JPH11179796A - Interior design material for press forming - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an interior design material formable by pressing. SOLUTION: This material consists of a sheet-like thermoplastic elastomer composition, an non-woven fabric and a thermoplastic resin composition under the condition that an integral laminate consists of the thermoplastic elastomer composition as a front layer, the non-woven fabric as an intermediate layer and the thermoplastic resin composition as a rear layer. In this inner packaging material for pressing, its shrinkage factor at forming and its tensile strength are remarkably improved, resulting in making the forming by pressing possible.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin sheet material which can be used as an interior material of an automobile or the like which can be formed by a press mold.

[0002]

2. Description of the Related Art Conventionally, various kinds of interior materials for automobiles have been used, such as carpets and polyvinyl chloride resin mats (PVC mats). Among them, carpets are separately formed according to their materials, such as press molding, and PVC mats are vacuum molded. Further, since the elongation and shrinkage after the press molding and the vacuum molding are different from each other, the final dimensions of the product are different even if the same molding die is used. Therefore, it is necessary to separately prepare molds for press molding and vacuum molding even in order to manufacture products having the same dimensions. For these reasons, the manufacturing process of the interior material and the investment cost have been extra.

[0003]

When a thermoplastic elastomer or PVC, which is known as a material for vacuum molding, is press-molded, uneven thickness (scaling), tearing, and curling tend to occur. In particular, uneven thickness occurs when the local elongation is large,
The residual stress also increases, and the amount of shrinkage of this portion also increases. In addition, since the molding shrinkage differs between vacuum molding and press molding, if the same molding die is used, the size of the product will differ depending on the molding method.

[0004] The present invention has been made in view of the above situation, and has as its object to provide an interior material that can be formed by press molding for an interior material that is usually vacuum formed.

[0005]

Means for Solving the Problems In order to solve the above-mentioned problems, the present inventors have conducted studies and found that the thermoplastic elastomer, the nonwoven fabric, and the thermoplastic resin are laminated and integrated to form a press. The occurrence of uneven thickness is suppressed,
It has been found that even when the thermoplastic elastomer tries to shrink after molding, the laminated non-woven fibers suppress shrinkage. Further, the laminated thermoplastic resin can prevent the interior material for press molding from curling.

That is, the interior material for press molding of the present invention comprises a thermoplastic elastomer, a nonwoven fabric and a thermoplastic resin, wherein the thermoplastic elastomer is a surface layer, the nonwoven fabric is an intermediate layer, and the thermoplastic resin is a back layer. As described above.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The interior material for press molding of the present invention comprises a thermoplastic elastomer composition, a nonwoven fabric and a thermoplastic resin composition. The thermoplastic elastomer composition is used as a surface layer, and the nonwoven fabric is used as an intermediate layer. The thermoplastic resin composition is laminated and integrated so as to form a back layer.

[0008] The lamination of the interior material for press molding of the present invention is carried out by using a combination of calendering and extrusion. That is, the nonwoven fabric is laminated while the thermoplastic elastomer composition is formed into a sheet by calendering, and the thermoplastic resin composition formed into a sheet by extrusion is laminated and integrated on the nonwoven fabric side of the laminate. The thermoplastic elastomer composition has 60 parts by weight of a polymerization type thermoplastic elastomer obtained by simultaneously polymerizing polypropylene and a rubber component, 10 to 30 parts by weight of a linear low-density polyethylene, 5 to 30 parts by weight of an ultra-low-density polyethylene, and a block. Polypropylene 3-1
It is a mixture comprising 0 parts by weight and 0.5 to 3 parts by weight of a composite stabilizer.

The thermoplastic elastomer includes a polymerizable type, a blend type, a dynamically crosslinked type, and a partially crosslinked type. The blend type and the dynamic cross-linking type can be calendered, but the temperature range in which they can be processed is narrow and it is difficult to adjust the temperature. The partially cross-linked type has a high melting temperature and is difficult to calender. For this reason,
The thermoplastic elastomer used in the present invention is limited to a polymerization type, and among them, a melt flow rate (230
(C, 2.1 kg) 0.5 to 3.0 is suitable for calendering.

The linear low-density polyethylene is used for improving the bank revolving property of the calender, and is blended in an amount of 10 to 30 parts by weight based on 60 parts by weight of the polymerizable thermoplastic elastomer. If the amount is less than 10 parts by weight or more than 30 parts by weight, the bank reciprocity deteriorates. Linear low-density polyethylene has a melt flow rate (ASTM).
D1238) of 0.5 to 3.0 can be calendered. The linear low-density polyethylene is C ₆
The copolymer system is 100 times less than the C ₄ copolymer system.
Good elongation at break in a high temperature range of up to 160 ° C.

Ultra-low-density polyethylene is used for adjusting the hardness of a product.
5 to 30 parts by weight is blended with respect to 0 parts by weight. By blending 5 to 30 parts by weight of the ultra-low density polyethylene, the bank revolving property of the calendar is improved. However, when the blending amount is less than 5 parts by weight or more than 30 parts by weight, the bank revolving property of the calendar is adversely deteriorated. Further, the ultra low density polyethylene preferably has a melt flow rate (JIS K6760) of 5.0 or more. If the melt flow rate is less than 5.0, the calender around the bank deteriorates and becomes unsuitable for use.

Block polypropylene is used to adjust the melt viscosity during calendering to a higher level and to facilitate the pulling of thin sheets. 3 to 10 parts by weight per 60 parts by weight of the polymerizable thermoplastic elastomer is used. Be blended. If the compounding amount is less than 3 parts by weight, the sheet take-off property is not improved. If the compounding amount is more than 10 parts by weight, the melt viscosity is too high, the surface of the sheet becomes rough, and the finish of the sheet becomes hard.
The block polypropylene preferably has a melt flow rate (ASTM D1238) of 2 to 10.

The composite stabilizer is preferably a barium / calcium-based metal soap with a silica-based inorganic filler added thereto, and 0.5 to 3 parts by weight based on 60 parts by weight of the polymerizable thermoplastic elastomer. The lubricity of the metal roll during processing can be improved. If the amount is less than 0.5 part by weight, no improvement in the lubricity of the metal roll is observed. If the amount exceeds 3 parts by weight, the composite stabilizer migrates to the sheet surface, and becomes unsuitable.

The thickness of the thermoplastic elastomer composition layer is as follows:
It is preferably 0.5 to 5.0 mm. When the thickness is less than 0.5 mm, wrinkles of the nonwoven fabric are apt to remain, and further, scalp and tear are likely to occur during press molding. If it exceeds 5.0 mm, the amount of shrinkage after molding becomes large, so that the purpose of common use of press dies cannot be achieved. The nonwoven fabric increases the set rate of the thermoplastic elastomer after molding and suppresses shrinkage after molding due to local elongation due to molding. Further, the nonwoven fabric functions as a backup substrate for the surface material.
The weight per unit area of the nonwoven fabric is 50 to 300 g / m ^2.
Is preferred. When the weight per unit area is less than 50 g / m ² , a phenomenon referred to as “through through” occurs when the resin passes through the nonwoven fabric during lamination with the thermoplastic elastomer composition, and it is not possible to suppress shrinkage of the molded article after molding. Will be enough. If it exceeds 300 g / m ² , wrinkles are likely to be generated in the interior material during press molding.

As the non-woven fabric, a blend of polyester and rayon is used. The blending is performed because a nonwoven fabric of a single material such as an acrylic, cotton, vinylon, or rayon material does not thermally fuse with the thermoplastic elastomer composition. The thermoplastic resin composition suppresses curl due to a difference in shrinkage between the thermoplastic elastomer and the nonwoven fabric. Further, the thermoplastic resin also functions as an adhesive when the interior material of the present invention is laminated with a silencer or cushion material and molded into an interior material for automobiles.

The thermoplastic resin composition is a low-density polyethylene having a melt flow rate (JIS K6760) of 15 or more or a melt flow rate (JIS K6758).
Is 20 or more. If the low-density polyethylene or polypropylene has a melt flow rate less than the above, it cannot be used because the moldability of the T-die sheet, the thread removal strength of the carpet pile, and the adhesion during molding with a silencer or cushion material are inferior.

As the thermoplastic resin composition, a resin mixture can be used. That is, the vinyl acetate content is 5 to 30.
% By weight, 20 to 70 parts by weight of an ethylene / vinyl acetate copolymer having a melt index of 0.1 to 100 g / 10 minutes, and a concentration of 70% or more obtained by mixing a substance having compatibility with the copolymer as a coagulant. And a mixture comprising 80 to 30 parts by weight of a compound containing an inorganic filler.

The thermoplastic resin composition has a weight per unit area of 200 to 3000 g / m ² ,
Is less than 200 g / m ² becomes insufficient effect of preventing curling of the skin material and the nonwoven fabric, causing uneven thickness due to rubbing mold during press thickness increases more than 3000 g / m ² molding. The surface thermoplastic elastomer composition layer can be composed of a single layer, but the virgin thermoplastic elastomer composition layer on the surface side, and a recycled thermoplastic elastomer composition layer as a second layer beneath the other layer. It can have a two-layer structure. That is, a sheet made of a new material is used for the surface layer, and a sheet made by remanufacturing a thermoplastic elastomer of the offcuts generated in the manufacturing process is laminated on the back side.

The raw material of the sheet to be remanufactured is a scrap of a laminate of a thermoplastic elastomer surface layer and a highly foamed polypropylene foam generated in the manufacturing process.
This is a chip obtained by pulverizing into an m-square, introducing the mixture into a regenerating melter, and melt-mixing the chips. To make a laminate, a scrap layer is laminated on a nonwoven fabric by a calendar, and then a virgin layer is laminated on the nonwoven fabric by a calendar.

Since the thermoplastic elastomer raw material to be regenerated and melted contains a urethane-based surface treating agent and a primer, if it is subjected to calendering as it is, the lubricating properties of the metal roll will be insufficient and the metal will stick to the roll. For this reason,
The barium / calcium metal soap-based stabilizer and the inorganic lubricant are used in an amount of 1 to 5 parts by weight per 100 parts by weight of the thermoplastic elastomer raw material.
By blending parts by weight, the lubricity of the metal roll is improved, and calendering becomes possible.

[0021]

The present invention will be described below with reference to examples. (Example) As shown in the sectional view of FIG. 1, an interior material according to an example of the present invention has a surface portion 1 made of a thermoplastic elastomer composition, an intermediate layer 2 made of a nonwoven fabric, and a back layer 3 made of polyethylene. This is an interior material that is laminated, joined together, and integrated. Further, the thermoplastic elastomer layer of the surface layer portion 1 includes a surface layer 11 made of a virgin thermoplastic elastomer composition and a second layer 12 made of a recycled thermoplastic elastomer composition. The thickness of each of the thermoplastic elastomer layers of the surface layer 11 and the second layer 12 is 0.25 mm for the surface layer 11 and 1.0 mm for the second layer 12.
mm.

The virgin thermoplastic elastomer composition used for the surface layer 11 has a melt flow rate (230
60 ° C., 2.16 kg) 1.5, 60 parts by weight of a polymerizable thermoplastic elastomer having a JIS A hardness of 72, and a linear low-grade resin having a melt flow rate (ASTM D1238) of 2.1, a Shore D hardness of 50 and a density of 0.920. Density polypropylene 2
0 parts by weight and the melt flow rate (JIS K676
0) 15 parts by weight of ultra low density polyethylene having 20.0, Shore D hardness of 44 and density of 0.905, 5.0 parts by weight of block polypropylene having melt flow rate (ASTM D1238) 5.0 and density of 0.91, and composite stability 1 part by weight of an agent and 4 parts by weight of a pigment.

The recycled thermoplastic elastomer composition used for the second layer 12 is coated on a thermoplastic elastomer skin layer having a density of 330 g / m ³ , which is used for door trim vacuum molding as an interior material for automobiles, with a density of 70 g / m ³ . The remnants of the laminate obtained by heat-sealing the polypropylene foam are introduced into a reclaiming / melting machine to be compounded, and the compound is formed into chips, and 100 parts by weight and 3 parts by weight of a barium / calcium metal soap-based stabilizer.

The nonwoven fabric of the intermediate layer 2 is a mixed spinning made of 80% of 6-denier polyester and 20% of 3-denier rayon, and has a density of 100 g / m ³ . The back layer 3 has a melt flow rate (JIS K6760) 18, a density (JIS K7121) 0.918, a bending stiffness (Olsen) (JIS K7106) 1250, and a melting point (JIS).
K7121) 106, Vicat softening temperature (JIS K7
206) 82 is a low density polyethylene having an areal density of 250 g / m ² .

The interior material according to the embodiment of the present invention is an interior material laminated by calendaring and extrusion. In the interior material of this example, a scrap layer was calender-laminated on a nonwoven fabric at a roll temperature of 180 ° C., and then a virgin layer was calender-laminated on the non-woven fabric at a roll temperature of 180 ° C. to obtain an intermediate structure.

Subsequently, using an extruder equipped with a T-die, a cylinder temperature of 160 to 295 ° C. and a T-die temperature of 250
A low-density polyethylene sheet is formed under processing conditions of up to 260 ° C., and before the formed sheet is cooled and solidified, the intermediate structure is fed from below the T-die, and the intermediate structure and the low-density polyethylene sheet are bonded together by a pressure roll. It was used as an interior material for press molding.

Comparative Example 1 The interior material of Comparative Example 1 is shown in FIG.
As shown in the cross-sectional view, a surface layer 4 and a backing
And a backing layer 5
You. The surface layer comprises a pile 6 and a base cloth 7. Pile 6
Stabs a polypropylene pile thread into the base fabric to form a loop
The base cloth 7 has a weight per unit area.
Is 120 g / m^TwoSpunbond. Also pile
6 has a weight per unit area of 400 g / m^TwoIt is. Ba
The locking layer 5 is made of polyethylene and has a unit surface on the back layer.
Weight per product is 750g / m ^TwoWelded.

(Comparative Example 2) The interior material of Comparative Example 2 is a foam P of an interior material for automobiles formed by conventional vacuum forming.
It is a VC mat. (Measurement of molding shrinkage) The measurement of the molding shrinkage was performed using test pieces of 30 × 150 mm obtained from the interior materials of the examples and comparative examples, and the test temperatures were 100, 120 and 140 ° C.
And In addition, two marked lines are formed on the test piece at an interval of 100 mm.

Both ends of the test piece were fixed with chucks along two marked lines of the test piece, and the test piece was cured at the test temperature for 5 minutes. At this time, since the chuck to which the test piece was fixed was fixed along the two marked lines, the interval between the chucks was 100 mm, which was equal to the interval between the two marked lines. After curing at the test temperature,
The test piece was stretched at the test temperature until the distance between the chucks, that is, the distance between the marked lines of the test piece became 150 mm. As soon as the test piece was stretched, it was taken out in the stretched state and air-cooled at room temperature for 5 minutes. After air cooling, the test piece was removed from the chuck and left at room temperature for 1 hour.

After the standing, the interval [L (mm)] between the marked lines formed on the test piece was measured, and the molding shrinkage obtained from the equation 1 was obtained. Table 1 shows the obtained molding shrinkage.

[0031]

[Formula 1] Molding shrinkage (%) = (150−L) × 100/150

[0032]

[Table 1] As can be seen from Table 1, the molding shrinkage of the example of the present invention is almost the same as the value of the tuft carpet of Comparative Example 1 regardless of the test temperature, and is greatly improved over the foamed PVC mat of Comparative Example 2. ing. (Measurement of 50% Modulus) Regarding the method of measuring the 50% modulus, the load was measured when the interval between the marked lines of the test piece was stretched from 100 mm to 150 mm during the measurement of the molding shrinkage.

Table 2 shows the measurement results of the 50% modulus.

[0034]

[Table 2] As can be seen from Table 2, the tensile strength of the example of the present invention obtained from the 50% modulus is equivalent to that of the comparative example 1 of the tufted carpet, and is much larger than the comparative example 2 of the foamed PVC mat. .

The interior material according to the embodiment of the present invention has a smaller molding shrinkage and a higher tensile strength than the foamed PVC mat of Comparative Example 2 molded by vacuum molding, and is required for press molding. It was confirmed that it had excellent physical properties.
Next, it was confirmed that an actual press-formed product was obtained using the interior material of the example of the present invention.

As shown in the process diagram of FIG. 3, the interior material 8 is placed on the upper surface of the mounting table 20 with its back layer 3 up, and the interior material 8 is heated by irradiating an infrared heater 21 from above. The interior material 8 was taken out with the back layer 3 at 130 ° C.
At this time, the surface layer 1 was heated to 110 ° C. As shown in FIG. 3, a felt-shaped silencer 10 made of a fiber laminate is placed on the bottom of the concave portion 24 of the lower mold 23 of the molding die 22 in advance. Then, the back layer 3 of the interior material 8 was placed on the lower mold 23 with the lower side, and the upper mold 25 was lowered and press-molded. The mold 22 is not heated by itself, but is maintained at a temperature of about room temperature. The interior material 8 is compression-molded by the molding die 22 and molded along the shape of the die, heat is taken by the molding die 22 and cooled, and the molded shape is fixed. On the other hand, the silencer 10 is pressed against the lower layer 3 in a molten state, and is fused to the lower layer 3. In this state, the molded interior part was taken out of the molding die 22.

As shown in FIG. 3, the obtained interior part 26 has a shape along the floor of the automobile to which the silencer 10 is integrally joined, and has a quality as a floor material. .

[0038]

The interior material of the present invention has significantly improved molding shrinkage and tensile strength as compared with the conventional foamed PVC mat,
Uneven thickness and breakage, which tend to occur when a conventional vacuum forming material is press-formed, are suppressed, and press-forming can be performed. Furthermore, the interior material for press molding of the present invention has almost the same dimensional stability and tensile strength as tufted carpets, and can be molded with a press mold used for tufted carpets. This makes it possible to reduce costs by using a common mold.

The thermoplastic elastomer material used for the surface layer of the interior material for press molding of the present invention can be a recycled product. Use of recycled products is useful in reducing the burden on the environment and effectively using resources.
The specific gravity of the thermoplastic elastomer material of the interior material is PV
Since C is 1.25, whereas C is 1.25, the weight of the interior material can be reduced.

[Brief description of the drawings]

FIG. 1 is a diagram showing a cross section of an embodiment of the present invention.

FIG. 2 is a diagram showing a cross section of the tufted carpet shown in Comparative Example 2 of the present invention.

FIG. 3 is a view showing a molding step when the interior material of the present invention is hot-pressed together with a silencer to form an interior material to which the silencer is bonded.

[Explanation of symbols]

1: Surface layer 2: Intermediate layer 3: Back layer 11: Surface layer 12: Second layer 4: Surface layer 5: Backing layer 6: Pile 7: Base fabric 8: Sheet-like interior material 10: Silencer 20: Mounting table 21 : Infrared heater 22:
Mold 23: Lower mold 24: Lower mold recess 25:
Upper model 26: Interior parts

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Fumihide Tateno 3-1-1, Hinodai, Hino-shi, Tokyo Inside Hino Automotive Industry Co., Ltd. (72) Inventor Akinori Arai 4-3-1-3 Midori, Sumida-ku, Tokyo Le Industrial Co., Ltd.

Claims (11)

[Claims] 1. A thermoplastic resin composition comprising a sheet-like thermoplastic elastomer composition, a nonwoven fabric, and a thermoplastic resin composition, wherein the thermoplastic elastomer composition is a surface layer, the nonwoven fabric is an intermediate layer, and the thermoplastic resin composition. Characterized by being laminated and integrated so as to form a back layer. 2. The interior material for press molding according to claim 1, wherein said thermoplastic elastomer composition has a thickness of 0.5 to 5.0 mm. 3. The nonwoven fabric has a weight per unit area of 5
0~300g / m ² and is claim 1 for press molding interior material according. 4. The interior material for press molding according to claim 1, wherein said thermoplastic resin composition is one of polyethylene, polypropylene, a mixture of ethylene / vinyl acetate copolymer and calcium carbonate. . 5. The interior material for press molding according to claim 4, wherein the weight of the thermoplastic resin composition per unit is 200 to 3000 g / m ² . 6. The thermoplastic elastomer composition according to claim 1, wherein the thermoplastic elastomer composition is a virgin olefin-based thermoplastic elastomer.
The interior material for press molding as described. 7. The thermoplastic elastomer composition comprises 60 parts by weight of a polymerizable thermoplastic elastomer and 10 to 30 parts by weight of a linear low-density polyethylene,
30 parts by weight, 3 to 10 parts by weight of block polypropylene,
0.5 to 3 parts by weight of a composite stabilizer, the nonwoven fabric is a blend of polyester and rayon, and the thermoplastic resin composition is a melt flow rate (JIS K
The interior material for press molding according to claim 6, characterized in that the interior material for press molding is a low-density polyethylene having a melt flow rate (JIS K6758) of 20 or more or polypropylene having a melt flow rate (JIS K6758) of 20 or more. 8. The thermoplastic elastomer composition comprises 10 to 30 parts by weight of a linear low-density polyethylene and 60 to 10 parts by weight of an ultra-low-density polyethylene in 60 parts by weight of a polymerizable thermoplastic elastomer.
30 parts by weight, 3 to 10 parts by weight of block polypropylene,
0.5 to 3 parts by weight of a composite stabilizer, the nonwoven fabric is a blend of polyester and rayon, the thermoplastic resin composition has a vinyl acetate content of 5 to 30% by weight,
20 to 70 parts by weight of an ethylene / vinyl acetate copolymer having a melt index of 0.1 to 100 g / 10 min and a substance having compatibility with the copolymer blended as a coagulant, and inorganic filler is added at a concentration of 70% or more. 80 containing ingredients
The interior material for press molding according to claim 6, which is a mixture consisting of 30 to 30 parts by weight. 9. The thermoplastic elastomer, wherein a virgin olefin-based thermoplastic elastomer composition is laminated on a surface layer and a recycled olefin-based thermoplastic elastomer composition is laminated on a second layer. The interior material for press molding according to claim 1. 10. The virgin thermoplastic elastomer composition comprises 60 parts by weight of a polymerizable thermoplastic elastomer, 10 to 30 parts by weight of a linear low-density polyethylene, 5 to 30 parts by weight of an ultra-low-density polyethylene, and 3 to 1 part by weight of a block polypropylene.
0 parts by weight and 0.5 to 3 parts by weight of a composite stabilizer are mixed. The recycled thermoplastic elastomer composition is obtained by melt-mixing a laminate of a thermoplastic elastomer surface layer and a highly foamed polypropylene foam and re-chipping. 100 parts by weight of a barium / calcium metal soap-based stabilizer and 1 to 5 parts by weight of an inorganic lubricant are mixed, the nonwoven fabric is a blend of polyester and rayon, and the thermoplastic resin composition is a melt flow rate. (JIS K6760)
The interior material for press molding according to claim 9, wherein the low-density polyethylene is a polypropylene having a melt flow rate (JIS K6758) of 20 or more. 11. The virgin thermoplastic elastomer composition comprises 60 parts by weight of a polymerizable thermoplastic elastomer, 10 to 30 parts by weight of a linear low-density polyethylene, 5 to 30 parts by weight of an ultra-low-density polyethylene, and 3-1 of a block polypropylene.
0 parts by weight and 0.5 to 3 parts by weight of a composite stabilizer are mixed. The recycled thermoplastic elastomer composition is obtained by melt-mixing a laminate of a thermoplastic elastomer surface layer and a highly foamed polypropylene foam and re-chipping. 100 parts by weight of a barium / calcium metal soap-based stabilizer and 1 to 5 parts by weight of an inorganic lubricant are mixed, the nonwoven fabric is a blend of polyester and rayon, and the thermoplastic resin composition has a vinyl acetate content. 5 to 30% by weight, 20 to 70 parts by weight of an ethylene / vinyl acetate copolymer having a melt index of 0.1 to 100 g / 10 minutes, and 70% containing a substance having compatibility with the copolymer as a coagulant. The press molding according to claim 9, wherein the mixture comprises 80 to 30 parts by weight of a compound containing the inorganic filler at the above concentration. Wood.