JPH09226034A - Foamed laminated sheet for automobile interior material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a foamed laminated sheet for an automobile interior material of superior heat resistance and dimensional stability to be manufactured inexpensively and easily by laminating non-foamable layers composed of a thermoplastic resin containing an inorganic film at least on one face of a modified polyphenylene ether resin foamed layer. SOLUTION: A non-foamable layer 4 composed of a thermoplastic resin 4, preferably of a modified PPE resin containing an inorganic filler, is laminated as an automobile interior material at least on one face of a modified polyphenylene ether(PPE) resin foamed layer 3. An inorganic filler, talc, calcium carbonate and mica of 1-50 pts.wt. to thermoplastic resin of 100 pts.wt. are contained in the non-foamable layer 4. A rubber content of 1-15 pts.wt. is contained is the thermoplastic resin constituting the non-foamable layer 4. In the foamed layer 3, a mixed resin composed of PPE resin containing a PPE component of 25-75 pts.wt. and a polystyrene (PS) component of 30-75 pts.wt. and PS resin, graft copolymer resin composed of phenylene ether and styrene and the like are contained as base resins.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a modified polyphenylene ether (hereinafter abbreviated as modified PPE) resin foamed layer in which a non-foamed layer is laminated to improve heat resistance, and is lightweight, formable, soundproof, and heat insulating. The present invention relates to an inexpensive foam laminated sheet for automobile interior materials, which has excellent impact resistance.

[0002]

2. Description of the Related Art Conventionally, as an automobile interior material, a urethane foam laminated on a base material mainly composed of a thermoplastic resin foam, or styrene-maleic anhydride on the upper and lower surfaces of a foamed layer of a styrene-maleic anhydride copolymer. A laminate sheet formed by laminating a non-foamed layer of an acid copolymer into a desired shape is widely used. These automobile interior materials are characterized by being lightweight, having high heat insulating properties, and having excellent moldability. However, conventional automobile interior materials, especially automobile ceiling base materials, when used in applications where they are exposed to high temperatures for a long time, have problems such as hanging down under their own weight (heat sag) due to insufficient heat resistance. There was something to do.

Therefore, in order to improve heat resistance, modified PPE is formed on the upper and lower surfaces of the modified PPE resin foam layer having high heat resistance.
A foamed laminated sheet for automobile interior materials using a foamed laminated sheet in which a non-foamed resin-based layer is laminated has been proposed (Actual Kaihei 4
-11162). The foamed laminated sheet for automobile interior materials using the modified PPE resin is excellent in heat resistance and is lightweight, and is said to have improved heat sag at high temperatures. On the other hand, in recent years, the emphasis has been placed on the comfort of the vehicle interior space, and the interior space of the automobile has become large in order to provide room for the interior space. For this reason, the weight reduction of general automobile ceiling base materials has been carried out, and the quality requirements for heat resistance and dimensional stability of automobile ceiling base materials have become more severe.

[0004] In order to solve these problems,
Conventionally, automobile interior materials based on composite materials of inorganic glass fibers and plastics have been used. But,
With this structure, although the quality of heat resistance can be maintained,
There is a problem that the weight cannot be reduced and the cost becomes high.

[0005]

In view of the above situation, the present invention has an excellent heat resistance (non-heat sag property) and an excellent dimensional stability, and can be manufactured inexpensively and easily in an automobile interior material. The present invention provides a foam laminated sheet for use.

[0006]

[Means for Solving the Problems] In order to reduce the weight while maintaining the heat resistance, the present inventors have diligently changed the structure of the foam laminated sheet for automobile interior materials by using the modified PPE resin foam layer. As a result of the examination, by mixing an inorganic filler with the thermoplastic resin of the non-foamed layer, it has excellent heat resistance and is effective in suppressing the linear expansion coefficient. I found what I could get. The present inventors have used a non-foamed layer containing an inorganic filler on at least one side of a foamed layer for automobile interior materials, which is lightweight and has high heat resistance that has never been obtained. Good dimensional stability, moldability, and impact resistance. The inventors have invented a foamed laminated sheet for a vehicle interior material of a modified PPE resin having sound insulation, heat insulation and cost competitiveness.

In order to solve the above-mentioned problems, according to the present invention, a thermoplastic resin containing an inorganic filler, preferably a non-foamed layer made of a modified PPE resin is laminated on at least one surface of a modified PPE resin foam layer as an automobile interior material. Provided is a foamed laminated sheet for automobile interior materials. Moreover, in order to solve the said subject, this invention contains the foaming laminated sheet for automotive interior materials in which the non-foaming layer contains 1-50 weight part inorganic filler with respect to 100 weight part thermoplastic resin.

Further, in order to solve the above-mentioned problems, the present invention provides a foam laminated sheet for an automobile interior material in which a non-foam layer containing an inorganic filler is used on the upper surface of the foam layer (the ceiling surface side in the vehicle). Further, in order to solve the above problems, the present invention provides a foamed laminated sheet for automobile interior materials, which uses a modified polyphenylene ether resin as a base resin as a non-foamed layer containing an inorganic filler.

In order to solve the above-mentioned problems, according to the present invention, a foam layer comprises 25 to 70 parts by weight of a PPE component and 30 to 75 parts by weight of a polystyrene component, a mixed resin of a PPE resin and a PS resin, and phenyl ether. Primary obtained by using a modified PPE resin made of a graft copolymer resin with styrene or a mixed resin of the copolymer resin and a PS resin as a base resin, adding a foaming agent to the base resin, and extruding and foaming the resin. A foam laminated sheet for automobile interior material, which has a thickness of 1 to 5 mm, a primary expansion ratio of 3 to 20 times, a cell diameter of 0.05 to 0.3 mm, and a foam layer having a closed cell ratio of 70% or more as contents. And

The method for producing the modified PPE resin foam layer used in the present invention is to add various additives to the modified PPE resin, melt and knead with an extruder, and press the foaming agent under high temperature and high pressure. A suitable method is to adjust the foaming optimum temperature, extrude into a low pressure zone (usually in the atmosphere), and then form into a sheet by a mandrel or the like. Examples of the base resin of the modified PPE resin foam layer include a mixed resin of PPE and PS, a graft copolymer of phenyl ether and styrene, a mixed resin of the copolymer and PS resin, etc. A mixed resin of PPE and PS is preferable in that

Examples of the PPE resin polymerization monomer used in the present invention include 2,6-dimethylphenylene-1,4-ether, 2-methyl-6-ethylphenylene-1,4-ether and 2 , 6-Diethylphenylene-1,4-ether, 2-methyl-6-n-propylphenylene-1,4-ether, 2-methyl-6-n-butylphenylene-1,4-ether, 2-methyl- 6-
Chlorphenylene-1,4-ether, 2-methyl-6
-Bromphenylene-1,4-ether, 2-ethyl-
6-Chlorophenylene-1,4-ether and the like can be mentioned, and these can be used alone or in combination of two or more kinds.

Examples of the styrene-based monomer graft-copolymerized with phenyl ether or the styrene-based monomer for polystyrene polymerization blended with PPE include styrene, α-methylstyrene, 2,4-dimethylstyrene, monochlorostyrene and dichloro. Examples thereof include styrene, p-methylstyrene, ethylstyrene and the like. In any of the above-mentioned polyphenylene ether and polystyrene, a compound capable of being polymerized with each of them, for example, acrylonitrile, methacrylonitrile, methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, maleic anhydride, etc. Also includes those obtained by polymerizing two or more kinds.

The above-mentioned method for producing a graft copolymer of polyphenylene ether and a styrene compound may be a conventionally known method, for example, Japanese Patent Publication Nos. 52-30991, 52-38596 and 52-142799. It is disclosed. Examples of the foaming agent used in the production of the modified PPE-based resin foam layer include hydrocarbons such as butane, propane, pentane, methyl chloride, dichloromethane, chlorofluoromethane, dichloroethane, dichlorodifluoroethane, and halogenated hydrocarbons. Alternatively, they may be used in combination.

The base resin of the modified PPE resin foam layer used in the present invention may contain a cell regulator, an impact resistance improver, a lubricant, an antioxidant, an antistatic agent, a pigment, etc., if necessary. can do. In the present invention, the foamed sheet using the modified PPE resin as the base resin is the PPE component 25 to 7
P, which is 0 to 30 parts by weight and 75 to 30 parts by weight of polystyrene component
Using a mixed resin of PE and PS, a graft copolymer of phenyl ether and styrene, a mixed resin of the copolymer and PS resin as a base resin, and adding a foaming agent to the base resin for extrusion foaming. The obtained primary thickness is preferably 1 to 5 mm, the primary expansion ratio is 3 to 20 times, the cell diameter is 0.05 to 0.3 mm, and the closed cell ratio is preferably 70% or more. PPE3
0 to 65 parts by weight and the polystyrene component 35 to 70 parts by weight are more preferable, and PPE 35 to 60 parts by weight and the polystyrene component 40 to 65 parts by weight are even more preferable. The amount of volatile components remaining in the foamed sheet is 1 to 5 parts by weight,
It is preferably 2 to 4 parts by weight.

When the mixed weight part of the PPE resin is small, the heat resistance tends to be inferior, and when the mixed weight part of the PPE resin is large, the viscosity at the time of heating and flowing may be increased to make foam molding difficult. . When the primary thickness of the foamed sheet is less than 1 mm, it may be unsuitable as a foamed laminated sheet for automobile interior materials due to poor strength and heat insulating properties. Further, when the primary thickness of the foamed sheet is 5 mm or more, it is difficult for heat to be transferred to the central portion in the thickness direction of the modified foamed layer at the time of molding heating, so that sufficient heating cannot be performed and moldability may deteriorate. Further, if the heating time is extended to perform sufficient heating, the cells on the surface of the foam layer will be broken, and it will be difficult to obtain an acceptable product. When the primary expansion ratio is less than 3 times, the flexibility is poor and damage due to bending is likely to occur, and a lightweight product cannot be obtained. When it is 20 times or more, the strength and moldability tend to be poor.
When the cell diameter is 0.05 mm or less, strength cannot be obtained, and
When it is 3 mm or more, the heat insulating property tends to be poor. Further, when the closed cell ratio is 70% or less, the heat insulating property and the rigidity are poor, and it becomes difficult to obtain the secondary expansion ratio at the time of molding and heating, and the moldability tends to be poor.

As a method for laminating a non-foamed layer on the modified PPE resin foamed layer in the present invention, a resin which has been molded into a film shape in advance is foam-molded and supplied on the upper and / or lower surface of the foamed layer such as a heat roll. Examples of the method include a method of adhering by a method of coextrusion, a method of coextrusion lamination using a multi-layer extrusion die, and the like. A method of laminating and fixing the layers with a cooling roller or the like is preferable. Above all, a method of laminating by extruding a foamed layer into an extruded foam sheet and extruding a non-foamed layer in-line is particularly preferable.

Polystyrene resin (PS resin), heat-resistant polystyrene resin (heat-resistant PS resin), and modified PPE are used as the thermoplastic resin of the non-foamed layer.
Resin, polypropylene (PP) resin, polyethylene (PE) resin, polyethylene terephthalate (PE
T) -based resins, polyamide (nylon) -based resins, and the like, which may be used alone or in combination of two or more, and are PS-based, because of their adhesiveness to the modified PPE-based resin foam layer.
Heat-resistant PS-based and modified PPE-based resins are suitable. Heat resistant PS
Examples of the system resin include copolymers of styrene and a carboxyl group-containing monomer, for example, styrene-maleic anhydride copolymer, styrene-acrylic acid copolymer, styrene-methacrylic acid copolymer, styrene-itaconic acid copolymer. Examples thereof include blends of polymers and copolymers thereof with polymers such as polystyrene, polycarbonate, and polyphenylene oxide. The modified PPE resin is particularly preferable in terms of heat resistance, rigidity, and adhesiveness with the foamed sheet.

As the modified PPE resin preferably used for the non-foamed layer, the same as the modified PPE resin used for the foamed layer, PPE containing 25 to 70 parts by weight of PPE component and 75 to 30 parts by weight of polystyrene component. Examples thereof include a mixed resin of PS, a graft copolymer of phenyl ether and styrene, a mixed resin of the copolymer and PS resin, and the like, and a mixed resin of PPE and PS is preferable in terms 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 that can be polymerized with the body are the same as those of the foam layer, and thus the description thereof is omitted. However, a styrene-butadiene copolymer typified by high-impact polystyrene (HIPS) is added as a preferable specific example of the PS-based resin because the non-foamed layer has a large impact resistance improving effect.

The ratio of PPE component of the modified PPE resin is 2
When the amount is less than 5 parts by weight, the heat resistance of the molded article tends to be poor, and when the ratio of the PPE component of the modified PPE resin is 70 parts by weight or more, the molding tends to be difficult. . In the foamed laminated sheet of the present invention, the non-foamed layer is laminated on both sides or one side of the foamed layer, but the latter, which is inexpensive in manufacturing cost and lightweight, is preferable.

The inorganic filler to be mixed in the non-foamed layer in the present invention is not particularly limited, and talc (magnesium silicate), calcium carbonate (heavy, light, colloidal, etc.), mica, magnesium oxide, magnesium carbonate, sulfuric acid. Examples thereof include barium, calcium sulfate, calcium sulfite, silica, clay, kaolin, white carbon, magnesium hydroxide, carbon black, zeolite and molybdenum, and among these, talc, calcium carbonate and mica are particularly preferable. The amount of the inorganic filler added is 1 to 50 parts by weight, preferably 5 parts by weight, based on 100 parts by weight of the modified PPE resin.
４０40 parts by weight. If this addition amount is less than 1 part by weight, a clear effect of filling the inorganic material such as heat resistance cannot be obtained,
If it is added in excess of 50 parts by weight, the viscosity of the resin increases and a large load is applied to the extruder, which is not preferable, and the impact strength of the non-foamed layer is significantly reduced.

In the thermoplastic resin of the non-foamed layer used in the present invention, an impact resistance improver, a lubricant, an antioxidant, an antistatic agent, a pigment, etc. may be used alone or in combination of two or more kinds, if necessary. It can be added. The impact resistance improver is a non-foaming layer that is laminated on a modified PPE resin foam layer, and is used for transporting an automobile interior material molded by secondary foaming, or for further punching processing on the automobile interior material. It is used to prevent cracking of the foam layer, and is used by being mixed with the thermoplastic resin forming the non-foam layer. Specifically, natural rubber and synthetic rubber are used as the impact modifier. Suitable rubbers or rubbery polymers include, for example, natural crepe rubber, SBR type rubber, GR-N type rubber, butadiene rubber, butadiene-styrene rubber or synthetic rubber produced from isoprene, elastomeric modified dienes. Examples thereof include polymers and rubber-like polymers of polybutadiene and styrene.
The amount of the impact resistance improver to be added is generally preferably such that the thermoplastic resin forming the non-foamed layer contains 1 to 15 parts by weight of a rubber component.

As a method for specifying the amount of the rubber component in the modified PPE resin containing the rubber component, the mixed resin is dissolved in a solvent in which the rubber component is insoluble and the modified PPE resin is dissolved,
There are a method of separating the insoluble matter and measuring the weight (fractionation method), a method of measuring and quantifying by IR and the like. For example, the rubber component is S
In the case of BR, the modified PPE containing rubber is dissolved in a toluene solvent and the weight of the insoluble portion is measured to calculate the weight ratio of the rubber component.

In the foam laminated sheet of the present invention, the thickness of the non-foam layer laminated on the foam layer is preferably 50 to 300 μm. When the thickness is less than 50 μm, the strength, rigidity, heat resistance and the like are poor, and when the thickness is more than 300 μm, the moldability is poor. The modified PPE resin foam laminated sheet used in the present invention can be laminated with a skin material used as a conventional automobile interior material, for example, a woven fabric, a non-woven fabric, a foam layer or the like, if necessary. As the base material of the skin material, synthetic resins such as polyethylene terephthalate, polypropylene, polyamide, polyacrylonitrile and nylon, and natural materials such as wool and cotton can be used, and they may be combined.

Examples of the method for adhering the skin material to the modified PPE resin foam laminated sheet used in the present invention include a method for adhering it to the foam laminated sheet via an adhesive. Examples of adhesives include thermoplastic adhesives, hot melt adhesives, rubber adhesives, thermosetting adhesives, monomer-reactive adhesives, inorganic adhesives, natural adhesives, etc. Hot melt adhesives are suitable in this respect. Hot melt adhesives include olefin-based, modified olefin-based, polyurethane-based, ethylene / vinyl acetate copolymer resin-based, polyamide-based, polyester-based, thermoplastic rubber-based, styrene-butane copolymer, styrene-isoprene copolymer-based An example of which is a resin.

As a method for adhering the skin material, a method in which an adhesive is preliminarily adhered to the skin material is adhered to the foamed laminated sheet using a heat roll or the like, or it is temporarily fixed to the foamed laminated sheet and molded during heat molding. A method of bonding at the same time,
A method of adhering the skin material to the foam laminated sheet using a heat roll or the like, or temporarily fixing the skin material to the foam laminated sheet in which the adhesive is laminated on the foam laminated sheet by the binder lamination method or the adhesive formed in advance in a film shape by the heat lamination method. Then, a method of simultaneously performing molding and adhesion at the time of heat-molding, a method of simultaneously adhering a skin material when laminating an adhesive on a foam laminated sheet, and the like can be mentioned.

As a method for molding a foamed laminated sheet for automobile interior materials according to the present invention, the laminated sheet is guided by clamping it in the center of a heating furnace having heaters above and below, and heated to a temperature suitable for molding to carry out secondary foaming. After that, vacuum molding, pressure molding, free drawing molding, plug and ridge molding, ridge molding, matched mold molding, straight molding, drape molding, reverse draw molding, air slip molding, etc. Examples of the molding method include plug-assist molding and plug-assist reverse draw molding. In addition, it is desirable that the secondary thickness of the foamed layer is 2.0 to 10 mm due to secondary foaming of the foamed layer during molding.

When the foamed laminated sheet for automobile interior materials according to the present invention is fixed to an automobile, a non-foamed layer containing an inorganic filler is used as shown in FIG. It is desirable to arrange it on the side) from the viewpoint of strength at high temperature.

[0029]

The foamed laminated sheet for automobile interior materials, which has improved heat resistance by providing a non-foamed layer having at least one surface filled with an inorganic filler, is not only improved in heat sag at high temperatures but also lightweight and inexpensive. It has excellent quality and cost competitiveness that have never existed before.

[0030]

Embodiments of the present invention will be described below. The present invention is not limited by these. Table 1 shows resins used in Examples and Comparative Examples, Table 2 shows fillers, and Table 3 shows other materials.

[0031]

[Table 1]

[0032]

[Table 2]

[0033]

[Table 3]

Regarding the heat resistance test of the molded product of the foamed laminated sheet, the heat sag test (cantilever heat resistance test) is carried out by the following method.
Was done. 225 mm with a part of the molded body as a test piece
Cut out in a dimension of (extruded MD direction of foamed laminated sheet) × 25 mm (width TD direction of foamed laminated sheet), clamp one end 25 mm of the test piece to a holder, and leave one side in a free state and overhang it by 200 mm Let Mark the measurement point on the upper surface of the free end and add 5g to the position 5mm from the free end.
A weight was put on and a load was applied. A marked line was provided to measure the sag of the free end of the test piece, and the distance between the marked line and the measurement point was measured before heating. Next, the test piece holder was placed in a constant temperature bath set at 85 ± 1 ° C. for 2 hours. Then, the test piece holder was taken out from the constant temperature bath, the distance between the measurement point of the heated test piece and the marked line was measured, and the amount of sagging of the tip of the test piece was calculated.

The evaluation criteria are as follows. A: The sagging of the test piece is less than 5 mm. ◯: The sagging of the test piece is 5 mm or more and less than 10 mm. X: The sagging of the test piece is 10 mm or more. (Primary expansion ratio, average cell diameter, closed cell ratio) Primary expansion ratio: The density df of the foamed sheet is defined by JIS K72.
22 to measure the density dp of the modified PPE resin according to JI
It was measured according to SK7112. Primary expansion ratio = df / dp Average cell diameter: The cross section of the foamed sheet was observed with an optical microscope and an electron microscope, and an arbitrary n = 20 or more cell diameter was measured and averaged to calculate. Closed cell ratio: The foamed sheet was measured according to ASTM D-2856 (using a multi-vicnometer (manufactured by Beckman)).

[0036]

Example 1 For 100 parts by weight of a mixed resin in which PPE resin (A) and PS resin (C) were mixed so that the PPE resin component was 40% by weight and the PS resin component was 60% by weight, i
A foaming agent containing so-butane as a main component (iso / n = 85
/ 15) 3 parts by weight and 0.32 parts by weight of talc are kneaded by heating with an extruder, cooled to a resin temperature of 198 ° C., and extruded with a circular die to have a primary thickness of 2.6 mm,
A primary foaming ratio of 10 times, a closed cell rate of 85%, an average cell diameter of 0.19 mm, and a basis weight of 240 g / m ² were obtained as a foamed layer.
The obtained sheet was wound into a roll.

The obtained sheet was fed out, and the PPE resin (B), PS resin (C) and impact resistance improver were adjusted so that the PPE resin component was 30% by weight, the PS resin component was 64% by weight, and the rubber component was 6% by weight. A mixture of 100 parts by weight of (D) and 10 parts by weight of talc (E) was melted and kneaded and extruded at a resin temperature of 278 ° C. using a T-die.
A non-foamed layer having a thickness of 150 μm was laminated on one side of the foamed layer.
The obtained laminated sheet was wound into a roll. next,
The surface of the foamed layer on the side different from the non-foamed layer was temporarily fixed to the surface of the foamed layer (I) with the hot melt film adhesive (H) interposed therebetween. Clamping the four sides of the foamed laminated sheet where the skin material and the hot melt film adhesive were temporarily fixed, put it in a heating furnace and heat it to a surface temperature of 155 ° C, and perform plug molding with a mold whose temperature was adjusted to 60 ° C. A foam laminate for an automobile interior material, which was adhered to and laminated on the above, was obtained. This product was subjected to trimming and punching processing to obtain a foam laminated molding for automobile interior materials.

A test piece was cut out from the obtained foam laminate for automobile interior material and subjected to a heat sag test with the non-foamed layer as the upper surface. As a result, there was almost no sagging of the test piece. Table 4 shows the inorganic filler species contained in the non-foamed layer of the foamed laminate for automobile interior materials, the arrangement of the non-foamed layer during the heat resistance test, and the heat sag test result.

[0039]

Example 2 Except that 20 parts by weight of calcium carbonate (F) was used instead of talc (E) as the inorganic filler.
A foam laminate for an automobile interior material was obtained by the same method as described in Example 1. When a test piece was cut out from the obtained foam laminate for automobile interior material and subjected to a heat sag test with the non-foamed layer as the upper surface, almost no sagging of the test piece occurred. Table 4 shows the inorganic filler species contained in the non-foamed layer of the foamed laminate for automobile interior materials, the arrangement of the non-foamed layer during the heat resistance test, and the heat sag test result.

[0040]

[Example 3] Example 1 except that 10 parts by weight of mica (G) was used instead of talc (E) as an inorganic filler.
A foam laminate for an automobile interior material was obtained by the same method as described. When a test piece was cut out from the obtained foam laminate for automobile interior material and subjected to a heat sag test with the non-foamed layer as the upper surface, almost no sagging of the test piece occurred. Table 4 shows the inorganic filler species contained in the non-foamed layer of the foamed laminate for automobile interior materials, the arrangement of the non-foamed layer during the heat resistance test, and the heat sag test result.

[0041]

[Example 4] An automobile was manufactured by the same method as that described in Example 1 except that the non-foamed layer side, which was laminated with the skin material (I) via the hot melt film adhesive (H), was temporarily fixed. A foam laminate for an interior material was obtained. A test piece was cut out from the obtained foam laminate for an automobile interior material, and a non-foamed layer was placed on the lower surface (the skin material was facing down), and a heat sag test was carried out. As a result, some sagging was observed on the test piece. Table 4 shows the types of inorganic fillers contained in the non-foamed layer of the foam laminate for automobile interior materials, the arrangement of the non-foamed layer during the heat resistance test, and the cantilever heat resistance test results.

[0042]

Comparative Example 1 A foam laminate for an automobile interior material was obtained by the same method as that described in Example 1 except that the inorganic filler was not used. A test piece was cut out from the obtained foam laminate for an automobile interior material and subjected to a heat sag test with the non-foamed layer as an upper surface. As a result, sagging of the test piece was observed. Table 4 shows the types of inorganic fillers contained in the non-foamed layer of the foam laminate for automobile interior materials, the arrangement of the non-foamed layer during the heat resistance test, and the cantilever heat resistance test results.

[0043]

[Table 4]

The foamed laminated sheet having the non-foamed layer containing the inorganic filler shown in Examples 1 to 4 as described above is compared with the foamed laminated sheet having the non-foamed layer not containing the inorganic filler of Comparative Example 1, It can be seen that it has a very excellent effect on heat resistance. Further, comparing Examples 1, 2, 3 and Example 4, it can be seen that the effect of excellent heat resistance is exhibited by providing the non-foaming layer on the upper surface when fixing the foamed laminated sheet.

[0045]

As described above, the use of the foamed laminated sheet for automobile interior materials containing the inorganic filler in at least one non-foamed layer of the present invention reduces the weight and cost of the conventional inorganic glass fiber-based substrate. Provided is a foamed laminated sheet for automobile interior material, which is improved in the problem of height and has excellent quality.

[Brief description of drawings]

FIG. 1 shows an example of an arrangement of a foam laminated sheet for an automobile interior material of the present invention in an automobile ceiling portion.

[Explanation of symbols]

 1 Ceiling outer plate 2 Automotive ceiling base material 3 Foam layer 4 Non-foam layer containing filler

Claims (7)

[Claims] 1. A foamed laminated sheet for automobile interior materials, wherein a non-foamed layer made of a thermoplastic resin containing an inorganic filler is laminated on at least one side of a modified polyphenylene ether resin foamed layer. 2. The foamed laminated sheet for automobile interior materials according to claim 1, wherein the non-foamed layer is made of a resin containing 1 to 50 parts by weight of an inorganic filler with respect to 100 parts by weight of the thermoplastic resin. 3. The foamed laminated sheet for automobile interior materials according to claim 1 or 2, wherein the inorganic filler is at least one selected from talc, calcium carbonate and mica. 4. The non-foamed layer is a heat-resistant polystyrene resin or a modified polyphenylene ether resin.
The foamed laminated sheet for an automobile interior material according to 2 or 3. 5. The foamed laminated sheet for automobile interior materials according to claim 4, wherein the non-foamed layer contains an impact resistance improver as a rubber component in an amount of 1 to 15% by weight. 6. The foam layer comprises a polyphenylene ether component 2
5 to 70 parts by weight and 30 to 75 parts by weight of polystyrene component, mixed resin of polyphenylene ether resin and polystyrene resin, graft copolymer resin of phenyl ether and styrene, or mixture of copolymer resin and polystyrene resin. A modified polyphenylene ether-based resin made of a resin is used as a base resin, and a primary thickness obtained by adding a foaming agent to the base resin and performing extrusion foaming is 1 to 5 mm, a primary expansion ratio is 3 to 20 times, and an average cell diameter is 0.05-0.3 mm,
The foamed layer having a closed cell rate of 70% or more,
The foamed laminated sheet for automobile interior materials according to 3, 4, or 5. 7. The foam laminated sheet for an automobile interior material according to claim 1, 2, 3, 4, 5, or 6, wherein a non-foam layer containing an inorganic filler is provided on the upper surface of the foam layer.