JPH0985902A - Air impermeable hot-melt film and interior material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To suppress the pitting surface of a skin material by forming an air impermeable hot-melt film so as to provide an air impermeable resin layer on one outermost surface and to provide a hot-melt resin layer on the other outermost surface. SOLUTION: This air impermeable hot-melt film is constituted by arranging an air impermeable resin layer 1 composed of a thermoplastic resin film with an m.p. of 130-250 deg.C on one outermost surface and arranging a hot-melt resin layer 2 fusing a base material and an air impermeable resin layer 1 on the other outermost surface. This air impermeable hot-melt film can be easily fused to a cushion material composed of foamed soft polyurethane by a frame lamination method. Therefore, this hot-melt film is excellent in the thermal adhesiveness with a base material and the interior material obtained using this film does not almost generate pits on a skin surface.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a non-breathable hot melt film, and an interior material having the film interposed, particularly an automobile interior material.

[0002]

2. Description of the Related Art As an interior material for an automobile or a room, a material in which a skin material and a base material are bonded together via a hot melt film is used. In particular, various innovations have been made for automobile interior materials from the viewpoints of weight reduction, heat insulation, non-breathability, and the like.

As a hot melt film, there have been proposed many uses of a multilayer hot melt film in which both sides of a non-air permeable film are laminated in a sandwich form with a hot melt adhesive film in order to prevent air permeability in the cross-sectional direction.

On the other hand, as a skin material arranged inside the automobile, there is used a cloth, a knit, a raised knit, an artificial leather or the like provided with a cushion layer (3) such as foamed soft polyurethane. When this cushion layer (3) is thermocompression-bonded to a base material via a conventional three-layer hot melt film, a depression (commonly known as avatar) is likely to occur on the surface of the skin material when the melting point of the hot melt resin layer is low. .

Japanese Unexamined Patent Publication (Kokai) No. 7-60883 discloses a non-air-permeable hot melt film having a two-layer structure. In this film, a heat-resistant resin layer (non-air-permeable resin layer) is used on the substrate side. It cannot be used when the substrate is resin board or corrugated board.

[0006]

DISCLOSURE OF THE INVENTION The present invention is directed to an automobile or the like in which a cushion material such as foamed soft polyurethane is backed on the back surface of a skin material such as a knitted fabric, and the cushion material is fused to a substrate with a non-breathable hot melt film. In the interior material of
An object of the present invention is to provide a non-breathable hot melt film suitable for suppressing flutter on the surface of a skin material that often occurs, and an interior material fused through the non-air permeable hot melt film.

[0007]

The present invention provides a non-breathable hot melt film and skin having a non-breathable resin layer (1) on one outermost surface and a hot melt resin layer (2) on the other outermost surface. The material (4), the cushion layer (3), the non-breathable hot melt film (5) and the substrate (6) are provided in this order, and the non-breathable resin layer (1) of the non-breathable hot melt film is the cushion layer. The present invention relates to an interior material having a structure facing (3).

The resin for the non-air-permeable resin layer (1) used in the present invention has a melting point of 130 ° C. or higher, preferably 130-250.
It is a thermoplastic resin film having a temperature of ℃, more preferably 140 to 230 ℃, higher than the molding temperature, preferably 20 ℃ or higher, and a resin that can be melt-bonded by a frame laminate of flexible polyurethane foam is desirable.

Examples of suitable resins include high melting point polyamide resins, high melting point polyolefin resins, polyester resins, polyurethane resins, acrylic resins, polycarbonate resins and the like.

As the high melting point polyamide resin, nylon 6/66, 6, 6/10, 12, 11, etc .; as the high melting point polyolefin, polypropylene resin, ethylene-
Examples thereof include vinyl alcohol copolymers.

The basic constitution of the non-breathable hot melt film of the present invention is shown in FIG. 1, and the basic constitution of the interior material is shown in FIG.

FIG. 1 is a schematic cross-sectional view of a non-breathable hot melt film. In the figure, (1) is a non-breathable resin layer, (2) is a hot melt resin layer, and FIG. 2 is a schematic cross section of an interior material. Figure,
(3) is a cushion layer, (4) is a skin material, (5) is a non-breathable hot melt film, and (6) is a base material.

Since the non-breathable resin layer (1) is used to block the air permeability between the base material and the skin material and prevent the surface of the skin material from being contaminated by ventilation, it is used during heat fusion. It is desirable that mechanical damage and pinholes are not formed. Therefore, the thickness is 5 μm or more, more preferably 10 μm.
-30 μm is suitable. When the thickness is 30 μm or more, the extensibility deteriorates, and the drawability of the narrowed portion deteriorates during heat fusion with the substrate.

The hot melt resin layer (2) is used for fusing the base material (6) and the non-breathable resin layer (1). Therefore, the melting temperature of the hot melt resin is 70 to 150 ° C, especially 80
It is preferably about 130 ° C. Especially when a low temperature thermocompression bonding material such as a cardboard or a resin board is used as the base material, a temperature lower than the thermocompression bonding temperature, for example, 70 to 1
It is preferable to use a resin having a melting point of 30 ° C. Further, in the case of such low temperature thermocompression bonding, since the melt viscosity of the hot melt resin is usually high at a low temperature, it becomes difficult to achieve the permeability into the corrugated cardboard or the resin board as the base material. Therefore, a resin having a very low MI is not suitable as the resin used. The preferred MI is 5 to 100, more preferably 6 to 5.
0.

The thickness of the hot melt resin layer (2) is 10 to 5
It is 0 μm, more preferably 20 to 40 μm.

Suitable resins for the hot melt resin layer (2) are polyolefin resins, low melting point polyamide resins, polyester resins, thermoplastic polyurethane resins and the like. Polyolefin resins are cost-effective.

As the polyolefin resin, polyethylene, such as low density polyethylene, medium density polyethylene, high density polyethylene, linear low density polyethylene, branched low density polyethylene, polypropylene, modified polypropylene, 1-butene, 2-butene, Isobutene,
1,3-butadiene and the like; olefin monomer copolymer,
Copolymers with other polymerizable double bond-containing monomers such as styrene and vinyl chloride; ethylene-vinyl acetate copolymers, ethylene-ethyl acrylate copolymers, ethylene-methyl acrylate copolymers, ethylene-butyl acrylate Copolymer, ethylene-methylmethacrylate copolymer, ethylene-ethylmethacrylate copolymer, ethylene-butylmethacrylate copolymer, ethylene-
Examples thereof include (meth) acrylic acid copolymers, ethylene-maleic acid copolymers, ethylene-itaconic acid copolymers, and modified resins such as acid-modified ones thereof.

Two or more kinds of these polyolefins may be mixed and used. Other additives such as a viscosity modifier, a tackifier, and an antioxidant may be added. Olefin homopolymers such as polyethylene homopolymers have poor fusion-bonding properties with base materials such as cardboard, resin board or thermoformable polyurethane when used alone, and therefore other polyethylene resins such as ethylene-vinyl acetate and ethylene-ethyl acrylate are used. , Ethylene- (meth) acrylic acid, ethylene-maleic acid copolymers, acid-modified olefin resins and the like are preferably used in combination.

Polyamides include nylon 6/66 /
12, nylon 6/610/12, nylon 6/66 /
610/12, nylon 6/66/11/12, etc. are illustrated. In terms of adhesion, at least one of aminocarboxylic acids made from ω-aminoundecanoic acid as a raw material is used as a monomer.
What is contained as a component is preferable.

When the base material is cardboard, resin board or the like, particularly preferable hot melt resin is ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, ethylene-methyl acrylate copolymer, ethylene-butyl acrylate copolymer. Coal, ethylene-methyl methacrylate copolymer, ethylene-ethyl methacrylate copolymer, ethylene-butyl methacrylate copolymer,
Ethylene- (meth) acrylic acid copolymers, ethylene-maleic acid copolymers, ethylene-itaconic acid copolymers, modified resins such as these acid-modified, acid-modified resins of polyethylene, or mixtures of these with polyethylene, etc. It is a modified polyethylene resin.

The non-breathable hot melt film of the present invention is a three-layer structure in which, in addition to the above two-layer structure, another resin layer is provided between the non-breathable resin layer (1) and the hot melt resin layer (2). The above multi-layer structure may be adopted. Such a resin layer is mainly
An adhesive layer for adhering the layers (1) and (2), or an intermediary layer for accommodating the two when the fusion properties of the layers are insufficient, or by melting together with the hot melt resin layer (2) It is used to express various functions such as a layer for controlling fluidity.

In the present invention, the method for producing the air-impermeable hot melt film is not particularly limited, and any method generally used for producing a laminated film in the related art such as a coextrusion method, an extrusion laminating method and a dry laminating method can be used. It is not particularly limited.

The total thickness of the multilayer hot melt film is 20 to
The thickness is preferably adjusted to 80 μm, more preferably 30 to 70 μm.

In the present invention, the interior material has a cushion material (3) such as expanded polyurethane foam on the back side of the skin material. Conventionally, the cushion material and the non-breathable resin layer (1) have been fused by a hot melt film,
It has been found that this often causes pecking of the skin material. In the present invention, the non-breathable film is adhered to the foamed soft polyurethane layer by a frame laminating method, a dry laminating method or the like without the interposition of the hot melt film to eliminate the pockmark.

As such a skin material, a non-woven fabric generally adopted as an interior material, for example, a polyester non-woven fabric;
There are textiles, knits, and brushed knits. The thickness of the skin material is preferably 1 to 3 mm.

The cushioning material used in the present invention is a foamed soft polyurethane, which is joined to the non-breathable film by a method such as frame lamination, dry lamination or hot melt lamination.

The density is preferably 0.016 to 0.050 g / cm ₃ , and more preferably 0.020 to 0.035 g / cm ³ . The thickness of the cushion material is 1 to 10 mm, more preferably 2 to 5 m
m. If the thickness is less than 1 mm, it is difficult to join by frame lamination or the like, and if it is more than 10 mm, ventilation is generated in the lateral direction, and the skin material is easily soiled. It also becomes expensive. If the cushioning material is thin, the softness of the interior material is lost and the surface feels flat.

As the base material of the present invention, those used as conventional base materials for automobile interiors may be appropriately used. Examples of such substrates are inorganic fibers, organic fibers or non-woven fabrics in which mixed fibers thereof are adhered to each other by a thermoplastic resin, formed from felt of organic fibers or inorganic fibers impregnated with a thermosetting resin. There are a base material in which a glass fiber layer or the like is adhered to both sides of a board, a resin foam such as urethane, or a cardboard. Cardboard, resin board and the like are thermocompression-bonded to the skin material in the next step after the step of being hot-molded (shaped) by a hot press. Normally, a hot press is used for this thermocompression bonding, and the temperature is set to 110 so as not to damage the skin material.
Heat fusion at a low temperature of ~ 130 ° C. As described above, when the thermocompression bonding temperature is low, if the MI of the hot melt film is small, the melting temperature becomes high, and the hot melt film does not penetrate into the base material and sufficient fusion bonding strength cannot be obtained. Therefore, when such a material is used, it is preferable to use a resin having high fluidity at low temperature, particularly MI5 or more, as the hot melt resin layer (2).

The manufacturing method of the interior material of the present invention is as follows. First, the non-breathable resin layer (1) of the non-breathable hot melt film is attached to the foamed soft polyurethane side of the skin material backed with the foamed soft polyurethane, and then the Hot melt resin layer (2)
Is thermally fused to the base material (6). In case of hot pressing, the press mold temperature is 110 to 140 ° C, the clearance is 0.3 to 1.5 mm, the time is 10 to 60 seconds.

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

Example 1 The non-breathable hot melt film shown in FIG. 1 was produced by coextrusion (T-die method) with the following constitution. Non-breathable resin layer (1): Copolymer nylon 6/66, melting point 200 ° C, thickness 15 μm Hot melt resin layer (2): Copolymer polyamide, 6/610/12, melting point 105 ° C, MI12, thickness 30 μm Overall thickness 45 μm

Example 2 A non-breathable hot melt film was produced by the co-extrusion inflation molding method according to the following formulation. Non-breathable resin layer (1): Copolymer nylon 6/66, melting point 200 ° C, thickness 15 μm, hot melt resin layer (2): Ethylene-acrylic acid copolymer resin melting point 95 ° C, MI 8.0, thickness 30 μm

Example 3 Non-air-permeable resin layer (nylon 6, melting point 220 ° C., thickness 20
μm, cast film) on hot melt resin layer (eletin-ethyl acrylate copolymer resin, melting point 90 ° C., MI
20) was extruded in a thickness of 30 μm and laminated to obtain a two-layer film having a thickness of 50 μm.

Example 4 A skin material made of a knit (tricot) of polyester fibers,
Foamed soft polyurethane cushion material and Examples 1 to 1
The non-breathable hot melt film obtained in 3 was used as the non-breathable resin layer (1) on the cushioning material (3) side, and the non-breathing resin layer was adhered by the frame laminating method of the cushioning material to form the skin laminated material. Got Then, the hot melt resin layer (2) of the obtained skin laminated material is laminated on the resin board substrate (thickness: 3 mm) with the substrate (6) side facing it and bonded by hot pressing under the following conditions to produce an interior material. did.

Heat press conditions Upper mold temperature: 120 ° C., Lower mold temperature: 160 ° C. Clearance: 0.5 mm, Time 30 seconds

Comparative Example Same as Example 1 except that a copolyamide 6 / 6-10 / 12 (melting point 105 ° C., MI 12 and thickness 30 μm) is provided on both sides of the non-air-permeable resin layer (1) of Example 1. Thus, a hot melt film having a three-layer structure and an air-impermeable resin layer (1) in the middle was obtained. A skin laminate was obtained in the same manner as in Example 4, and then laminated with a resin board to produce an interior material. A peeling test, a heat-resistant creep test, and a pinhole test of a non-breathable hot melt film of the obtained interior material and skin laminated material were performed by the following methods. Table-Results
It is shown in FIG.

Test Method (1) Peeling Test The skin laminated material and the interior material were cut into a width of 25 mm, and the adhesive strength was measured by an Instron type tensile tester. Conditions Skin laminated material T peeling, 23 ° C, tensile speed 200 mm / min Interior material 180 ° peeling, 23 ° C, tensile speed 200 mm / min (2) Pinhole test Hot melt resin layer surface of the skin laminated material and cushioning material of the interior material Commercially available pinhole detection liquid (Nippon Kozai Co., Ltd., Microcheck) on the non-breathable resin surface with the skin removed
Was sprayed and left for 1 minute, and the liquid was wiped off to check for the presence of pinholes. (3) Heat-resistant creep test The interior material is cut into a width of 25 mm, the skin material with cushion layer is peeled from the base material, a 100 g load is applied to the skin material with cushion layer while maintaining the state of 180 ° peeling, and in an atmosphere of 85 ° C. It was allowed to stand for 24 hours and the degree of peeling was examined.

[0037]

[Table 1]

[0038]

INDUSTRIAL APPLICABILITY The non-breathable hot melt film of the present invention can be easily fused to a cushion material such as foamed soft polyurethane by a method such as frame lamination, and has excellent thermal adhesiveness to a base material. The interior material obtained by using it has almost no pockmarks on the skin surface, although the cushion material is interposed.

[Brief description of drawings]

FIG. 1 is a schematic cross-sectional view of a non-breathable hot melt film.

FIG. 2 is a schematic cross-sectional view of an interior material.

[Explanation of symbols]

 (1) Non-breathable resin layer (2) Hot-melt resin layer (3) Cushion layer (4) Skin material (5) Non-breathable hot-melt film (6) Substrate

Claims (4)

[Claims] 1. A non-breathable hot melt film having a non-breathable resin layer (1) on one outermost side and a hot melt resin layer (2) on the other outermost side. 2. The non-breathable hot melt film according to claim 1, comprising two layers of a non-breathable resin layer and a hot melt resin layer. 3. The non-breathable resin layer has a melting point of 130 to 250 °.
Which is a thermoplastic resin film layer having a melting point of 70 to 130 ° C. and a melt flow index.
The non-breathable hot melt film according to claim 1, which has a (MI) of 3 to 100. 4. A non-breathable resin layer of a non-breathable hot melt film, comprising a skin material (4), a cushion layer (3), a non-breathable hot melt film (5) and a substrate (6) in this order.
An interior material having a structure in which (1) faces the cushion layer (3).