mechanical strength, that is, the rigidity decreases, so the inorganic fibers and the thermoplastic resin It is preferable to set it in the range of 5: 1 to 1: 5 by weight ratio with.

As a method for producing the mat-like material, any method may be adopted. Generally, an inorganic fiber and a thermoplastic resin fiber are supplied to a card machine, which are defibrated and needle punched, Manufacture mats. The needle punch is preferably punched at ^{2 to} 100 points, and more preferably 10 to 50 points, per cm ^{2 in} order to improve the mechanical strength of the mat-like material and the thermoforming core material obtained.

The density of the mat-like material becomes heavier as the density increases, and the mechanical strength of the mat-like material decreases as the density decreases, so 0.01 to 0.2 g / cm ³ is preferable. The weight of the mat is 2 to obtain mechanical strength.
0 to 1500 g / m ² is preferable, and 3 is more preferable.
It is from 00 to 800 g / m ² .

As the inorganic fibers and the thermoplastic resin fibers used for the mat-like material, those similar to those of the present invention 1 are used. A thermoplastic resin film is laminated on at least one outside of the mat-like material to obtain a laminate. In addition, it is preferable that a thermoplastic resin film is laminated on both sides of the mat-like material to form a sandwich laminate. By forming a sandwich laminate in this way, when the thermoplastic resin film is heated, a part of it does not impregnate into the mat-like material but remains on both outsides of the mat-like material. It is preferable because the strength of can be obtained.

The thermoplastic resin film of the present invention 1
A film made of a thermoplastic resin similar to the above is used.
The thickness of the film is preferably 50 to 500 μm, because the mechanical strength decreases as the film becomes thinner and the film becomes heavier as the film becomes thicker.
More preferably, it is 70 to 300 μm.

The present invention 3 has a step of obtaining a laminated sheet. A thermoplastic resin film is laminated on at least one outer side of the mat-like material, and a thermoplastic resin layer (a) and a heat-resistant and rigid resin layer (b) are laminated on at least one outer side of the obtained laminate.
And a heat-activatable resin layer (c)
(B) / (c)] are laminated so that the thermoactive resin layer (c) is on the outside to obtain a laminated sheet. In addition, as the multilayer material, a material in which an adhesive layer is further provided between the (a) layer and the (b) layer or between the (b) layer and the (c) layer may be used. It is necessary that the multilayer material be provided with fine through holes, and the size and density thereof may be the same as those formed in the sheet-shaped article of the first invention.

In the present invention 3, the method for producing the multilayer material is not particularly limited, and a coextrusion method, an extrusion laminating method, a dry laminating method or the like is applied. A preferred method is a co-extrusion method, that is, a method of co-extruding a thermoplastic resin and a heat-resistant and rigid resin via an adhesive resin, and a method of producing a laminated sheet by a conventional method such as T die, More economical.

In the present invention 3, there is a step of heating the laminated sheet, compressing it, expanding it in the thickness direction, and hardening the thermoplastic resin fibers and the thermoplastic resin in a molten state. The laminated sheet obtained by the above method is heated at a temperature not higher than the melting temperature of the heat-resistant and rigid resin and not lower than the melting temperature of the thermoplastic resin forming the thermoplastic resin film and the thermoplastic resin layer (a), and heating Compress at temperature. The compression pressure is ^{2 to 20} kg / cm ² , and the compression time is 2-1.
A range of 0 seconds is preferred.

After this compression, the entire laminated sheet (mat-like material and multilayer material) is expanded in the thickness direction. The expansion in the thickness direction may be recovered by the elasticity of the inorganic fibers, but in order to facilitate the release of the multilayer material outside the laminated sheet at room temperature, for example, sandwich it with a Teflon coated steel sheet or glass cloth sheet etc. You may force it by vacuum-sucking both the surfaces.

In this heating and compression step, the thermoplastic resin film and the thermoplastic resin forming the thermoplastic resin layer (a) are melted and impregnated into the mat-like material, and the inorganic resin and inorganic resin are also melted. Bind one another. On the other hand, the heat-resistant and rigid resin does not melt and does not impregnate into the mat-like material. Further, the thermoactive resin (c) outside the heat-resistant and rigid resin is melted, but not impregnated into the mat-like material.

The thermoplastic resin fibers in the molten state, the thermoplastic resin and the heat activated resin may be cured by natural cooling, forced cooling, or by expanding and curing. Alternatively, it may be cured after spreading.

In the present invention 3, since the multilayer film is provided with fine through holes, when the laminated sheet is sandwiched between Teflon-coated steel plates or glass cloth sheets and compressed, the laminated sheet and the Teflon coating are provided. The air accumulated between the coated steel sheet or glass cloth sheet is driven out to the mat-like object side through the fine through holes by the compression pressure at the time of compression, and the space between the laminated sheet and the Teflon-coated steel sheet or glass cloth sheet is perfect. Stick to.

At the same time, since the outermost layer of the multilayer sheet in contact with the Teflon-coated steel sheet or glass cloth sheet, that is, the heat-activatable resin (c) is in a molten state and is in a fluid state, the fine through holes are fused. It is filled with a heat activated resin (c).

When the laminated sheet is expanded in the thickness direction, the laminated sheet and the Teflon-coated steel sheet or glass cloth sheet are in close contact with each other and no air can be collected, so that the expanded sheet can be uniformly expanded. The resulting thermoformable core material does not have any depression.

[0036]

The thermoformable core material of the present invention 1 has a heat-resistant rigidity having a melting temperature higher than that of the thermoplastic resin fiber on at least one outer side of a mat-like material formed mainly of inorganic fibers and thermoplastic resin fibers. A sheet-like material is formed from a resin layer and a thermoactive resin layer having only one crystal melting temperature peak,
Since the sheet-like material is provided with the fine through-holes, air pressure is not lost between the pressure plate and the laminated sheet in the compression process without impairing the lightness, heat resistance, heat shaping property and ventilation blocking property. Since it is not possible, there is no dent on the surface, and it is possible to laminate the skin material without providing an adhesive coating and drying step for laminating the skin material, and when adhering the skin material to the thermoformable core material Since the skin material can be brought into direct contact with the surface of the heat-active resin layer, the skin material can be laminated with excellent adhesiveness by the melt activation of the heat-active resin.

The interior material of the present invention 2 is formed by laminating a skin material on the surface of the thermoactive resin layer of the thermoformable core material of the present invention 1 and shaping it, so that it is lightweight, heat resistant, and heat shapeable. In addition, the skin material is provided on the surface in a state of having excellent adhesive strength without impairing the ventilation blocking property.

In the method for producing a thermoformable core material of the present invention 3, a thermoplastic resin film is laminated on at least one outer side of a mat-like material formed mainly of inorganic fibers and thermoplastic resin fibers. A step of obtaining a product, a thermoplastic resin layer (a), a heat-resistant and rigid resin layer (b) having a higher melting temperature than the thermoplastic resin fiber and the thermoplastic resin film, and a crystal melt on at least one outside of the laminate. A multilayer material [(a) / (b) / (c)] including a thermoactive resin layer (c) having only one temperature peak and having fine through-holes is provided outside the thermoactive resin layer (c). To obtain a laminated sheet, the laminated sheet is heated at a temperature equal to or lower than the melting temperature of the heat-resistant and rigid resin to melt and compress the thermoplastic resin fiber and the thermoplastic resin, Thermal activity without contact with mat Without impregnating the resin into the mat-like material, impregnating the thermoplastic resin into the mat-like material and binding the molten thermoplastic resin fibers and the inorganic fibers to each other with the thermoplastic resin, and then in the thickness direction. The thermoformable core material can be manufactured with good workability by comprising the steps of expanding and curing the thermoplastic resin fibers and the thermoplastic resin in a molten state.

Then, the multilayer material [(a) / (b) /
(C)] is provided with fine through holes, so that the laminated sheet and the Teflon-coated steel sheet or glass cloth sheet are compressed when the laminated sheet is sandwiched between the Teflon-coated steel sheet or glass cloth sheet or the like. The air trapped in the space is expelled to the mat-like object side through the fine through holes by the compression pressure at the time of compression, and when the laminated sheet is expanded in the thickness direction, the laminated sheet and the Teflon-coated steel sheet or glass cloth Since the sheets are in close contact with each other and no air can be collected, the sheets can be uniformly spread and the thermoformable core material having no dents on the surface can be manufactured with good workability.

[0040]

EXAMPLES The present invention will be specifically described below with reference to examples, but the present invention is not limited thereto.

Example 1 A glass fiber having a length of 40 to 75 mm and a diameter of 9 μm and 6 denier (thickness: about 30 μm)
m) and 50 mm cut high density polyethylene fiber,
The mixture was blended in a weight ratio of 2: 1 and supplied to a card machine, defibrated and mixed to obtain a cotton-like material. Next, needle punching at a density of 20 points / cm ² on this cotton-like material,
A mat-like product having a basis weight of about 500 g / m ² was obtained.

Next, as shown in FIG. 1, on one surface of the mat-like material 11 thus obtained, a high density polyethylene resin [melting point: 135 ° C., MFR 7.0] having a thickness of about 130 μm.
m thermoplastic resin film 12 was laminated. Further, a thermoplastic resin layer 131 made of a high-density polyethylene resin (melting point 135 ° C., MFR 2.0) containing a maleic anhydride-modified polyethylene resin (MFR 0.91) and a nylon-6 resin on the opposite surface of the mat-like material 11. A heat-resistant and rigid resin layer 132 having a melting point of 230 ° C. and ethylene and 1-butene are copolymerized using a catalyst having a single active point so as to have a uniform monomer composition, and a crystal melting temperature peak of 125 is obtained.
A heat-activatable resin layer 133 made of linear low-density polyethylene (NTX-101, MFR3.0, manufactured by Mobil) having only one point at a temperature of 130 μm / layer in this order.
The multilayer film 13 obtained by coextrusion at 20 μm / 60 μm has a hole diameter of 0.2 mm and a hole density of 55,555 holes / m ^2.
Of which the micro through holes are provided are laminated so that the thermoactive resin layer 133 is on the outer side, and the thickness is about 7 mm and the weight is about 800.
A laminated sheet of g / m ² was prepared.

The produced laminated sheet was sandwiched from both outer sides with a Teflon-coated glass cloth sheet, and 20
It is supplied to a hot air heating furnace at 0 ° C., left for 5 minutes, transferred to a flat plate press heated at 200 ° C. while being sandwiched between glass cloth sheets, and compressed so that the thickness of the laminated sheet becomes 0.9 mm. Hold for 5 seconds. Next, the flat plate press is spread so that the distance between them is about 7 mm, and the laminated sheet is sandwiched with a glass cloth sheet and transferred to a flat plate-shaped vacuum expanding device,
Suction the glass sheet from both sides at a rate of 0.5 mm / sec, widen the gap between the suction plates to 6 mm, and release the suction.
It was taken out and air-cooled for 3 minutes. Next, the glass cloth sheet is peeled off, and the thickness is about 5.5 mm and the weight is about 800 g / m ^2.
A flat thermoformable core material was obtained. The obtained thermoformable core had a uniform thickness without surface dents due to air accumulation in the compression step.

The surface of the obtained flat-plate thermoformable core on which the thermoactive resin layer was laminated was heated with an infrared heater to a surface temperature of 1
After heating to 15 ° C, a urethane skin material is laminated on the surface of the thermoactive resin layer, transferred to a flat plate press having a predetermined shape, compressed so that the interval becomes 4.0 mm, and held for 10 seconds to heat. At the same time as forming the moldable core material, the skin material was attached. Next, the laminate was taken out from the flat plate press to obtain an interior material.

When the skin material adhesive strength of this interior material was measured, it was confirmed that the skin material was broken and sufficient adhesive strength was obtained. Further, when the air permeability of the obtained interior material was measured, it was 0.3 cc / cm ² · sec or less, and it was confirmed that the air permeability was sufficient. Further, the heat resistant temperature for adhesion of the skin material of this interior material was measured to be 125 ° C., and it was confirmed that it could withstand the melting point of the thermoactive resin layer. [Comparative Example 1] As a thermally activated resin, ethylene and 2-methylpentene were copolymerized using a catalyst having a plurality of active sites, and a linear low temperature having a crystal melting temperature peak at two points of 125 ° C and 105 ° C. An interior material was obtained in the same manner as in Example 1 except that high-density polyethylene (Mitsui Petrochemical Co., Ltd .: Ultzex 20100C, MFR 10.0) was used. When the skin material adhesive strength of the obtained interior material was measured, it was confirmed that the skin material was broken and sufficient adhesive strength was obtained.
The air permeability of this interior material was measured and found to be 0.3cc
/ Cm ² · sec or less, and it was confirmed that the ventilation blocking property was sufficient, but when the heat resistant temperature for adhesion was measured, it was 105
C., which was inferior to Example 1 in heat resistance.

[Comparative Example 2] Example 1 except that fine through holes were not provided in the multilayer film 13 in Example 1.
A laminated sheet was prepared in the same manner as above, a thermoformable core material was then obtained, and a skin material was further laminated to obtain an interior material.

In the thermoformable core material, a dent caused by an air pocket formed between the pressure plate and the laminated sheet in the compression step was observed, and this remained after the skin material was laminated and a uniform appearance was not obtained. It was

[0048]

Since the thermoformable core material of the present invention 1 has the above-mentioned constitution, the thermoformable core material having no dent on the surface and excellent in air permeability is obtained as described above. Further, a thermoformable core material to which the skin material can be attached can be obtained without providing an adhesive coating and drying step.

Since the interior material of the present invention 2 has the above-mentioned constitution, the surface material has an adhesive strength on the surface without impairing the lightness, heat resistance, heat shaping property, and air permeability. It is provided in excellent condition.

The method for producing a thermoformable core material according to the third aspect of the present invention is configured as described above, so that the thermoformable core material having the above-mentioned effect and having no dent on the surface can be obtained. It can be manufactured with good workability.

[0051]

[Brief description of drawings]

FIG. 1 is a cross-sectional view illustrating a laminating step of a laminated sheet in an example of a method for producing a thermoformable core material of the present invention.

[Brief description of reference numerals]

 11 Matte Material 12 Thermoplastic Resin Film 13 Multilayer Film 131 Thermoplastic Resin Layer 132 Heat Resistant Rigid Resin Layer 133 Thermoactive Resin Layer

Continuation of front page (51) Int.Cl. ⁶ Identification number Office reference number FI technical display location D04H 1/58 B // B29K 101: 12 105: 06 B29L 7:00 9:00

Claims (3)

[Claims] 1. A heat-resistant and rigid resin layer having a melting temperature higher than that of the thermoplastic resin fiber and a crystal melting temperature peak are provided on at least one outside of the mat-like material formed mainly of inorganic fibers and thermoplastic resin fibers. A thermoformable core comprising a heat-activatable resin layer having only one point, and a heat-resistant and rigid resin layer of a sheet-like material having fine through holes provided facing the mat-like material side. Material. 2. An interior material, characterized in that a surface material is laminated on the thermoactive resin layer surface of the thermoformable core material according to claim 1 and shaped. 3. A step of laminating a thermoplastic resin film on at least one outside of a mat-like material formed mainly of inorganic fibers and thermoplastic resin fibers to obtain a laminate, and at least one outside of the laminate. On the other hand, the thermoplastic resin layer (a), the heat-resistant and rigid resin layer (b) having a higher melting temperature than the thermoplastic resin fiber and the thermoplastic resin film, and the thermoactive resin layer having only one crystal melting temperature peak ( a multilayer material [(a) / (b) /
(C)] is laminated so that the thermoactive resin layer (c) is on the outside to obtain a laminated sheet, and the laminated sheet is heated at a temperature equal to or lower than the melting temperature of the heat-resistant rigid resin to produce a thermoplastic resin fiber. And, the thermoplastic resin is melted and compressed, and the thermoplastic resin is impregnated into the mat-like material and melted without impregnating the heat-resistant and rigid resin and the thermoactive resin that does not contact the mat-like material into the mat-like material. After binding the inorganic fibers to each other with the thermoplastic resin fiber and the thermoplastic resin in the state, it is spread in the thickness direction, and comprises a step of curing the thermoplastic resin fiber and the thermoplastic resin in the molten state. A method for producing a thermoformable core material.