JPH09174729A - Interior facing material for automotive ceiling - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a low-cost interior facing material for an automotive ceiling having a light weight and excellent heat resistance by little manufacturing steps by providing a non-foamed layer only on the one side surface of a modified polyphenylene ether resin foamed layer, and disposing the non-foamed layer at the indoor side. SOLUTION: A modified polyphenylene ether resin non-foamed layer 4 is laminated only on the one side surface of a modified polyphenylene ether resin foamed layer 3, and the layer 4 is disposed at the indoor side of an automobile. Accordingly, since the layer 3 is formed of the modified polyphenylene ether resin, the heat resistance and moldability become excellent. Since the layer is the foamed layer 1, the used resin amount of low density and light weight may be little. On the other hand, since the layer 4 is formed of the modified polyphenylene ether resin, its heat resistance and dimensional stability become excellent. Thus, the interior facing material for the automotive ceiling having light weight, high heat resistance, excellent dimensional stability, moldabilityy, impact resistance, sound insolation, heat insulation, and cost competitiveness is obtained.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention belongs to the technical field of manufacturing and using interior materials for automobile ceilings. More specifically, it belongs to the technical field of manufacturing and using interior materials for automobile ceilings, which are excellent in heat resistance and light weight.

[0002]

2. Description of the Related Art Conventionally, as an automobile interior material, particularly an automobile ceiling interior material, a urethane foam laminated on a base material mainly composed of a thermoplastic resin foam, or a foam layer of a styrene-maleic anhydride copolymer. A laminate sheet in which a non-foamed layer of a styrene-maleic anhydride copolymer is laminated on both upper and lower surfaces of the above is molded into a desired shape is widely used. And these automobile interior materials are lightweight and have high heat insulation,
It has the feature of excellent moldability.

However, the conventional automobile interior materials, particularly automobile ceiling interior materials, have insufficient heat resistance when used for a long period of time when exposed to high temperatures. Problems such as deformation may occur.

In order to solve these problems, an automobile interior material based on a composite material of inorganic glass fiber and plastic has been conventionally used.

However, in the case of this composite material, although the heat resistance can be set to a desired level, there is a problem that the weight cannot be reduced and the cost becomes high.

Therefore, an interior material for an automobile ceiling has been proposed, which uses a foamed laminated sheet in which a modified PPE resin non-foamed layer is laminated on both sides of a lightweight and heat-resistant modified polyphenylene ether (PPE) resin foamed layer. Yes (Actual Kaihei 4-1)
1162). The interior material for an automobile ceiling using the modified PPE-based resin is excellent in heat resistance and lightweight, so that it is said that it is possible to improve deformation at high temperatures and sag due to its own weight.

[0007]

However, the interior material for an automobile ceiling using the modified PPE resin has non-foaming layers on both sides, and therefore has a non-foaming layer on only one side. Compared with the above, there are drawbacks in that the manufacturing process of the foam laminated sheet corresponding to the interior base material for an automobile ceiling is increased or complicated, the material cost is increased, the cost is increased, and the weight is reduced.

[0008]

In view of the above circumstances, the present inventors have proposed a modified PPE system to provide an interior material for an automobile ceiling, which has excellent heat resistance and which can be manufactured inexpensively and easily. As a result of earnest studies on the structure of the resin foam laminated sheet, by providing a non-foaming layer only on one side and arranging the non-foaming layer on the indoor side (bottom surface), it is possible to achieve a light weight and high heat resistance that has never been achieved before. Modified PP with dimensional stability, moldability, impact resistance, sound insulation, heat insulation and cost competitiveness
It has come to manufacture interior materials for automobile ceilings made of E-based resin.

That is, according to the present invention, a primary foam laminated sheet obtained by laminating a modified polyphenylene ether resin (II) non-foamed layer on only one side of a modified polyphenylene ether resin (I) foamed layer is secondarily foamed and molded. The thus obtained interior material for an automobile ceiling, wherein the non-foaming layer side is arranged on the interior side (claim 1), modified polyphenylene ether resin (II) non-foaming The interior material for an automobile ceiling according to claim 1, wherein a skin material is further laminated on the layer (claim 2), and the modified polyphenylene ether resin (I) foam layer is a polyphenylene ether resin 25 to 75% (% by weight, hereinafter). The same) and a polystyrene resin 75 to 25% mixture and / or polyphenylene ether resin 25 to 75% styrene monomer 7
A foamed laminated sheet obtained by secondary foaming a primary foamed laminated sheet to form an interior material for an automobile ceiling (claim 3) according to claim 1 or 2, which is composed of a copolymer obtained by polymerizing 5 to 25%. The thickness T of the foamed layer is adjusted to 0.3t ≦ T with respect to the free thickness t of the foamed layer of the foamed laminated sheet at the time of secondary foaming, and manufactured. The thickness T of the foam layer of the foam laminated sheet obtained by secondary foaming of the primary foam laminated sheet according to claim 4, wherein the foamed laminated sheet has a thickness T of the foam laminated sheet at the time of secondary foaming. The interior material for an automobile ceiling according to claim 1, 2 or 3, which is manufactured by adjusting the free thickness t of the foam layer to be 0.5t≤T.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION The interior material for an automobile ceiling of the present invention is
Secondary foaming of a primary foam laminated sheet obtained by laminating a modified PPE resin (II) non-foaming layer on only one side of a modified polyphenylene ether (PPE) resin (I) foaming layer (primary foaming layer) It is a secondary foamed laminated sheet molded body (interior material for an automobile ceiling) in which the non-foamed layer side is arranged on the indoor side (lower surface) obtained by molding.

The interior material for an automobile ceiling will be described with reference to the drawings.

As shown in FIG. 2, which is a cutaway explanatory view of the automobile, the interior material 2 for the automobile ceiling is attached to the interior side of the roof 1 of the automobile. In the present invention, the modified PPE resin (II) non-foamed layer 4 is the modified PPE resin (I) foamed layer 3 as shown in FIG.
Of the modified PPE resin (I
I) The non-foamed layer 4 is arranged on the indoor side (lower surface). Also,
Generally, it has a structure in which the skin material 6 is laminated via the adhesive 5. In addition, in FIG. 1, 7 shows a windshield.

The modified PPE-based resin (I) foam layer 3 constituting the interior material 2 for automobile ceiling is a base layer of the interior material for automobile ceiling, and this layer is composed of the modified PPE-based resin (I). Since it is formed, the secondary foamed laminated sheet having good heat resistance and moldability and good heat resistance can be easily molded, and since this layer is a foamed layer,
It has low density and light weight, uses a small amount of resin, has cost competitiveness, and has excellent sound insulation and heat insulation.

The modified PPE resin (I) non-foamed layer formed on only one surface of the modified PPE resin (I) foamed layer is a layer laminated to improve rigidity, strength and dimensional stability. Since this layer is formed of the modified PPE resin (II), heat resistance and dimensional stability are improved. Further, since the same type of resin as the foam layer is used, the adhesiveness is good, and further, since this layer is a non-foam layer,
Good rigidity, strength, and dimensional stability.

Further, since the interior material for an automobile ceiling as described above is used with the non-foamed layer side facing the indoor side, it has excellent heat resistance, and since the foamed layer comes to the roof side, squeaking noises are reduced.

Modified PPE resin (I) The modified PPE resin (I) forming the foamed layer is a mixed resin of a PPE resin and a polystyrene resin (PS resin), PP
Copolymers such as grafts and blocks obtained by polymerizing a styrene-based monomer on an E-based resin are exemplified. Among these, a mixed resin of a PPE-based resin and a PS-based resin is preferred from the viewpoint of easy production.

Examples of the PPE resin include poly (2,6-dimethylphenylene-1,4-ether),
Poly (2-methyl-6-ethylphenylene-1,4-ether), poly (2,6-diethylphenylene-1,4)
-Ether), poly (2,6-diethylphenylene)-
1,4-ether), poly (2-methyl-6-n-propylphenylene-1,4-ether), poly (2-methyl-6-n-butylphenylene-1,4-ether),
Poly (2-methyl-6-chlorophenylene-1,4-ether), poly (2-methyl-6-bromophenylene-
1,4-ether) and poly (2-ethyl-6-chlorophenylene-1,4-ether). These may be used alone or in combination of two or more. Among them, poly (2,6-dimethylphenylene-1,4-ether) is preferable from the viewpoint of versatility of raw materials and cost. When it is desired to impart flame retardancy, poly (2-methyl-6-) containing a halogen element is used.
Chlorphenylene-1,4-ether), poly (2-methyl-6-bromophenylene-1,4-ether), and poly (2-ethyl-6-chlorophenylene-1,4-ether) are preferred.

P forming a mixed resin with the PPE resin
The S-based resin is a resin containing styrene or a derivative thereof, for example, α-methylstyrene, 2,4-dimethylstyrene, monochlorostyrene, dichlorostyrene, p-methylstyrene, ethylstyrene or the like as a main component (60% or more). . Therefore, the PS resin is not limited to a homopolymer or a copolymer consisting only of styrene or a styrene derivative, and may be a copolymer produced by copolymerizing with another monomer. Further, for example, when polymerizing styrene or a styrene derivative, such as high impact polystyrene, a polymer obtained by adding synthetic rubber or rubber latex may be used.

Other monomers copolymerizable with styrene or a derivative thereof that can be used in the production of the PS resin include, for example, acrylonitrile, methacrylonitrile,
Examples thereof include methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, and maleic anhydride. These may be used alone or in combination of two or more kinds.

Specific examples of the PS resin include polystyrene, styrene-α-methylstyrene copolymer, styrene-butadiene copolymer represented by high-impact polystyrene, and styrene-acrylonitrile copolymer. . Among these, polystyrene is preferable in terms of versatility and cost.

Specific examples of the styrene monomer to be polymerized, preferably graft-polymerized, to the PPE resin include, for example, styrene, α-methylstyrene, 2,4-
Examples include dimethylstyrene, monochlorostyrene, dichlorostyrene, p-methylstyrene, ethylstyrene and the like. These may be used alone or in combination of two or more. Of these, styrene is preferred in terms of versatility and cost.

When polymerizing a styrene-based monomer on the PPE-based resin, a monomer copolymerizable with the styrene-based monomer in a range where the styrene-based monomer is the main component (60% or more); For example, acrylonitrile, methacrylonitrile,
One or two of methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, etc.
More than one species may be included.

As a method for producing a graft copolymer obtained by polymerizing a PS-based monomer on the PPE-based resin, a conventionally well-known method may be used, for example, JP-B-52-30991 and JP-B-52-38596. A radical polymerization initiator and a styrene monomer are added to a PPE resin disclosed in a gazette or the like, and the mixture is stirred in a anhydrous state in the presence or absence of an organic solvent in a temperature range of 130 to 200 ° C. A method such as polymerizing a styrene-based monomer may be used.

The above PPE resin and PS resin or PP
The proportion of the styrene monomer (which may contain a monomer copolymerizable with the styrene monomer) to be polymerized in the E resin is 25 to 75% of the PPE resin, and further 35.
~ 60%, especially 38 to 58%, styrene monomer 75 to polymerize PS resin or PPE resin
25%, further 65-40%, especially 62-42%
Is preferred. If the proportion of the PPE-based resin is too small, the heat resistance tends to be inferior. If the proportion of the PPE-based resin is too large, the viscosity at the time of heating and flowing may increase, making foam molding difficult.

The thickness of the primary foamed layer of the modified PPE resin (I) foamed layer containing the modified PPE resin as the base resin is 1 to 5 mm, more preferably 1.5 to 3.5 mm,
The expansion ratio is 3 to 20 times, further 5 to 15 times, the cell diameter is 0.05 to 0.9 mm, and further 0.1 to 0.7.
mm, the closed cell rate is preferably 70% or more, and more preferably 80% or more. In addition, the amount of volatile components remaining in the primary foam layer is 1 to 5%, more preferably 2 to 4% with respect to the total weight of the foam layer.
% Is preferred. The amount of residual volatile components is measured, for example, by heating the foam layer sample above the decomposition temperature above the temperature at which the modified PPE resin (I) begins to soften to sufficiently volatilize the volatile components, and measure the difference in weight before and after heating. Or measured by gas chromatography.

When the thickness of the primary foam layer is less than 1 mm, the strength and heat insulation properties are insufficient, and there are cases where it is not suitable as a primary foam layer for interior materials for automobile ceilings. On the other hand, if it exceeds 5 mm, heat will be
Hard to reach the center of the E-based resin foam layer in the thickness direction,
For this reason, there is a case where sufficient heating cannot be performed and moldability deteriorates. In addition, if the heating time is extended to perform sufficient heating, cells on the surface of the foam layer may be broken, which may make it difficult to obtain an acceptable product. Also, when the expansion ratio of the primary foam layer is less than 3 times,
Poor flexibility, easy to break due to bending, etc.
In addition, it is difficult to obtain a lightweight one. If the ratio exceeds 20 times, there is a tendency that the strength and the moldability are reduced due to the difficulty in heating to the center. Further, when the cell diameter is less than 0.05 mm, it is difficult to obtain sufficient strength, and when it exceeds 0.9 mm, the heat insulating property tends to be poor. In addition, when the closed cell rate is less than 70%, heat insulating property,
Insufficient stiffness and the desired 2
The secondary expansion ratio tends to be poor, and the moldability tends to be poor.
In addition, if the residual volatile component is less than 1%, the secondary expansion ratio may be too low, and good molding may not be possible.
If it exceeds 5%, air pockets may occur between the non-foamed layer and the dimensional stability over time may deteriorate.

The modified PPE resin used in the present invention (I) The base resin for producing the foamed layer may contain, if necessary, a cell regulator, an impact modifier, a lubricant, an antioxidant, You may add an antistatic agent, a pigment, etc.

The modified PPE resin (II) non-foamed layer is formed on only one side of the primary foamed layer as described above.
As the modified PPE resin (II) forming the PE resin (II) non-foamed layer, as in the case of the primary foamed layer, the PPE resin and the polystyrene resin (PS resin) are used.
And copolymers such as grafts and blocks obtained by polymerizing a styrene-based monomer with a PPE-based resin. Among these, a mixed resin of a PPE-based resin and a PS-based resin is preferred from the viewpoint of easy production.

Specific examples and preferred examples of the PPE-based resin, specific examples and preferred examples of the PS-based resin, specific examples and preferred examples of the styrene-based monomer, and further, those contained in the PS-based resin or the styrene-based monomer. Specific examples of the monomer capable of polymerizing with the body are the same as in the case of the primary foam layer,
Description is omitted. However, as a preferred specific example of the PS resin, a styrene-butadiene copolymer represented by high impact polystyrene is added because the effect of improving the impact resistance of the non-foamed layer is large.

The ratio of the PPE resin in the non-foamed layer of the modified PPE resin (II) to the PS resin or the styrene monomer polymerized into the PPE resin is PPE.
15 to 75% of the system resin, and further 25 to 60%,
The styrene monomer to be polymerized on the PS resin or the PPE resin is preferably from 85 to 25%, more preferably from 75 to 40%. If the proportion of the PPE-based resin is too small, the heat resistance of the molded article tends to be inferior. If the proportion of the PPE-based resin is too large, the viscosity at the time of heating and flowing increases, which may make extrusion molding difficult. .

In the primary foam laminated sheet of the present invention, the non-foam layer laminated on the primary foam layer is laminated only on one side of the foam layer. As a result, the weight is reduced, the process for producing the primary foam laminated sheet is shortened or simplified, the material cost is reduced, and the overall production cost is reduced, which is preferable.

The non-foamed layer has a thickness of 50 to 300 μm,
Furthermore, 75 to 200 μm is preferable. When the thickness of the non-foamed layer is less than 50 μm, strength, rigidity, heat resistance and the like tend to be inferior, and when the thickness is more than 300 μm, moldability tends to be inferior.

When forming the modified PPE resin (II) non-foamed layer, the base resin forming the modified PPE resin (II) non-foamed layer may contain an impact resistance improver, if necessary.
Fillers, lubricants, antioxidants, antistatic agents, pigments and the like may be added alone or in combination of two or more.

The impact resistance improver transports an interior material for an automobile ceiling, which is obtained by laminating a non-foamed layer of modified PPE resin (II) on a foamed layer of modified PPE resin (I) and then secondary-foaming the molded product. It is a component used to prevent cracking of the non-foamed layer during the punching process of the interior material for automobile ceilings. As a result of the study by the present inventors, its effectiveness was found. It was done.

The impact resistance improver may be used without particular limitation as long as it exhibits its effect when mixed with the base resin. In this case, the modified PPE resin (II) and the like may be reacted by mixing.

Examples of the impact resistance improver include rubber such as natural rubber and synthetic rubber, and graft polymerization of a monomer having a carbon-carbon double bond such as styrene and methyl methacrylate around rubber particles. Those that have been used are preferably used.

Specific examples of the rubber include styrene-butadiene rubber, butadiene rubber, isoprene rubber, ethylene-propylene copolymer, ethylene-propylene-diene copolymer, acrylonitrile-butadiene copolymer, chloroprene rubber and butyl rubber. , Urethane rubber, silicone rubber, polysulfide rubber, hydrogenated nitrile rubber, polyether special rubber, fluoro rubber, tetrafluoroethylene-propylene rubber, acrylic rubber, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, propylene oxide rubber , Ethylene-acrylic rubber, liquid rubber, norbornene rubber, styrene-based thermoplastic elastomer, olefin-based thermoplastic elastomer, urethane-based thermoplastic elastomer, polyester-based thermoplastic elastomer, polyamide Thermoplastic elastomers, 1,2
Polybutadiene-based thermoplastic elastomer, PVC-based thermoplastic elastomer, fluorine-based thermoplastic elastomer, MB
S resin, ethylene-vinyl acetate copolymer and the like. These may be used alone or in combination of two or more. Of these, styrene-butadiene rubber is preferable from the viewpoint of good compatibility with the modified PPE resin and versatility.

The amount of impact modifier added is 2 to 25%, more preferably 5 to 20%, based on the modified PPE resin (II).
Is preferred. When the impact resistance improver is less than 2%,
The effect of improving the flexibility and impact resistance of the non-foamed layer will not be sufficiently exhibited, and the damage due to bending or impact will not be sufficiently prevented. Also, the amount of impact modifier used is 25
If it exceeds%, the heat resistance and rigidity will be poor.

The filler is a component used for improving strength, rigidity, dimensional stability and the like, and the filler used is not particularly limited. Specific examples of the filler include talc (magnesium silicate), calcium carbonate (heavy, light, colloid, etc.), mica, magnesium oxide, magnesium carbonate, barium sulfate, calcium sulfate, calcium sulfite, silica, clay, kaolin , White carbon, magnesium hydroxide, carbon black, zeolite, molybdenum and the like. Of these, talc, calcium carbonate and mica are particularly preferred.

The amount of the filler added is 1 to 5 with respect to 100 parts of modified PPE resin (II) (parts by weight, the same applies hereinafter).
It is 0 part, preferably 5 to 40 parts. If the addition amount is less than 1 part, the clear effect of filling the filler (inorganic substance) cannot be obtained, and if the addition amount exceeds 50 parts, the viscosity of the resin composition increases and a large load is applied to the extruder. For this reason, it is not preferable, and the impact strength of the non-foamed layer is significantly reduced.

A preferred specific example of the primary foam laminate sheet in which the modified PPE resin (II) non-foamed layer is formed on only one surface of the modified PPE resin (I) foamed layer as described above is the modified PPE resin described above. A preferable example of the foamed layer (I) and a preferable example of the modified PPE resin (II) non-foamed layer may be combined.

The interior material for an automobile ceiling of the present invention is a secondary foamed laminated sheet molded body obtained by heating the primary foamed laminated sheet as described above to secondary foam and molding it using a mold. However, the thickness T of the foamed layer of the secondary foamed laminated sheet molding is 0.3t ≦ with respect to the free thickness t of the foamed layer at the time of secondary foaming.
T, more preferably 0.5t ≦ T, and particularly preferably 0.7t ≦ T. If T is less than 0.3t,
A large residual strain remains in the foam layer of the secondary foam laminated sheet molded body, and the heat resistance tends to be poor.

The thickness T of the foam layer of the secondary foam laminated sheet molding is the thinnest portion of the bent portion where heat resistance is a problem (usually the front bent portion or the rear bent portion; Then, the thickness of the bent portion of the front part). In addition, the free thickness t of the foam layer at the time of the secondary foaming is 2 when heating is performed under the same conditions as molding using a mold and molding by the mold is not performed (mold is not used). The thickness of the foam layer of the next foam laminated sheet.

The relationship between the thickness T of the foamed layer of the secondary foamed laminated sheet molded body and the free thickness t of the foamed layer of the foamed laminated sheet at the time of secondary foaming varies depending on the mold clearance at the time of molding. It can be changed by changing the thickness T of the foam layer of the secondary foam laminated sheet molded body. The die clearance when the skin material or the like is laminated on the primary or secondary foam laminated sheet may be a clearance including the thickness of the skin material.

Further, regarding the above-mentioned relationship, the thickness of the foam layer of the primary foam laminated sheet is changed, the secondary expansion ratio is changed by adjusting the residual volatile component ratio, and the like. It can also be changed by changing the free thickness t of the layer. The thickness of the foam layer of the primary foam laminated sheet can be changed by a method such as changing the take-up speed during the production of the primary foam sheet. 1
When the thickness of the foam layer of the secondary foam laminated sheet is reduced, the free thickness t of the foam layer at the time of secondary foam molding becomes small, and when it is increased, the free thickness t of the foam layer becomes growing. Further, the residual volatile component rate is adjusted by changing the amount of the foaming agent during the production of the primary foamed sheet, and by curing the primary foamed laminated sheet (for example, at a temperature at which secondary foaming does not occur for several days to Exposure for several months). When the residual volatile component ratio is low, the secondary expansion ratio is suppressed, and the free thickness t of the foam layer at the time of secondary expansion becomes small.

As described above, the free thickness t of the foam layer during the secondary foaming can be changed without changing the thickness T of the foam layer of the secondary foam laminated sheet molding (interior material for automobile ceiling). Thus, the molding can be performed in the range of 0.3t ≦ T.

When there is only one mold as in the straight forming of vacuum forming, the thickness T of the foam layer of the secondary foam laminated sheet molding and the free thickness of the foam layer during the secondary foaming. The thickness t becomes substantially equal, which is preferable from the viewpoint of heat resistance. Since it is vacuum forming, it has good moldability and is a preferable method.
One.

The thickness of the formed secondary foam laminated sheet is 2.0 to 10 mm, preferably 3.0 to 8 m.
m, expansion ratio with respect to primary foam sheet (secondary expansion ratio)
1.2 to 4 times, more preferably 1.5 to 3 times, the average cell diameter is 0.1 to 2.0 mm, and further 0.2 to 4 times.
1.5 mm, the closed cell rate is 60% or more, and more preferably 70% or more.

When the thickness of the secondary foam laminated sheet molded body is less than 2.0 mm, the strength and heat insulating property are poor and there are cases where it is not suitable as an interior material for automobile ceilings. on the other hand,
If it exceeds 10 mm, it tends to be unnecessarily bulky and the inside of the vehicle tends to be narrow. When the secondary expansion ratio is less than 1.2 times, the flexibility is inferior and breakage due to bending or the like is likely to occur. On the other hand, if it exceeds four times, the strength tends to decrease. Furthermore, when the average cell diameter is less than 0.1 mm,
It is difficult to obtain sufficient strength, and if it is larger than 0.9 mm, the heat insulating property tends to be poor. Furthermore, the closed cell ratio is 6
If it is less than 0%, the rigidity may be poor.

If necessary, a skin material may be laminated on the interior material for an automobile ceiling, which is the secondary foamed laminated sheet molded body.

Specific examples of the skin material include a skin material used as a conventional automobile interior material, such as a woven fabric and a nonwoven fabric. These may be those using synthetic resins such as polyethylene terephthalate, polypropylene, polyamide, polyacrylonitrile, nylon, and the like, or natural materials such as wool and cotton, or a combination thereof. Further, when flame retardancy is required for the interior material for an automobile ceiling of the present invention, it is preferable to use a skin material provided with flame retardancy.

Next, a method of manufacturing the interior material for an automobile ceiling of the present invention will be described.

The modified PPE resin (I) foam layer (primary foam layer) used in the present invention is a mixed resin of PPE resin and PS resin, or a graft copolymer of styrene monomer to PPE resin. If necessary, various additives are added to a polymerized copolymer or the like by an extruder to obtain 150 to 400
Melting and kneading at 150 ° C, then 150-400 ° C, 30-5
Blowing agent 1 for 100 parts of resin under high pressure and high temperature of 00 atm
Optimum foaming temperature (150-300 ℃)
And extrude it into a low pressure range (usually in the atmosphere)
It can be manufactured by a method such as forming into a sheet shape with a mandrel or the like while taking it up under a condition of 0.5 to 4.0 m / min.

As the foaming agent used for producing the modified PPE resin (I) foamed layer, hydrocarbon-based agents such as butane, propane, pentane, methyl chloride, dichloromethane, chlorofluoromethane, dichloroethane and dichlorodifluoroethane are used. Examples thereof include foaming agents and halogenated hydrocarbon foaming agents. These may be used alone or in combination of two or more. Among them, hydrocarbon blowing agents are preferred from the viewpoint of versatility and cost.

The modified PPE resin (I
I) As a method for laminating the non-foamed layer, a method in which a resin which has been molded into a film in advance is foam-molded and adhered to the upper surface or the lower surface of the supplied primary foamed layer by a heat roll or the like, and a multilayer extrusion die is used. Examples of the method include a coextrusion laminating method in which the resin composition of the non-foaming layer supplied from the extruder is laminated in layers on the upper surface or the lower surface of the primary foaming layer which is foam-formed in advance and is in a plastic state. A method of fixing the foam layer with a cooling roller or the like is preferable. Above all, a method of laminating by extruding a foamed sheet of a primary foamed layer and extruding a non-foamed layer in-line is preferable in terms of cost since the number of production steps is reduced.

As a method for producing a molded secondary foam laminated sheet which is an interior material for an automobile ceiling from the obtained primary foam laminated sheet, the primary foam laminated sheet is clamped in the center of a heating furnace having heaters at the top and bottom. Then, it is heated to a temperature suitable for molding, for example, 120 to 200 ° C. for secondary foaming, and then vacuum molding or pressure molding is performed in a temperature-controlled mold. As examples of vacuum forming and pressure forming, plug forming,
Examples include free drawing molding, plug-and-ridge molding, ridge molding, matched molding, straight molding, drape molding, reverse draw molding, air slip molding, plug assist molding, plug assist reverse draw molding and the like. Among these, a method capable of changing the mold clearance such as plug molding or matched molding is preferable.

It is preferable to mold the foamed laminated sheet in a state before the keloid state is generated on the surface of the foamed laminated sheet by the heating in the molding. As a result of the study of the present inventors, it has been found that when molding is performed in a state where a keloid state is generated on the surface during molding heating, the closed cell ratio is reduced and the rigidity of the molded body is reduced. The keloid state is caused by the foam breaking of the foamed layer, and therefore, the closed cell rate is reduced.

For example, the thickness T of the foam layer of the secondary foam laminated sheet molded body of the primary foam laminated sheet is set to a free thickness of the foam layer of the foam laminated sheet at the time of secondary foaming. Secondary foaming is performed so as to satisfy 0.3t ≦ T with respect to t, and molding is performed.

In the case of vacuum molding, secondary foaming is performed using a mold having only one mold like straight molding.
You may shape.

In this way, the interior material for an automobile ceiling of the present invention is manufactured.

When the interior material for automobile ceiling, which is the molded secondary foamed laminated sheet, has a skin, the manufacturing method is as follows. A method of bonding using
A method in which an adhesive is laminated on a primary foam laminated sheet by a binder lamination method or an adhesive previously formed in a film shape by a thermal lamination method, and then the skin material is adhered using a heat roll or the like. Examples of the method include a method of temporarily fixing the skin material and simultaneously performing molding and bonding during heat molding, and a method of simultaneously bonding the skin material when laminating the adhesive on the primary foam laminated sheet.

Examples of the adhesive include thermoplastic adhesives, hot melt adhesives, rubber adhesives, thermosetting adhesives, monomer reactive adhesives, inorganic adhesives and natural adhesives. A hot-melt adhesive is preferable because of its easy adhesion.

Examples of the hot melt adhesive include polyolefin type, modified polyolefin type, polyurethane type,
Examples thereof include those containing a resin such as ethylene-vinyl acetate copolymer resin system, polyamide system, polyester system, thermoplastic elastomer system, styrene-butadiene copolymer system and styrene-isoprene copolymer system.

In the interior material for an automobile ceiling of the present invention as described above, the non-foaming layer is not provided on both sides of the modified PPE resin (I) foam layer as in the conventional method, but the non-foaming layer is provided only on one side. By arranging and using the non-foamed layer on the indoor side (lower surface), it is possible to obtain an inexpensive interior material for an automobile ceiling, which has good heat resistance and has few manufacturing steps.

[0065]

EXAMPLES The interior material for an automobile ceiling of the present invention will be described in more detail based on the following examples, but the invention is not intended to be limited thereto.

The resins used in Examples and Comparative Examples are shown in Table 1, and other materials are shown in Table 2.

The PPE resin in Table 1 is a polymer of 2,6-dimethylphenylene-1,4-ether, the PS resin is polystyrene, and the rubber component is styrene-butadiene rubber. The film (D) is a polyamide hot melt film, and the skin material (E) is a polyethylene terephthalate fiber nonwoven fabric.

[0068]

[Table 1]

[0069]

[Table 2]

Further, the mounting heat resistance test and the compressibility of the interior materials for automobile ceilings (secondary foam laminated sheet moldings) in Examples and Comparative Examples were evaluated according to the following methods.

(Mounting heat resistance test) Interior material for automobile ceiling (size 930 mm × 1425 mm, angle of bent portion of front portion is 120 ° as shown in FIG. 6, center of bent portion (from front side for obtaining angle) 15 mm from the point where the line that bisects the angle of the intersection of the extension line of the
It is. (This length is approximately the same as the length of the front part of the interior material for automobile ceilings, from the intersection of the two extension lines.)
Was mounted on the ceiling of the car and fixed through a sun visor, room mirror, room lamp, ganish pillar, and in the same way as the actual car. Also, there are 6 measurement points on the front part, 120m symmetrical to the center line of the interior material for automobile ceilings.
It was marked at m intervals (a to f in FIG. 3). A marked line was provided near the measurement point on the front part to measure the distance in the vertical direction. Next, after putting the automobile ceiling part with the automobile ceiling interior material attached to the temperature-controlled room set at 85 ° C for 24 hours, the dimensional change in the vertical direction of the measurement points stamped on the front part of the automobile ceiling interior material was placed. The absolute value of the quantity was measured.

(Compressibility) Thickness T of the foam layer of the interior material for automobile ceiling (secondary foam laminated sheet molded body) (front bent portion) and free thickness t of the foam layer of the foam sheet at the time of secondary foaming. The compression ratio (%) was calculated from the thickness T of the foamed layer of the secondary foamed laminated sheet molded body / the free thickness t of the foamed layer of the foamed laminated sheet at the time of secondary foaming.

Example 1 Mixed resin 100 in which 72.7 parts of modified PPE resin (A) and 27.3 parts of PS resin (B) were mixed so that PPE resin component was 40% and PS resin component was 60%. Part, i
A foaming agent containing so-butane as a main component (iso / n = 85
/ 15) 3 parts and talc 0.32 part are kneaded by an extruder at 305 ° C., cooled to a resin temperature of 198 ° C., extruded from a circular die, cut open, and wound through a take-up roll at a speed of 5 m / min. It was wound around a take-up roll.

The obtained primary foam sheet has a thickness of 2.3 m.
m, width 120 cm, primary expansion ratio 10 times, closed cell rate 8
5%, average cell diameter 0.19 mm, basis weight 240 g / m ²
Met.

The obtained primary foamed sheet was fed at 5 m / min, and the modified PPE resin (A) 54 was added so that the PPE resin component, the PS resin component and the rubber component were 30%, 64% and 6%, respectively. .5 parts and PS resin (B) 35.
A resin composition obtained by mixing 5 parts and 10 parts of an impact resistance improver (C) is melted and kneaded at 310 ° C., and extruded at a resin temperature of 278 ° C. using a T die to give a thickness on one side of the primary foam sheet 1
A non-foamed layer of 50 μm was laminated to produce a continuous primary foamed laminated sheet having a width of 120 cm. The obtained primary foam laminated sheet was cut, and the thickness was 120 cm × 160 cm and the thickness was 2.
A 5 mm primary foam laminated sheet was obtained.

The obtained cut primary foam laminated sheet was clamped on all sides and placed in a heating furnace having a furnace temperature of 200 ° C.,
Heat until the surface temperature reaches 150 ° C, and arrange with the mold whose temperature is adjusted to 80 ° C so that the convex mold side is on the non-foaming layer side.
After plug molding was performed for 10 seconds using a mold having a mold clearance of 3.5 mm, trimming was performed by punching, and FIG. 3 (the AA cross sectional explanatory view and BB cross sectional explanatory view are shown in FIG. 4 and FIG. No. 5), an interior material for an automobile ceiling (test sample, thickness 3.5 mm, foam layer thickness 3.4 mm) was obtained. In FIG. 3, 8 is an assist grip mounting hole, 9 is a sun visor mounting hole, 10 is a rearview mirror mounting hole, and 11 is an interior light mounting hole.

Further, under the same heating condition, a secondary foamed laminated sheet in a free foamed state without plug molding was obtained. The thickness of the secondary foam laminated sheet at this time is 5.6 mm.
(The thickness of the foam layer was 5.5 mm).

The test sample thus obtained was arranged as shown in FIG. 6 so that the non-foaming layer side was on the indoor side (the non-foaming layer was the lower surface), and the heat resistance was evaluated. Table 3 shows the results.

Example 2 Interior material for automobile ceiling trimmed by punching in the same manner as in Example 1 except that the mold clearance was 4.5 mm (test sample, thickness 4.5 mm, thickness of foam layer) 4.4 mm).

The obtained test sample was arranged as shown in FIG. 6 so that the non-foaming layer side was on the indoor side (the non-foaming layer was the lower surface), and the heat resistance was evaluated. Table 3 shows the results.

Comparative Example 1 In the same manner as in Example 1, a primary foam laminated sheet was obtained.

The obtained cut primary foam laminated sheet was clamped on all sides and placed in a heating furnace having a furnace temperature of 200 ° C.,
Heat the surface temperature to 150 ° C, and arrange it so that the convex mold side is on the foam layer side with a mold whose temperature is adjusted to 80 ° C. Plug with a mold clearance of 3.5 mm for 10 seconds. After molding, trimming is performed by punching, and the same shape as that of the first embodiment as described in FIG. 3 (the AA sectional explanatory view and the BB sectional explanatory diagram are FIG. 7 and FIG. 8). The interior material for automobile ceiling (test sample, thickness 3.5 mm, foam layer thickness 3.4 mm) was obtained.

The heat resistance was evaluated by arranging the obtained test sample as shown in FIG. 9 so that the foam layer side was on the indoor side (the non-foam layer was the upper surface). Table 3 shows the results.

Example 3 100 parts of modified PPE resin (A) containing 55% PPE resin component and 45% PS resin component, and a blowing agent containing iso-butane as a main component (iso / n = 85/15). 3 parts and 0.32 part of talc were kneaded by an extruder at 315 ° C., cooled to a resin temperature of 205 ° C., extruded from a circular die and cut open, and rolled into a take-up roll through a take-up roll at a speed of 5 m / min. It was wound into a shape.

The obtained primary foam sheet has a thickness of 2.3 m.
m, width 120 cm, primary expansion ratio 10 times, closed cell rate 8
7%, average cell diameter 0.17 mm, basis weight 240 g / m ²
Met. While paying out the obtained primary foamed sheet at a speed of 5 m / min, the modified PPE resin (A) 54. was added so that the PPE resin, the PS resin and the rubber component were 30%, 64% and 6%, respectively. 5 parts and PS resin (B) 3
A resin composition obtained by mixing 5.5 parts and 10 parts of an impact resistance improver (C) is melted and kneaded at 310 ° C., and extruded at a resin temperature of 278 ° C. using a T die to form one side of a primary foam sheet. A non-foamed layer having a thickness of 150 μm was laminated to manufacture a continuous primary foamed laminated sheet having a width of 120 cm. The obtained primary expanded laminated sheet was cut to obtain a primary expanded laminated sheet having a size of 120 cm × 160 cm and a thickness of 2.5 mm.

The obtained cut primary foam laminated sheet was clamped on all sides and placed in a heating furnace having a furnace temperature of 210 ° C.,
Heat until the surface temperature reaches 160 ° C, and arrange it so that the convex mold side is on the non-foaming layer side with a mold whose temperature is adjusted to 80 ° C.
After plug molding was performed for 10 seconds using a mold having a mold clearance of 3.5 mm, trimming was performed by punching, and FIG. 3 (the AA cross sectional explanatory view and BB cross sectional explanatory view are shown in FIG. 4 and FIG. 5) was obtained as an interior material for an automobile ceiling (test sample, thickness 3.5 mm, foam layer thickness 3.4 mm) having the same shape as in Example 1.

Further, under the same heating condition, a secondary foamed laminated sheet in a free foam state in which plug molding was not performed was obtained. The thickness of the secondary foam laminated sheet at this time is 5.6 mm.
(The thickness of the foam layer was 5.5 mm).

The test sample thus obtained was arranged as shown in FIG. 6 so that the non-foaming layer side was on the indoor side (the non-foaming layer was the lower surface), and the heat resistance was evaluated. Table 3 shows the results.

Comparative Example 2 In the same manner as in Example 3, a primary foam laminated sheet was obtained.

The obtained cut primary foam laminated sheet was clamped on four sides and placed in a heating furnace having a furnace temperature of 210 ° C.,
Heat up to a surface temperature of 160 ° C, place it in a mold controlled to 80 ° C with the convex mold side facing the foam layer, and use a mold with a clearance of 3.5 mm for 10 seconds. After molding, trimming is performed by punching, and the same shape as that of the first embodiment as described in FIG. 3 (the AA sectional explanatory view and the BB sectional explanatory diagram are FIG. 7 and FIG. 8). The interior material for automobile ceiling (test sample, thickness 3.5 mm, foam layer thickness 3.4 mm) was obtained.

The obtained test sample was placed as shown in FIG. 9 so that the foam layer side was on the indoor side (the non-foam layer was the upper surface), and the heat resistance was evaluated. Table 3 shows the results.

Example 4 In the same manner as in Example 1, a primary foam laminated sheet was obtained.

Then, the four sides of the primary foam laminated sheet having the skin material in which the skin material (E) shown in Table 2 is temporarily fixed with the hot melt film (D) on the non-foamed layer surface of the primary foam laminated sheet is clamped. Then, it is placed in a heating furnace having a furnace temperature of 200 ° C., heated so that the surface temperature becomes 150 ° C., and is arranged so that the convex mold comes to the non-foaming layer side with the mold whose temperature is adjusted to 80 ° C. After performing plug molding with a die clearance of 5 mm, trimming was performed by punching to obtain an interior material for an automobile ceiling (test sample) having the same shape as in Example 1.

The obtained test sample was placed as shown in FIG. 10 so that the non-foaming layer side was on the indoor side (the non-foaming layer was the lower surface), and the heat resistance was evaluated. Table 4 shows the results.

Example 5 In the same manner as in Example 3, a primary foam laminated sheet was obtained.

Next, the four sides of the primary foam laminated sheet having the skin material in which the skin material (E) shown in Table 2 is temporarily fixed to the non-foamed layer surface of the primary foam laminated sheet with the hot melt film (D) are clamped. Then, it is placed in a heating furnace at a furnace temperature of 210 ° C., heated so that the surface temperature becomes 160 ° C., and arranged with the convex mold side facing the non-foaming layer side with a mold whose temperature is adjusted to 80 ° C. After performing plug molding with a mold clearance of 5 mm, trimming was performed by punching to obtain an automobile ceiling interior material (test sample) having the same shape as in Example 1.

The test sample thus obtained was arranged as shown in FIG. 10 so that the non-foaming layer side was on the indoor side (the non-foaming layer was the lower surface), and the heat resistance was evaluated. Table 4 shows the results.

Comparative Example 3 In the same manner as in Example 1, a primary foam laminated sheet was obtained.

Then, the four sides of the primary foam laminated sheet having the skin material obtained by temporarily fixing the skin material (E) shown in Table 2 to the foam layer surface of the primary foam laminated sheet with the hot melt film (D) were clamped. The mold is placed in a heating furnace with a furnace temperature of 200 ° C., heated to a surface temperature of 150 ° C., and the mold is arranged so that the convex mold side is on the foam layer side with a mold whose temperature is adjusted to 80 ° C. After performing plug molding with a clearance of 5 mm, trimming by punching was performed, and Example 1 was performed.
Interior material for automobiles with the same shape as the above (sample for testing)
I got

The heat resistance was evaluated by arranging the obtained test sample as shown in FIG. 11 so that the foam layer side was on the indoor side (the foam layer was the lower surface). Table 4 shows the results.

[0101]

[Table 3]

[0102]

[Table 4]

From the results shown in Table 3, the deformation of the front portion due to the heat resistance test was small in the Examples as compared with the Comparative Examples.
It can be seen that the heat resistance is excellent. Further, it can be seen that Example 2 is a preferable mode in which the compressibility is small, the deformation amount by the heat resistance test is small, and the heat resistance is excellent as compared with Example 1. Further, it can be seen that even if the PPE resin ratio of the foam layer is changed as in Example 3 and Comparative Example 2, the example has better heat resistance.

Further, from the results of Table 4, even when the skin material is laminated via the hot melt adhesive, in Examples 4 and 5, the deformation of the front portion due to the heat resistance test is smaller than that in Comparative Example 3. It can be seen that the heat resistance is excellent.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram of the vicinity of an upper part of an automobile windshield for explaining a state in which an automobile ceiling interior material of the present invention is attached to an automobile.

FIG. 2 is a cutaway explanatory view for explaining a state in which the interior material for an automobile ceiling of the present invention is attached to an automobile.

FIG. 3 is an explanatory plan view for explaining a planar shape after trimming by punching the interior materials for automobile ceilings molded in Examples 1 to 5 and Comparative Examples 1 to 3 of the present invention.

FIG. 4 is an AA cross-sectional explanatory view of FIG. 3 regarding an interior material for an automobile ceiling formed in Examples 1 to 3 of the present invention.

5 is a cross-sectional view taken along line BB of FIG. 3 for the interior materials for automobile ceilings molded in Examples 1 to 3 of the present invention.

FIG. 6 is a cross-sectional explanatory view in the vicinity of an upper portion of an automobile windshield for explaining a state in which an automobile ceiling interior material formed in Examples 1 to 3 of the present invention is mounted on an actual vehicle.

FIG. 7 is an AA cross-sectional explanatory view of FIG. 3 regarding an interior material for an automobile ceiling molded in Comparative Examples 1 and 2 of the present invention.

FIG. 8 is a cross-sectional view taken along line BB in FIG. 3 showing the interior materials for automobile ceilings molded in Comparative Examples 1 and 2 of the present invention.

FIG. 9 is a cross-sectional explanatory view of the vicinity of an upper portion of an automobile windshield for explaining a state in which an automobile ceiling interior material formed in Comparative Example 3 of the present invention is mounted on an actual vehicle.

FIG. 10 is a cross-sectional explanatory view in the vicinity of an upper portion of an automobile windshield for explaining a state in which an automobile ceiling interior material formed in Examples 4 to 5 of the present invention is mounted on an actual vehicle.

FIG. 11 is a cross-sectional explanatory view in the vicinity of an upper portion of an automobile windshield for explaining a state in which an automobile ceiling interior material formed in Comparative Example 3 of the present invention is mounted on an actual vehicle.

[Explanation of symbols]

 1 Roof 2 Interior material for automobile ceiling 3 Modified PPE resin (I) Foam layer 4 Modified PPE resin (II) Non-foam layer 5 Adhesive 6 Skin material 7 Windshield 8 Assist grip mounting hole 9 Sun visor mounting hole 10 Room Mirror mounting hole 11 Indoor light mounting hole

Claims (5)

[Claims] 1. A primary foamed laminated sheet comprising a modified polyphenylene ether resin (I) foamed layer laminated with a non-foamed layer of the modified polyphenylene ether resin (II) only on one side of the foamed layer. An interior material for an automobile ceiling, characterized in that the non-foamed layer side is arranged on the interior side. 2. A modified polyphenylene ether resin (I
The interior material for an automobile ceiling according to claim 1, wherein I) a skin material is further laminated on the non-foamed layer. 3. The modified polyphenylene ether-based resin (I) foam layer comprises polyphenylene ether-based resins 25 to 7
A mixture of 5% by weight and polystyrene type resin 75 to 25% by weight and / or polyphenylene ether type resin 25
The interior material for an automobile ceiling according to claim 1 or 2, which comprises a copolymer obtained by polymerizing 75% to 75% by weight of 75% to 25% by weight of a styrene monomer. 4. The thickness T of the foam layer of the foam laminated sheet obtained by secondary foaming and molding the primary foam laminated sheet is the free thickness t of the foam layer of the foam laminated sheet at the time of secondary foaming. On the other hand, the interior material for an automobile ceiling according to claim 1, 2 or 3, which is manufactured by adjusting so that 0.3t ≦ T. 5. The thickness T of the foam layer of the foam laminated sheet obtained by secondary foaming and molding the primary foam laminated sheet is the free thickness t of the foam layer of the foam laminated sheet at the time of secondary foaming. On the other hand, the interior material for an automobile ceiling according to claim 1, 2 or 3, which is manufactured by adjusting so that 0.5t ≦ T.