JPS5842450A - Laminated interior finish material and its manufacture - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a laminated interior material which is used as an interior material, particularly a ceiling material and a door trim of vehicles such as automobiles, and has a structure in which a skin layer on the side of a cushion layer is present on a hard base material. Regarding the manufacturing method.

Interior materials using thermoplastic resins such as polypropylene, vinyl chloride resin, ABSi + resin, and polystyrene, or their foams, are often used for automobiles because of their excellent physical properties such as productivity and moisture resistance. It is being This interior material is manufactured by laminating a skin layer with a cushion layer such as urethane foam on a base material.
- Gu, 210. ! In 2, we proposed an interior material characterized by attaching a base material and a skin material with a cushion layer using an olefin hot-melt adhesive, and molding the base material and skin material at the same time.

Figure 1 shows interior A'A according to the embodiment of the above utility model registration application.
In the cross-sectional view, the skin material 7 is a layer of high impact polystyrene film layered on both sides of foamed polystyrene resin (g), and polyurethane foam, etc. is layered on the skin layer (b) of textile fabric or polyvinyl chloride sheet. After temporarily fixing the layer formed by melting and applying the cushion adhesive 3 made of foam, the skin material 7 and the base material are placed in separate heating furnaces and heated to the required temperature. After heating, the skin material 7 and the base material g are overlapped and molded into a desired shape using molds on both sides.

The above-mentioned interior material has characteristics such as good productivity and ability to be deep drawn during molding. However, this interior material also had the following problems. In other words, when the pressing pressure of the mold is increased in order to accurately obtain the molded shape or the thickness of the base material using the foam after molding, the hot melt adhesive 3 penetrates into the cells of the foam of the cushion layer j. As a result, some particles remained or the entire thickness of the cushion layer 3- became thinner.

The present invention is based on the utility model registration application filed earlier by the inventor of the tree.
flA-210,! It is a development of 2, and its purpose is to prevent avatars from occurring even if the presser pressure of the mold is increased during molding.
Therefore, it is an object of the present invention to provide a laminated interior material that makes it easy to obtain an accurate molded shape and molded thickness of a base material, and has a smooth skin surface, and a method for manufacturing the same.

Hereinafter, the present invention will be explained based on the drawings.

FIG. 1 is a cross-sectional view of an embodiment of the laminated internal publication according to the present invention. The difference from the conventional laminated interior material shown in FIG. 1 is that a nonwoven fabric j is attached to the thin surface of the base material of the cushion layer j. The third method for manufacturing the laminated interior material of the present invention having such a configuration is as follows.
This will be explained based on the diagram.

The method of step 1) is the step of manufacturing the skin material in the lower stage of the base material.

First, about the manufacturing method for the base material d5? , reveal.

/ refers to the above-mentioned point 1) In addition to the styrene film, a film made of a copolymer of polystyrene and another resin, such as maleic anhydride, is also swollen. ! is a foam sheet made of the same type of resin as film/.

Seat! and film/ are laminated by means such as thermal adhesion to form a base material g having a three-layer structure. The base material is not limited to the above configuration, and may include general thermoplastic resins such as acrylic resins, copolymers of these resins and other thermoplastic resins, calcium carbonate, barium sulfate, mica, A non-foamed sheet made of resin or the like mixed with wood powder, talc, etc. as a filler can also be used. Foamed sheets of these resins can also be used. In short, it is softened by heating. Any sheet that can be molded into a shape and then hardened again by cooling to maintain its shape can be applied.

Next, hot melt adhesive 3 is applied or temporarily fixed on one side of base +i. The material of the hot melt adhesive 3 includes olefin, polyamide, polyester, and S.
B] (, polyurethane type, etc., and these are selected depending on the adhesiveness with the base material g, etc.).

For example, in the case of a three-layer sheet of styrene (see step 1) above, point 1)
Ester type is good. These hot melt adhesives 3 are applied directly to the base material using a roll coater, spray, etc.
Alternatively, only the hot melt adhesive 3 may be made into a film or a non-woven fabric by the S-Kun bonding method, and the hot melt adhesive 3 in the form of a film or non-woven fabric may be applied to the substrate using a hot rod or a hot roll.
Temporarily fasten to +. In this case, the non-release hot melt adhesive 3 is particularly suitable because it has air permeability and is difficult to generate bubbles at the interface with the base material during adhesion. Even if it is in the form of a film, it can be treated equally if it has a large number of small holes to make it breathable.

Next, the steps of the method for manufacturing the skin material 7 will be explained. The cushion layer is made of polyvinyl chloride foam, polypropylene foam, polyethylene foam, polybutadiene foam, etc. in addition to the above-mentioned polyurethane foam. B is laminated in advance using a polysalt surface adhesive or by means such as frame lamination. Next, a non-woven fabric is attached to the cushion layer t (ll) of the skin material 7.

The non-woven fabric 11- is made from synthetic fibers such as rayon, polyester, and polyamide by a wet method, a dry method, or a spunbond method.

The nonwoven fabric needs to have as uniform a layer as possible, be hard to tear, and have excellent physical properties such as surface J water resistance.

The basis weight of non-woven fabric is /31/m” to /,201
/m" is suitable. If the fabric weight is small, avatars are likely to occur on the skin layer when the pressure of the mold is reduced, and if the fabric weight is too large, it will be difficult to stretch, resulting in wrinkled skin. Otherwise, it is easily torn.The nonwoven fabric j is attached to the cushion layer j by a common method.For example, lamination with adhesive is available, and if the material of the cushion layer j is polyurethane foam, frame laminate is also used. can.

Next, the base material g to which the hot melt adhesive 3 is temporarily attached and the skin material 7 to which the nonwoven fabric t is pasted are individually heated in the base material heating furnace 7 and the skin material heating furnace 10, and when they are softened, they are heated in the heating furnace. It is taken out from the mold, compressed with a mold //, /:2, and taken out after cooling. The base material and the skin material 7 are firmly bonded during molding with the hot melt adhesive 3 softened by heating.

In this case, since the nonwoven fabric j is interposed between the hot melt adhesive 3 and the foam of the cushion layer j, it is possible to prevent the hot melt adhesive 3 from melting and penetrating into the cells of the foam. Therefore, the epidermal layer B is less likely to become an avatar. I
: Due to the heat insulating effect of the nonwoven fabric J, the heat when the pot melt adhesive 3 is melted is delayed in being transmitted to the cushion layer 5.
Therefore, it is possible to prevent the foam of the cushion layer j from being damaged by heat. Furthermore, by setting the foam of the cushion layer j and the compressive elastic modulus of the nonwoven fabric to different values, it is possible to reduce the feeling of bottoming out when pressed. This is shown in Figure 1.
Shown below.

A comparison is made between a conventional product and a product of the present invention, with the horizontal axis representing the compression ratio and the compression cart representing the vertical axis.The solid line represents the product of the present invention, and the broken line represents the conventional product.

Hereinafter, internal utilization was made and tested for the examples and corresponding control examples under the following conditions, and the results shown in Table 1 were obtained.

Example 1 A styrene film having a thickness of Q, mmO and a heat exchanger film was laminated on both sides of a foamed sheet of the same resin to form a base material with a weight of 02/3 and a thickness of 3. A hot melt adhesive 3 made of Bo11 ester spunbond nonwoven fabric with a basis weight of 3017 m'' and a softening temperature of 20 C was partially temporarily attached to one side using a hot rod.

Second thickness: 0. -! 3 mm PVC sheet (
7) The basis weight on the back side and the other side of this urethane foam! JT/GO polyester nonwoven fabric fabricated by a wet method was laminated by frame lamination.

The base material and the skin material 7 were each placed in a heating furnace and heated in a trench whose surface temperature was /30c1j0゛cK. After that, a press pressure of 2 K was applied using a double-sided mold.
Compressed at 9/7. After cooling, it was taken out and the appearance was observed and the epidermis was pressed with a finger to feel the sensation.

Example 2 A 2 mm thick ABS resin was used as the base material. The rest was the same as in Example/.

Example 3 Instead of temporarily fixing the spunbond nonwoven fabric hot melt adhesive 3 to the base material in Example/, 0-/l
A hot melt adhesive with a softening point of 20'O was applied to the substrate at a temperature of 301/m. In this case, the hot melt adhesive 3 was applied to the base material in the form of a bead. Others are the same as in Example.

Example 4 Polybutadiene foam was used instead of urethane foam in Example/. An acrylic Nicoljohn type adhesive was used for laminating the cushion layer and the polyvinyl chloride sheet of the skin layer B and the nonwoven fabric. Others are the same as Example 0. Control Example 1 In Example 1, the single-sided nonwoven fabric t of urethane foam was not used. Others are the same as in Example.

Control Example 2 The press pressure of the mold in Control Example/.ノに9/
I did it at 7.

Comparative Example 3 In Example j, the single-sided nonwoven fabric t of polybutadiene foam was not used. Others are the same as in Example≠.

As explained above, in the laminated interior material of the present invention, a nonwoven fabric is attached to the surface of the cushion layer facing the base material, the base material and the skin material are heated and softened separately, and then both are heated and softened. Since the overlapping mold is molded into the desired shape, the bonding agent between the base material and the skin material does not penetrate into the cushion layer during molding, and avatars do not occur on the skin layer, and the thickness of the cushion layer is reduced. It does not become thin, and the heat insulating effect of the nonwoven fabric prevents the cushion layer from being damaged by the heat generated when the bonding agent melts.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view of a conventional interior material, FIGS. 2 and 2 are cross-sectional views of an embodiment of the interior material according to the present invention, FIG. The figure shows the results of comparing the bottoming feeling when the skin layer side is pressed between the conventional product and the wooden invention product. 3...Hot melt adhesive j...Nonwoven fabric j...Cushion layer 7...Skin material...Heating furnace for base material 10...Heating furnace for skin material //, /,! ...Forming mold patent applicant: Hayashi Telempu Co., Ltd. Figure 2 Figure 1 Figure 4

Claims (1)

[Claims] 1. In a laminated interior material having a structure in which a cushion layer-side skin material is present on a hard base material, a nonwoven fabric is attached to the surface of the cushion layer facing the base material, and the nonwoven fabric and A laminated interior material characterized in that a bonding layer for bonding the skin material to which the nonwoven fabric is adhered and the base material is provided between the base materials. 2. A step of manufacturing a base material by pasting a film on both sides of the sheet; a step of manufacturing a skin material by pasting a skin layer on one side of the cushion layer and a nonwoven fabric on the other side; a step of temporarily fixing or applying a bonding material to one side of the material or the surface of the nonwoven fabric side of the skin material; a step of placing the thus obtained base material and skin material in a heating furnace and heating them to a predetermined temperature; A method for manufacturing a laminated interior material, which includes a step of molding a heated base material and a skin material using a mold.