WO2017026034A1 - 自動車用内外装材及びその製造方法 - Google Patents

自動車用内外装材及びその製造方法 Download PDF

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Publication number
WO2017026034A1
WO2017026034A1 PCT/JP2015/072642 JP2015072642W WO2017026034A1 WO 2017026034 A1 WO2017026034 A1 WO 2017026034A1 JP 2015072642 W JP2015072642 W JP 2015072642W WO 2017026034 A1 WO2017026034 A1 WO 2017026034A1
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WO
WIPO (PCT)
Prior art keywords
thermoplastic resin
interior
resin layer
exterior material
exterior
Prior art date
Application number
PCT/JP2015/072642
Other languages
English (en)
French (fr)
Inventor
畑　良彦
服部　太郎
修 富田
Original Assignee
住江織物株式会社
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Filing date
Publication date
Application filed by 住江織物株式会社 filed Critical 住江織物株式会社
Priority to JP2017534057A priority Critical patent/JP6560353B2/ja
Priority to US15/751,531 priority patent/US20180229466A1/en
Priority to CN201580082309.2A priority patent/CN107921913B/zh
Priority to PCT/JP2015/072642 priority patent/WO2017026034A1/ja
Publication of WO2017026034A1 publication Critical patent/WO2017026034A1/ja

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/266—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
    • B29C48/154—Coating solid articles, i.e. non-hollow articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
    • B29C51/145—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets having at least one layer of textile or fibrous material combined with at least one plastics layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/022—Particular heating or welding methods not otherwise provided for
    • B29C65/028—Particular heating or welding methods not otherwise provided for making use of inherent heat, i.e. the heat for the joining comes from the moulding process of one of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/743—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc
    • B29C65/7437—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc the tool being a perforating tool
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/78—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus
    • B29C65/7858—Means for handling the parts to be joined, e.g. for making containers or hollow articles, e.g. means for handling sheets, plates, web-like materials, tubular articles, hollow articles or elements to be joined therewith; Means for discharging the joined articles from the joining apparatus characterised by the feeding movement of the parts to be joined
    • B29C65/7888—Means for handling of moving sheets or webs
    • B29C65/7894—Means for handling of moving sheets or webs of continuously moving sheets or webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/21—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/349—Cooling the welding zone on the welding spot
    • B29C66/3494—Cooling the welding zone on the welding spot while keeping the welding zone under pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/45—Joining of substantially the whole surface of the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/729—Textile or other fibrous material made from plastics
    • B29C66/7294—Non woven mats, e.g. felt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7318—Permeability to gases or liquids
    • B29C66/73181—Permeability to gases or liquids permeable
    • B29C66/73182—Permeability to gases or liquids permeable to gases
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7375—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured
    • B29C66/73753—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being partially cured, i.e. partially cross-linked, partially vulcanized
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
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    • B29C66/81427—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the design of the pressing elements, e.g. of the welding jaws or clamps characterised by the surface geometry of the part of the pressing elements, e.g. welding jaws or clamps, coming into contact with the parts to be joined comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
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Definitions

  • the present invention relates to an automobile interior and exterior material used as an automotive interior material such as an automobile floor mat and an automobile exterior material such as a fender liner.
  • melt flow rate means a melt flow rate measured at a test temperature of 190 ° C. and a test load of 21.2 N in accordance with JIS K7210-1999.
  • the present invention has been made in view of such a technical background, and provides an automotive interior / exterior material having excellent sound absorbing performance and a method for producing the same, and for automotive interior / exterior having excellent sound absorbing performance. It aims at providing the method of manufacturing a molded object.
  • the present invention provides the following means.
  • thermoplastic resin layer laminated on one surface of the fiber layer, The melt flow rate of the thermoplastic resin is in the range of 2 g / 10 min to 500 g / 10 min; An interior / exterior material for automobiles, wherein a plurality of through holes penetrating in the thickness direction of the resin layer are formed in the thermoplastic resin layer.
  • the fiber layer is a carpet fabric in which a pile having a basis weight of 250 g / m 2 to 2000 g / m 2 is planted on one surface of a base fabric having a basis weight of 80 g / m 2 to 150 g / m 2 . 3.
  • thermoplastic resin layer formed is in the range of 50 g / m 2 to 5000 g / m 2 .
  • a plurality of air holes are formed from the one surface of the fiber layer to an intermediate position in the thickness direction or to the other surface of the fiber layer, and the air holes penetrate through the thermoplastic resin layer. 6.
  • the automotive interior / exterior material according to any one of 1 to 5 above, wherein the automotive interior / exterior material is in communication with a hole.
  • thermoplastic resin film immediately after extrusion obtained by extruding a thermoplastic resin having a melt flow rate of 2 g / 10 min to 500 g / 10 min from an extruder and an air-permeable fiber layer are laminated.
  • thermoplastic resin layer When the thermoplastic resin layer is impregnated into a part of the one surface side of the fiber layer during the thermoforming, the thermoplastic resin layer is partially broken and thickened to the thermoplastic resin layer of the obtained molded body.
  • the breathable fiber layer since the breathable fiber layer is provided, the sound that has reached the fiber layer side is absorbed by the fiber layer and penetrates through the thermoplastic resin layer in the thickness direction. Is formed, the sound that has reached the thermoplastic resin layer side enters the air-permeable fiber layer through the through hole and is absorbed by the fiber layer, so that good sound absorption performance is obtained. .
  • the melt flow rate of the thermoplastic resin is set in the range of 2 g / 10 min to 500 g / 10 min, when the automotive interior / exterior material is thermoformed, the thermoplastic resin layer of the molded body is formed in the thickness direction.
  • a through-hole formed at the time of thermoforming is formed, and an excellent sound absorbing performance can be obtained by synergistic action of the through-hole and the formed hole at the time of thermoforming. Moreover, since the fiber layer is provided, good cushioning properties can also be obtained.
  • the basic air permeability for sound absorption is ensured (designed) by providing the through hole, and the thermoforming formed during thermoforming.
  • the time-drilling hole can be drilled during thermoforming by using (selecting) a thermoplastic resin having a specific melt flow rate within a limited range (2 g / 10 min to 500 g / 10 min) of the melt flow rate of the thermoplastic resin. Since the configuration (number, size of hole, etc.) of the holes can be adjusted, the sound absorption performance of the molded body can be controlled (designed).
  • the configuration in which a through hole for ensuring basic air permeability is provided for such various required characteristics of sound absorption performance can be adjusted by selecting the melt flow rate of the thermoplastic resin to be used.
  • a non-woven fabric having a constituent fiber fineness of 0.1 dtex to 100 dtex is used as the fiber layer. Therefore, when the automotive interior / exterior material is thermoformed, it is drilled during the thermoforming. A hole can be formed reliably, and more excellent sound absorption performance can be obtained.
  • thermoplastic resin is applied to an original carpet in which a pile having a basis weight of 250 g / m 2 to 2000 g / m 2 is planted on one surface of a base fabric having a basis weight of 80 g / m 2 to 150 g / m 2. Since the layers are laminated, when the automotive interior / exterior material is thermoformed, the hole formed during the thermoforming can be surely formed, and a better sound absorbing performance can be obtained.
  • thermoplastic resin layer is in the range of 50 g / m 2 to 5000 g / m 2 , the hole formed during thermoforming is formed when the automotive interior / exterior material is thermoformed. It can be formed more reliably, and an even better sound absorbing performance can be obtained.
  • the sound absorption performance of the molded body can be further improved.
  • the air hole is configured to communicate from one side of the fiber layer to the other side (open on both sides)
  • better sound absorption performance can be obtained by stabilizing the air permeability. Can do.
  • the interior / exterior material for automobiles of the present invention described above can be efficiently manufactured while ensuring stable quality.
  • a cooling roll is used as a roll having a perforation protrusion provided on the outer peripheral surface, the cooled perforation protrusion enters the thermoplastic resin layer and is formed in the thermoplastic resin layer.
  • the shape of the through hole can be made more uniform.
  • thermoforming penetrating in the thickness direction is formed in the thermoplastic resin layer.
  • the through hole and the thermoforming are formed. Due to the synergistic action of the perforated holes, excellent sound absorbing performance can be obtained.
  • the inner diameter of the opening at both ends of the through-hole is reduced when the interior / exterior material for automobiles is thermoformed, and therefore, more excellent sound absorbing performance is exhibited mainly in the fiber layer. It becomes.
  • FIG. 2 is a bottom view of the automotive interior / exterior material of FIG. 1. It is sectional drawing which shows other embodiment of the interior / exterior material for motor vehicles based on this invention. It is explanatory drawing which shows an example of the manufacturing method of the interior / exterior material for motor vehicles based on this invention. It is typical sectional drawing which shows an example of the molded object for motor vehicle interior / exterior obtained by thermoforming the vehicle interior / exterior material of FIG. It is typical sectional drawing which shows the other example of the molded object for motor vehicle interior / exterior obtained by thermoforming the vehicle interior / exterior material of FIG.
  • the automotive interior / exterior material 1 includes a breathable fiber layer 2 and a thermoplastic resin layer 3 laminated on one surface of the fiber layer 2. Further, a plurality of through holes 11 penetrating in the thickness direction of the resin layer are formed in the thermoplastic resin layer 3.
  • a thermoplastic resin having a melt flow rate of 2 g / 10 min to 500 g / 10 min is used as the thermoplastic resin constituting the thermoplastic resin layer 3.
  • FIG. 1 and 2 show an embodiment of an automotive interior / exterior material 1 according to the present invention.
  • a plurality of through holes 11 penetrating in the thickness direction of the resin layer 3 are formed in the thermoplastic resin layer 3, and the fiber layer 2 is formed from the one surface (laminated surface; lower surface) of the fiber layer 2.
  • a plurality of air holes 12 are formed up to the other surface (non-laminated surface; upper surface), and the air holes 12 communicate with the through holes 11 of the thermoplastic resin layer 3 (see FIG. 1).
  • the through hole 11 and the vent hole 12 communicated with each other constitute a mechanical hole.
  • the mechanical hole penetrates in the thickness direction of the automobile interior / exterior material 1. That is, in this embodiment, the mechanical hole penetrates the automobile interior / exterior material 1 in the thickness direction and opens on both surfaces (see FIG. 1).
  • the ventilation hole 12 connected to the said through-hole 11 is formed from the said one surface (lamination surface) of the fiber layer 2 to the intermediate position (midway position) of the thickness direction.
  • the air hole 12 may be configured not to reach the non-laminated surface of the fiber layer 2).
  • the interior / exterior material 1 for automobiles of the present invention includes the breathable fiber layer 2, the sound that has reached the fiber layer side is absorbed by the fiber layer 2 and is thick in the thermoplastic resin layer 3. Since a plurality of through-holes 11 penetrating in the vertical direction are formed, sound that has reached the thermoplastic resin layer side enters the air-permeable fiber layer 2 through the through-holes 11, and the fiber layer 2 Since it is absorbed, good sound absorption performance can be obtained.
  • the melt flow rate of the thermoplastic resin is set in the range of 2 g / 10 min to 500 g / 10 min, when the automotive interior / exterior material 1 is thermoformed, the thermoplastic resin layer 3 of the molded body 40 is thick.
  • thermoforming perforation hole 13 penetrating in the vertical direction is formed (see FIG. 5), and an excellent sound absorbing performance is obtained by the synergistic action of the through hole 11 and the thermoforming perforation hole 13 in the molded body 40. It will be. Furthermore, when the automotive interior / exterior material 1 is thermoformed, the thermoplastic resin layer 3 is resoftened or remelted in the molded body 40, and the inner diameters of the openings at both ends of the through hole 11 are reduced. Sound absorption performance can be obtained.
  • the breathable fiber layer 2 is not particularly limited, and examples thereof include a nonwoven fabric, a tuft carpet raw fabric having a pile, and the like. Although it does not specifically limit as said nonwoven fabric, For example, a needle punch nonwoven fabric, a spun bond nonwoven fabric, etc. are mentioned.
  • the fineness of the constituent fibers is preferably 0.1 dtex to 100 dtex.
  • the inner / outer packaging material 1 is thermoformed by setting it to 0.1 dtex or more, it is possible to reliably form a hole for thermoforming that penetrates the thermoplastic resin layer in the thickness direction, and it is sufficient to set it to 100 dtex or less. Sound absorption can be secured.
  • the fineness of the fibers constituting the nonwoven fabric is more preferably 2 dtex to 20 dtex.
  • the basis weight of the nonwoven fabric is preferably set to 200 g / m 2 to 2000 g / m 2 .
  • the basis weight of the nonwoven fabric is more preferably set to 250 g / m 2 to 500 g / m 2 .
  • the basis weight of the base fabric of the tuft carpet is preferably 80 g / m 2 to 150 g / m 2 , and more preferably 90 g / m 2 to 120 g / m 2 .
  • the pile basis weight of the original tuft carpet is preferably 250 g / m 2 to 2000 g / m 2 , and more preferably 300 g / m 2 to 600 g / m 2 .
  • the said fiber layer 2 you may use the thing of the structure on which the nonwoven fabric of 2 layers or more comprised by the fiber of mutually different fineness was laminated
  • the thermoplastic resin constituting the thermoplastic resin layer 3 is not particularly limited as long as it is a thermoplastic resin having a melt flow rate (MFR) in the range of 2 g / 10 min to 500 g / 10 min. Examples thereof include olefin copolymers. When the MFR is less than 2 g / 10 minutes, it is difficult to form the thermoforming hole 13 that penetrates the thermoplastic resin layer in the thickness direction when the inner / outer material 1 is thermoformed. It is also difficult to reduce the inner diameter of the openings at both ends of the through hole 11 when the inner / outer packaging material 1 is thermoformed.
  • MFR melt flow rate
  • the melt flow rate of the thermoplastic resin is preferably 5 g / 10 min to 200 g / 10 min.
  • melt flow rate (MFR) of the thermoplastic resin is 5 g / 10 min to 50 g / 10 min, the inner diameter of the openings at both ends of the through hole 11 is reduced when the inner / outer material 1 is thermoformed. Therefore, the sound absorption performance that is more excellent mainly in the fiber layer 2 is exhibited.
  • melt flow rate (MFR) of the thermoplastic resin is 100 g / 10 min to 200 g / 10 min
  • the thermoplastic resin is sufficiently applied to the fiber layer 2 when the inner / exterior material 1 is thermoformed. It can be impregnated, the air permeability of the molded body can be improved, and more excellent sound absorbing performance can be exhibited.
  • the melt flow rate in the state of containing these needs to be in the range of 2 g / 10 min to 500 g / 10 min. .
  • thermoplastic resin constituting the thermoplastic resin layer 3 is made to contain a filler
  • the filler is the starting point (core) of the formation of the hole 13 at the time of thermoforming. Therefore, the hole 13 is more easily formed during thermoforming.
  • said filler For example, calcium carbonate, aluminum hydroxide, barium sulfate, talc, mica etc. are mentioned.
  • the formation amount (adhesion amount) of the thermoplastic resin layer 3 is preferably set in the range of 50 g / m 2 to 5000 g / m 2 .
  • a uniform film layer thermoplastic resin layer 3
  • heat is generated when the automotive interior / exterior material 1 is thermoformed.
  • the drilling hole 13 can be reliably formed at the time of molding, and more excellent sound absorption performance can be obtained.
  • the formation amount (adhesion amount) of the thermoplastic resin layer 3 is more preferably set in the range of 150 g / m 2 to 2500 g / m 2 .
  • the inner diameter of the mechanical hole is preferably set to 0.1 mm to 5.0 mm. When it is 0.1 mm or more, good sound absorption performance can be secured, and when it is 5.0 mm or less, reduction of the inner diameters of the openings at both ends of mechanical holes (through holes and vent holes) by heating can be effectively achieved. .
  • the inner diameter of the mechanical hole (through hole, vent hole) is particularly preferably set to 0.5 mm to 2.0 mm.
  • the arrangement density of the mechanical holes is preferably set to 1000 / m 2 to 30000 / m 2, and preferably set to 3900 / m 2 to 8000 / m 2. Is particularly preferred.
  • positioning aspect of the said mechanical hole is not limited to the arrangement
  • 31 is an extrusion die, which is connected to an extruder.
  • 32 is a 1st roll and cooling type rolls, such as a water cooling type roll, are used.
  • a plurality of perforating protrusions 32A are formed to project.
  • the shape of the projecting portion 32A for drilling is a shape having a pointed tip with a conical tip provided at the tip of a cylindrical base as shown in FIG.
  • Reference numeral 33 denotes a second roll, and the outer peripheral surface thereof is a smooth outer peripheral surface on which no protrusions are formed.
  • a normal temperature roll is used as the second roll 33, but is not particularly limited to the normal temperature type.
  • the second roll 33 is preferably a rubber roll. Examples of the rubber roll include a silicone rubber roll.
  • thermoplastic resin film 3 immediately after extrusion obtained by extruding a thermoplastic resin having a melt flow rate of 2 g / 10 min to 500 g / 10 min from the extrusion die 31 of the extruder, In a state where the air-permeable fiber layer 2 is superposed, these are pressed between the pair of rolls 32 and 33. At this time, the first roll (cooling roll) 32 is brought into contact with the thermoplastic resin film 3 immediately after the extrusion, and the second roll 33 is pressed in such a manner as to contact the fiber layer 2.
  • thermoplastic resin film (thermoplastic resin layer) 3 Due to the clamping pressure between the pair of rolls 32 and 33, the perforation protrusion 32A on the outer peripheral surface of the first roll 32 penetrates at least the thermoplastic resin film (thermoplastic resin layer) 3 in the thickness direction, At the same time as the thermoplastic resin layer 3 provided with a plurality of through holes 11 is formed, the thermoplastic resin layer 3 is laminated and integrated on one surface of the fiber layer 2. The exterior material 1 is obtained.
  • the perforation protrusion 32A of the first roll 32 penetrates the thermoplastic resin film (thermoplastic resin layer) 3 in the thickness direction, and further the fiber layer.
  • the interior / exterior material 1 for an automobile shown in FIG. 1 can be manufactured by designing and manufacturing so as to penetrate to the other surface (non-laminated surface; the surface contacting the second roll 33).
  • the through hole 11 (and the vent hole 12 in the fiber layer 2) is formed in the thermoplastic resin layer 3 at the same time when the fiber layer 2 is bonded. It is preferable to make holes at the same time, but it is not particularly limited to such a manufacturing method.
  • the through holes 11 (and the fiber layer 2 are formed in the thermoplastic resin layer 3.
  • the through hole 11 (and the vent hole 12 in the fiber layer 2) may be formed in the thermoplastic resin layer 3 at the same time as the subsequent cutting process. Good.
  • the automotive interior / exterior molded body 40 having a predetermined shape is manufactured by thermoforming the automotive interior / exterior material 1 having the above-described configuration.
  • the thermoforming method is not particularly limited, and examples thereof include a hot press method. By hot pressing the automobile interior / exterior material 1, for example, the chassis shape or fender shape of an automobile, etc. Then, it is thermoformed into a shape that matches the part to be used.
  • the heating temperature at the time of thermoforming is not particularly limited as long as it is a moldable temperature, but is generally 160 ° C. to 240 ° C.
  • thermoforming When the thermoplastic resin layer 3 is impregnated in part of the one surface (laminated surface) side of the fiber layer 2 by the thermoforming, the resin layer 3 comes into contact with the constituent fibers of the fiber layer 2 (resin impregnation). ) Are partially broken, such as cracks and perforations, so that the obtained molded body 40 has a thermoformed drilling hole that penetrates the thermoplastic resin layer 3 (resin-impregnated fiber layer 23) in the thickness direction. 13 is formed (see FIG. 5). The size, number, etc. of the holes 13 at the time of thermoforming can be adjusted by the amount of the thermoplastic resin layer 3 formed, the fineness of the constituent fibers of the fiber layer 2, etc., in addition to the melt flow rate of the thermoplastic resin. it can.
  • the molding shape of the automobile interior / exterior molded body 40 is not particularly limited to that shown in FIG.
  • the obtained molded body 40 for automobile interior and exterior has excellent sound absorbing performance due to the synergistic action of the through hole 11 and the thermoforming hole 13. That is, an excellent sound absorbing performance is achieved by a synergistic effect of the sound absorbing action that has entered the fiber layer 2 through the through hole 11 and the sound absorbing action that has entered the fiber layer 2 through the hole 13 at the time of thermoforming. can get.
  • the inside and outside of the automobile having the cross-sectional shape shown in FIG. 6 can be obtained by combining various conditions such as the heating temperature during thermoforming, the amount of thermoplastic resin layer 3 formed (g / m 2 ), and the melt flow rate of the thermoplastic resin.
  • the wearing molded body 40 may be obtained. That is, in the molded body 40 of FIG. 6, the inner peripheral surface of the through hole 11 of the thermoplastic resin layer 3 is formed in a fine uneven shape (such as a wavy shape in a cross-sectional view).
  • the automobile interior / exterior molded body 40 is preferably used as, for example, an automobile floor mat, a fender liner, and an undercover (a cover attached to the lower side of an automobile chassis), but is not particularly limited to these exemplary uses. Absent.
  • Example 1 As shown in FIG. 4, the polyethylene resin film 3 immediately after extrusion obtained by extruding a polyethylene resin having a melt flow rate of 100 g / 10 min from the extrusion die 31 of the extruder, and the fineness of the constituent fibers are 6.6 dtex. In the state where the air-permeable needle punched nonwoven fabric 2 having a basis weight of 250 g / m 2 was superposed, these were sandwiched between the first roll (water-cooled roll) 32 and the second roll 33 described in the previous section. At this time, as shown in FIG.
  • the first roll (water-cooled roll) 32 was in contact with the polyethylene resin film 3 immediately after the extrusion, and the second roll 33 was pinched in such a manner as to contact the needle punched nonwoven fabric 2. Therefore, the perforation protrusion 32A on the outer peripheral surface of the first roll 32 penetrates through the polyethylene resin film (thermoplastic resin layer) 3 and the needle punched nonwoven fabric 2 in the thickness direction, and thereby penetrates in the thickness direction.
  • a polyethylene resin layer 3 provided with a plurality of through holes 11 is formed, and a needle punched nonwoven fabric layer 2 in which a plurality of vent holes 12 are formed penetrating in the thickness direction is formed on one side of the polyethylene resin layer 3.
  • An automotive interior / exterior material 1 was obtained which was laminated and integrated and in which the through holes 11 and the vent holes 12 communicated (see FIG. 1).
  • the amount of the polyethylene resin layer (thermoplastic resin layer) 3 formed is 150 g / m 2 , the inner diameter of the through hole 11 is 1.6 mm, and the inner diameter of the laminated surface of the vent hole 12 is 1. .6 mm, the inner diameter (opening diameter) of the non-laminated surface of the vent holes 12 is 0.1 mm to 0.2 mm, and the arrangement density of mechanical holes (mechanical holes in which the through holes 11 and the vent holes 12 communicate with each other) is 3900. Pieces / m 2 .
  • the automotive interior / exterior molded body 40 having a predetermined shape was manufactured by subjecting the automotive interior / exterior material 1 to hot pressing at 195 ° C.
  • a thermoforming hole 13 that penetrates the polyethylene resin layer (thermoplastic resin layer) 3 in the thickness direction was newly formed (see FIG. 5). ).
  • Example 2 The automotive interior / exterior material shown in FIG. 1 in the same manner as in Example 1 except that a polyethylene resin having a melt flow rate of 150 g / 10 min was used instead of the polyethylene resin having a melt flow rate of 100 g / 10 min. 1 was obtained. Furthermore, the automotive interior / exterior molded body 40 was manufactured by performing hot pressing using the automotive interior / exterior material 1 in the same manner as in Example 1.
  • Example 3 The interior / exterior material for automobiles shown in FIG. 1 in the same manner as in Example 1 except that a polyethylene resin having a melt flow rate of 400 g / 10 min was used instead of the polyethylene resin having a melt flow rate of 100 g / 10 min. 1 was obtained. Furthermore, the automotive interior / exterior molded body 40 was manufactured by performing hot pressing using the automotive interior / exterior material 1 in the same manner as in Example 1.
  • Example 4 The interior / exterior material for automobiles shown in FIG. 1 in the same manner as in Example 1 except that a polyethylene resin having a melt flow rate of 10 g / 10 min was used instead of the polyethylene resin having a melt flow rate of 100 g / 10 min. 1 was obtained. Furthermore, the automotive interior / exterior molded body 40 was manufactured by performing hot pressing using the automotive interior / exterior material 1 in the same manner as in Example 1.
  • Example 5 The automotive interior / exterior material shown in FIG. 1 in the same manner as in Example 1 except that a polyethylene resin having a melt flow rate of 50 g / 10 min was used instead of the polyethylene resin having a melt flow rate of 100 g / 10 min. 1 was obtained. Furthermore, the automotive interior / exterior molded body 40 was manufactured by performing hot pressing using the automotive interior / exterior material 1 in the same manner as in Example 1.
  • Example 6 The interior and exterior for automobiles shown in FIG. 1 in the same manner as in Example 1 except that the arrangement density of mechanical holes (mechanical holes in which the through holes 11 and the vent holes 12 communicate) is set to 7800 / m 2 . Material 1 was obtained. Furthermore, the automotive interior / exterior molded body 40 was manufactured by performing hot pressing using the automotive interior / exterior material 1 in the same manner as in Example 1.
  • Example 7 The interior / exterior for automobiles shown in FIG. 1 in the same manner as in Example 2 except that the arrangement density of mechanical holes (mechanical holes in which the through holes 11 and the vent holes 12 communicate with each other) is set to 7800 / m 2 . Material 1 was obtained. Furthermore, the automotive interior / exterior molded body 40 was manufactured by performing hot pressing using the automotive interior / exterior material 1 in the same manner as in Example 2.
  • Example 8> The interior and exterior for automobiles shown in FIG. 1 in the same manner as in Example 3 except that the arrangement density of mechanical holes (mechanical holes in which the through holes 11 and the vent holes 12 communicate) is set to 7800 / m 2 . Material 1 was obtained. Furthermore, the automotive interior / exterior molded body 40 was manufactured by performing hot pressing in the same manner as in Example 3 using the automotive interior / exterior material 1.
  • Example 9 The interior / exterior for automobiles shown in FIG. 1 in the same manner as in Example 4 except that the arrangement density of mechanical holes (mechanical holes formed by communicating through holes 11 and vent holes 12) is set to 7800 / m 2 . Material 1 was obtained. Furthermore, the automotive interior / exterior molded body 40 was manufactured by performing hot pressing using the automotive interior / exterior material 1 in the same manner as in Example 4.
  • Example 10 The interior / exterior for automobiles shown in FIG. 1 in the same manner as in Example 5 except that the arrangement density of mechanical holes (mechanical holes in which the through holes 11 and the vent holes 12 communicate with each other) is set to 7800 / m 2 . Material 1 was obtained. Furthermore, the automotive interior / exterior molded body 40 was manufactured by performing hot pressing in the same manner as in Example 5 using the automotive interior / exterior material 1.
  • Example 11 The interior / exterior for automobiles shown in FIG. 1 in the same manner as in Example 4 except that the arrangement density of mechanical holes (mechanical holes in which the through holes 11 and the vent holes 12 communicate with each other) is set to 11700 / m 2 . Material 1 was obtained. Furthermore, the automotive interior / exterior molded body 40 was manufactured by performing hot pressing using the automotive interior / exterior material 1 in the same manner as in Example 4.
  • Example 12 The interior / exterior for automobiles shown in FIG. 1 in the same manner as in Example 5 except that the arrangement density of mechanical holes (mechanical holes in which the through holes 11 and the vent holes 12 communicate with each other) is set to 11700 / m 2 . Material 1 was obtained. Furthermore, the automotive interior / exterior molded body 40 was manufactured by performing hot pressing in the same manner as in Example 5 using the automotive interior / exterior material 1.
  • thermoforming hole 13 that penetrates the polyethylene resin layer (thermoplastic resin layer) 3 in the thickness direction through hot pressing. It was formed (see FIG. 5).
  • Example 1 The interior for automobiles shown in FIG. 1 is the same as in Example 1 except that a polyethylene resin having a melt flow rate of 0.8 g / 10 min is used instead of the polyethylene resin having a melt flow rate of 100 g / 10 min. Exterior material 1 was obtained. Furthermore, the automotive interior / exterior molded body 40 was manufactured by performing hot pressing using the automotive interior / exterior material 1 in the same manner as in Example 1. In the obtained molded body 40, the hole 13 at the time of thermoforming penetrating the polyethylene resin layer (thermoplastic resin layer) 3 in the thickness direction was not formed.
  • ⁇ Comparative example 2> The interior / exterior material for automobiles shown in FIG. 1 in the same manner as in Example 1 except that a polyethylene resin having a melt flow rate of 550 g / 10 minutes was used instead of the polyethylene resin having a melt flow rate of 100 g / 10 minutes. 1 was obtained. Furthermore, the automotive interior / exterior molded body 40 was manufactured by performing hot pressing using the automotive interior / exterior material 1 in the same manner as in Example 1.
  • ⁇ Comparative Example 3> As the first roll, instead of a water-cooled roll having a perforation protrusion provided on the outer peripheral surface, a substantially cylindrical room temperature roll not having such a perforation protrusion is used. Thus, an automotive interior / exterior material was obtained. In the obtained automotive interior / exterior material, no mechanical hole is formed. Furthermore, the automotive interior / exterior molded article was manufactured by performing hot pressing in the same manner as in Example 1 using the automotive interior / exterior material.
  • ⁇ Comparative example 4> As the first roll, instead of a water-cooled roll provided with a perforation protrusion on the outer peripheral surface, a substantially cylindrical room temperature roll having no such perforation protrusion is used, as in Example 2. Thus, an automotive interior / exterior material was obtained. In the obtained automotive interior / exterior material, no mechanical hole is formed. Furthermore, the automotive interior / exterior molded body was manufactured by performing hot pressing in the same manner as in Example 2 using the automotive interior / exterior material.
  • Each molded body obtained in Comparative Examples 2 to 4 was formed with a thermoforming hole that penetrates the polyethylene resin layer (thermoplastic resin layer) 3 in the thickness direction through hot pressing. .
  • melt flow rate is 10 g / 10 min, 50 g / 10 min, 100 g / 10 min, 150 g / 10 min, 400 g / 10 min, 0.8 g / 10 min, 550 g. / 10 minutes of polyethylene resin is used, but the polyethylene resin having a different MFR can be adjusted mainly by selecting a polyethylene resin having a different molecular weight (number average molecular weight, weight average molecular weight).
  • the sound absorbing performance of the molded article for automobile interior and exterior obtained as described above was evaluated based on the following evaluation method.
  • ⁇ Sound absorption performance evaluation method The airflow resistance of each automobile interior / exterior molded article was measured using a KES air permeability tester (manufactured by Kato Tech Co., Ltd.). Those having an airflow resistance (AFR) in the range of 1000 Pa ⁇ sec / m to 16000 Pa ⁇ sec / m can be determined to have excellent sound absorption performance.
  • the KES breathability tester measures the pressure loss of the test piece (differential pressure from the atmospheric pressure due to the resistance of the test piece at a constant flow rate of 4 cm 3 / cm 2 ⁇ sec by standard measurement) using a pressure sensor. The airflow resistance is directly displayed.
  • the molded bodies obtained by thermoforming the automotive interior and exterior materials of Examples 1 to 12 according to the present invention have a ventilation resistance of 1000 Pa ⁇ sec / m to 16000 Pa ⁇ sec / m. It was within the range, and it was confirmed that the sound absorbing performance was excellent.
  • the molded body obtained by thermoforming the automotive interior / exterior material of Comparative Example 2 in which the melt flow rate of the resin constituting the thermoplastic resin layer is larger than the upper limit of the specified range of the present invention has a ventilation resistance of 1000 Pa ⁇ It deviated from the range of sec / m to 16000 Pa ⁇ sec / m, and it was found that good sound absorption performance could not be obtained.
  • the molded body obtained by thermoforming the automotive interior / exterior materials of Comparative Examples 3 and 4 in which the through-holes are not formed in the thermoplastic resin layer has a ventilation resistance of 1000 Pa ⁇ sec / m to 16000 Pa ⁇ sec / It deviated from the range of m, and it was found that good sound absorption performance could not be obtained.
  • the interior / exterior material for automobiles according to the present invention is suitably used as an automobile floor mat, fender liner, undercover, etc., but is not particularly limited to these exemplified applications.
  • the thermoplastic resin layer 3 side is disposed on the floor surface, and when used as a fender liner, the fiber layer 2 is disposed on the wheel house side.
  • the thermoplastic resin layer 3 is arrange

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Abstract

優れた吸音性能を備えた自動車用内外装材を提供する。 通気性の繊維層２と、繊維層の一方の面に積層された熱可塑性樹脂層３と、を備え、前記熱可塑性樹脂のメルトフローレートが２ｇ／１０分～５００ｇ／１０分の範囲であり、熱可塑性樹脂層３に該樹脂層の厚さ方向に貫通する貫通孔１１が複数個形成された構成とする。

Description

自動車用内外装材及びその製造方法
　本発明は、例えば、自動車用フロアーマット等の自動車用内装材、フェンダライナ等の自動車用外装材として用いられる自動車用内外装材に関する。
　なお、この明細書及び特許請求の範囲において、「メルトフローレート」の語は、ＪＩＳ　Ｋ７２１０－１９９９に準拠して試験温度１９０℃、試験荷重２１．２Ｎで測定されたメルトフローレートを意味する。
  従来より自動車内のフロアーには、足踏み感を良好にすると共に床側からの振動が伝わらないようにすること等を目的として、フロアーカーペットが敷設されている。そして、自動車内での静粛性を維持するべく、屋根、ドア、窓等から車室内に侵入する騒音に対する吸音性能を高めたものとして、例えば、表皮材（カーペット地）とフェルト状吸音部材とを熱可塑性樹脂粉末の溶融により形成された通気性接着層で接着一体化した自動車用フロアーカーペットが公知である（特許文献１参照）。屋根、ドア、窓などを介して車室内に侵入してくる騒音は、この通気性接着層を通過してフェルト状吸音部材に到達してここで吸音される。
実公平１－７６３６号公報
　ところで、近年、自動車内での快適性をより一層向上させるために、自動車の室内空間における静粛性をさらに高めることが強く求められるようになってきている。しかるに、上記従来の吸音フロアーカーペットでは騒音に対する吸音性能が不十分であり、さらに吸音性能を向上させることが強く求められていた。
　また、フェンダライナ等の自動車用外装材においても同様に吸音性能をさらに向上させることが強く求められていた。
　この発明は、かかる技術的背景に鑑みてなされたものであって、優れた吸音性能を備えた自動車用内外装材とその製造方法を提供すること、および優れた吸音性能を備えた自動車内外装用成形体を製造する方法を提供することを目的とする。
  前記目的を達成するために、本発明は以下の手段を提供する。
　［１］通気性の繊維層と、
　前記繊維層の一方の面に積層された熱可塑性樹脂層と、を備え、
  前記熱可塑性樹脂のメルトフローレートが２ｇ／１０分～５００ｇ／１０分の範囲であり、
　前記熱可塑性樹脂層に該樹脂層の厚さ方向に貫通する貫通孔が複数個形成されていることを特徴とする自動車用内外装材。
　［２］前記貫通孔の内径が０．１ｍｍ～５．０ｍｍであり、前記貫通孔の配置密度が１０００個／ｍ2～３００００個／ｍ2である前項１に記載の自動車用内外装材。
　［３］前記繊維層は、構成繊維の繊度が０．１デシテックス～１００デシテックスである不織布からなる前項１または２に記載の自動車用内外装材。
　［４］前記繊維層は、目付８０ｇ／ｍ2～１５０ｇ／ｍ2の基布の一方の面に、目付２５０ｇ／ｍ2～２０００ｇ／ｍ2のパイルが植設されたカーペット原反であり、
　前記基布の他方の面に前記熱可塑性樹脂層が積層されている前項１または２に記載の自動車用内外装材。
　［５］前記熱可塑性樹脂層の形成量は、５０ｇ／ｍ2～５０００ｇ／ｍ2の範囲である前項１～４のいずれか１項に記載の自動車用内外装材。
　［６］前記繊維層の前記一方の面から、厚さ方向の中間位置まで又は該繊維層の他方の面まで通気孔が複数形成されており、該通気孔は、前記熱可塑性樹脂層の貫通孔と連通していることを特徴とする前項１～５のいずれか１項に記載の自動車用内外装材。
　［７］メルトフローレートが２ｇ／１０分～５００ｇ／１０分である熱可塑性樹脂を押出機から押し出して得られた押出直後の熱可塑性樹脂膜、及び通気性の繊維層を重ね合わせた状態でこれらを一対のロール間で挟圧する工程を備え、
　前記一対のロールのうち熱可塑性樹脂膜に接触する第１ロールとして、外周面に複数個の穿孔用突起部が突設形成された冷却式ロールを用いることを特徴とする自動車用内外装材の製造方法。
　［８］前項１～６のいずれか１項に記載の自動車用内外装材に熱成形を行うことによって成形体を得ることを特徴とする自動車内外装用成形体の製造方法。
　［９］前記熱成形の際に熱可塑性樹脂層が繊維層の前記一方の面側の一部に含浸されることにより部分的に破断して前記得られた成形体の熱可塑性樹脂層に厚さ方向に貫通する熱成形時穿設孔が形成されている前項８に記載の自動車内外装用成形体の製造方法。
　［１０］前記熱成形の際に熱可塑性樹脂層の軟化又は溶融により、前記貫通孔の両端の開口部の内径が減縮する前項８または９に記載の自動車内外装用成形体の製造方法。
　［１］の発明では、通気性の繊維層を備えているから、該繊維層側に到達した音は、該繊維層において吸収されると共に、熱可塑性樹脂層に厚さ方向に貫通する貫通孔が複数個形成されているから、熱可塑性樹脂層側に到達した音は、貫通孔を介して通気性の繊維層に進入して該繊維層で吸収されるので、良好な吸音性能が得られる。かつ、熱可塑性樹脂のメルトフローレートが２ｇ／１０分～５００ｇ／１０分の範囲に設定されているから、自動車用内外装材を熱成形すると、成形体の熱可塑性樹脂層に厚さ方向に貫通する熱成形時穿設孔が形成され、該成形体において前記貫通孔と熱成形時穿設孔の相乗的作用により、優れた吸音性能が得られるものとなる。また、繊維層を備えているので、良好なクッション性も得られる。
　更に、本発明の自動車用内外装材によれば、前記貫通孔を設けておくことにより吸音のための基本的な通気性を確保（設計）すると共に、熱成形の際に形成される熱成形時穿設孔は、熱可塑性樹脂のメルトフローレートの限定範囲（２ｇ／１０分～５００ｇ／１０分）内において特定のメルトフローレートの熱可塑性樹脂を使用（選択）することにより熱成形時穿設孔の構成（数、孔の大きさ等）を調整することができるので、これにより成形体の吸音性能を制御できる（設計できる）。従って、例えば、自動車の車種毎に要求される吸音性能は異なるのであるが、このような様々な吸音性能の要求特性に対して、基本的な通気性を確保するための貫通孔を設ける構成は、共通化することができ、要求される様々な吸音性能に対しては使用する熱可塑性樹脂のメルトフローレートの選択によって調整することが可能となる。これにより、貫通孔形成設備としては、共通化することが可能であるので、設備コストを大幅に低減できる利点もある。要求される様々な吸音性能に対してそれ毎に貫通孔形成設備を多数種準備していたのでは非常に高コストとなるが、本発明によれば、このような高コスト化を回避できる利点もある。
　［２］の発明では、自動車用内外装材としての強度を十分に確保しつつ、優れた吸音性能を確保できる。
　［３］の発明では、繊維層として、構成繊維の繊度が０．１デシテックス～１００デシテックスである不織布が用いられているから、自動車用内外装材を熱成形した際に前記熱成形時穿設孔が確実に形成され得て、より優れた吸音性能が得られるものとなる。
　［４］の発明では、目付８０ｇ／ｍ2～１５０ｇ／ｍ2の基布の一方の面に目付２５０ｇ／ｍ2～２０００ｇ／ｍ2のパイルが植設されたカーペット原反に、熱可塑性樹脂層が積層されているから、自動車用内外装材を熱成形した際に前記熱成形時穿設孔が確実に形成され得て、より優れた吸音性能が得られる。
　［５］の発明では、熱可塑性樹脂層の形成量が、５０ｇ／ｍ2～５０００ｇ／ｍ2の範囲であるから、自動車用内外装材を熱成形した際に前記熱成形時穿設孔がより確実に形成され得て、より一層優れた吸音性能が得られる。
　［６］の発明では、成形体の吸音性能をさらに向上させることができる。中でも、通気孔が繊維層の一方の面から他方の面まで連通している（両面において開口している）構成である場合には、通気性が安定することでより良好な吸音性能を得ることができる。
　［７］の発明では、上述した本発明の自動車用内外装材を安定した品質を確保しつつ効率良く製造することができる。特に外周面に穿設用突起部が設けられたロールとして冷却式ロールを用いているから、冷却された穿設用突起部が熱可塑性樹脂層に進入するものとなり、熱可塑性樹脂層に形成する貫通孔の形状をより均一化することができる。
　［８］及び［９］の発明では、得られた成形体において熱可塑性樹脂層に厚さ方向に貫通する熱成形時穿設孔が形成されており、成形体において前記貫通孔と該熱成形時穿設孔の相乗的作用により、優れた吸音性能が得られる。
　［１０］の発明では、自動車用内外装材を熱成形した際に貫通孔の両端の開口部の内径が減縮するものとなるから、主に繊維層においてより優れた吸音性能が発揮されるものとなる。
本発明に係る自動車用内外装材の一実施形態を示す断面図である。 図１の自動車用内外装材の下面図である。 本発明に係る自動車用内外装材の他の実施形態を示す断面図である。 本発明に係る自動車用内外装材の製造方法の一例を示す説明図である。 図１の自動車用内外装材を熱成形することにより得られた自動車内外装用成形体の一例を示す模式的断面図である。 図１の自動車用内外装材を熱成形することにより得られた自動車内外装用成形体の他の例を示す模式的断面図である。
　本発明に係る自動車用内外装材１は、通気性の繊維層２と、該繊維層２の一方の面に積層された熱可塑性樹脂層３と、を備えている。また、前記熱可塑性樹脂層３に該樹脂層の厚さ方向に貫通する貫通孔１１が複数個形成されている。本発明では、前記熱可塑性樹脂層３を構成する熱可塑性樹脂として、メルトフローレートが２ｇ／１０分～５００ｇ／１０分の熱可塑性樹脂を用いる。
  本発明の自動車用内外装材１の一実施形態を図１、２に示す。前記熱可塑性樹脂層３に該樹脂層３の厚さ方向に貫通する貫通孔１１が複数個形成されていると共に、前記繊維層２の前記一方の面（積層面；下面）から繊維層２の他方の面（非積層面；上面）まで通気孔１２が複数形成されており、該通気孔１２は、前記熱可塑性樹脂層３の貫通孔１１と連通している（図１参照）。これら互いに連通した貫通孔１１及び通気孔１２により機械的孔が構成され、本実施形態では、この機械的孔は、自動車用内外装材１の厚さ方向に貫通している。即ち、本実施形態では、前記機械的孔は、自動車用内外装材１を厚さ方向に貫通して両面において開口している（図１参照）。
　なお、図３に示すように、前記貫通孔１１に連通する通気孔１２が、繊維層２の前記一方の面（積層面）から、厚さ方向の中間位置（中途位置）まで形成された構成であってもよい（通気孔１２が繊維層２の非積層面まで達していない構成であってもよい）。
　本発明の自動車用内外装材１では、通気性の繊維層２を備えているから、該繊維層側に到達した音は、該繊維層２において吸収されると共に、熱可塑性樹脂層３に厚さ方向に貫通する貫通孔１１が複数個形成されているから、熱可塑性樹脂層側に到達した音は、この貫通孔１１を介して通気性の繊維層２に進入して該繊維層２で吸収されるので、良好な吸音性能が得られる。かつ、熱可塑性樹脂のメルトフローレートが２ｇ／１０分～５００ｇ／１０分の範囲に設定されているから、自動車用内外装材１を熱成形すると、成形体４０の熱可塑性樹脂層３に厚さ方向に貫通する熱成形時穿設孔１３が形成され（図５参照）、該成形体４０において前記貫通孔１１と熱成形時穿設孔１３の相乗的作用により、優れた吸音性能が得られるものとなる。更に、自動車用内外装材１を熱成形すると、成形体４０において熱可塑性樹脂層３が再軟化又は再溶融して、貫通孔１１の両端の開口部の内径が減縮するので、より一層優れた吸音性能が得られる。
　本発明において、前記通気性の繊維層２としては、特に限定されるものではないが、例えば、不織布、パイルを有したタフトカーペット原反等が挙げられる。前記不織布としては、特に限定されるものではないが、例えば、ニードルパンチ不織布、スパンボンド不織布等が挙げられる。
　前記繊維層２として不織布を用いる場合、構成繊維の繊度は、０．１デシテックス～１００デシテックスであるのが好ましい。０．１デシテックス以上とすることで内外装材１を熱成形した際に熱可塑性樹脂層に厚さ方向に貫通する熱成形時穿設孔を確実に形成できると共に１００デシテックス以下とすることで十分な吸音性を確保できる。中でも、前記不織布を構成する繊維の繊度は、２デシテックス～２０デシテックスであるのがより好ましい。
  また、前記繊維層２として不織布を用いる場合、該不織布の目付量は、２００ｇ／ｍ2～２０００ｇ／ｍ2に設定されるのが好ましい。２００ｇ／ｍ2以上であることで十分な吸音性を確保できると共に２０００ｇ／ｍ2以下であることで軽量化を図ることができる。中でも、前記不織布の目付量は、２５０ｇ／ｍ2～５００ｇ／ｍ2に設定されるのがより好ましい。
　前記繊維層２としてタフトカーペット原反を用いる場合、該タフトカーペット原反の基布としては、より吸音性を向上できる点で、不織布を用いるのが好ましい。また、前記タフトカーペット原反の基布の目付は８０ｇ／ｍ2～１５０ｇ／ｍ2であるのが好ましく、中でも、９０ｇ／ｍ2～１２０ｇ／ｍ2であるのがより好ましい。また、前記タフトカーペット原反のパイル目付は、２５０ｇ／ｍ2～２０００ｇ／ｍ2であるのが好ましく、中でも、３００ｇ／ｍ2～６００ｇ／ｍ2であるのがより好ましい。
　なお、前記繊維層２として、例えば、相互に異なる繊度の繊維で構成された２層以上の不織布が積層された構成のものを使用してもよいし、熱可塑性樹脂層３との積層面にラテックス層が設けられた繊維層（不織布層など）を使用してもよい。
　前記熱可塑性樹脂層３を構成する熱可塑性樹脂としては、メルトフローレート（ＭＦＲ）が２ｇ／１０分～５００ｇ／１０分の範囲である熱可塑性樹脂であれば特に限定されず、例えば、ポリオレフィン、オレフィン系共重合体等が挙げられる。ＭＦＲが２ｇ／１０分未満である場合には、内外装材１を熱成形した際に熱可塑性樹脂層に厚さ方向に貫通する熱成形時穿設孔１３を形成することが困難となるし、内外装材１を熱成形した際に貫通孔１１の両端の開口部の内径を減縮させることも困難である。また、ＭＦＲが５００ｇ／１０分を超えると、内外装材１を熱成形した際に熱可塑性樹脂が流動し過ぎて、得られる成形体４０の通気抵抗が小さくなり過ぎ、十分な吸音性能が得られない。中でも、前記熱可塑性樹脂のメルトフローレートは、５ｇ／１０分～２００ｇ／１０分であるのが好ましい。
　前記熱可塑性樹脂のメルトフローレート（ＭＦＲ）が５ｇ／１０分～５０ｇ／１０分である場合には、内外装材１を熱成形した際に前記貫通孔１１の両端の開口部の内径が減縮する程度が大きくなるので、主に前記繊維層２においてより一層優れた吸音性能が発揮されるものとなる。
　また、前記熱可塑性樹脂のメルトフローレート（ＭＦＲ）が１００ｇ／１０分～２００ｇ／１０分である場合には、内外装材１を熱成形した際に前記熱可塑性樹脂を繊維層２に十分に含浸させることができて成形体の通気性を向上できてより優れた吸音性能が発揮されるものとなる。
　なお、前記熱可塑性樹脂が、後述する充填剤、添加剤等を含有する場合には、これらを含有した状態でのメルトフローレートが２ｇ／１０分～５００ｇ／１０分の範囲にある必要がある。
  前記熱可塑性樹脂層３を構成する熱可塑性樹脂に充填剤を含有せしめた場合には、内外装材１を熱成形した際に充填剤が熱成形時穿設孔１３の形成の起点（核）となるので、熱成形時穿設孔１３がより形成されやすくなる。前記充填剤としては、特に限定されるものではないが、例えば、炭酸カルシウム、水酸化アルミニウム、硫酸バリウム、タルク、マイカ等が挙げられる。
　前記熱可塑性樹脂層３の形成量（付着量）は、５０ｇ／ｍ2～５０００ｇ／ｍ2の範囲に設定されるのが好ましい。５０ｇ／ｍ2以上であることで安定的に均一なフィルム層（熱可塑性樹脂層３）を形成できる共に、５０００ｇ／ｍ2以下であることで自動車用内外装材１を熱成形した際に熱成形時穿設孔１３が確実に形成され得て、より優れた吸音性能が得られるものとなる。中でも、前記熱可塑性樹脂層３の形成量（付着量）は、１５０ｇ／ｍ2～２５００ｇ／ｍ2の範囲に設定されるのがより好ましい。
　前記機械的孔（貫通孔、通気孔）の内径は、０．１ｍｍ～５．０ｍｍに設定されるのが好ましい。０．１ｍｍ以上であることで良好な吸音性能を確保できると共に５．０ｍｍ以下であることで加熱による機械的孔（貫通孔、通気孔）の両端の開口部内径の減縮を効果的に達成できる。中でも、前記機械的孔（貫通孔、通気孔）の内径は、０．５ｍｍ～２．０ｍｍに設定されるのが特に好ましい。
　前記機械的孔（貫通孔、通気孔）の配置密度は、１０００個／ｍ2～３００００個／ｍ2に設定されるのが好ましく、３９００個／ｍ2～８０００個／ｍ2に設定されるのが特に好ましい。
　なお、前記機械的孔（貫通孔、通気孔）の配置態様は、図２に示す配置態様に限定されるものではない。
  次に、本発明の自動車用内外装材１の製造方法について図４を参照しつつ説明する。図４において、３１は、押出ダイスであり、押出機に接続されている。３２は、第１ロールであり、水冷式ロール等の冷却式ロールが使用される。前記第１ロール（冷却式ロール）３２の外周面に複数個の穿孔用突起部３２Ａが突設形成されている。本実施形態では、穿孔用突起部３２Ａの形状は、図４に示すような円柱形状の基部の先端に円錐形状の先端部が設けられた先端が尖った形状であるが、特にこのような形状に限定されるものではなく、例えば、円柱形状、円錐形状の他、三角錐形状、四角錐形状、五角錐形状、六角錐形状等の多角錐形状であってもよい。また、３３は、第２ロールであり、その外周面は、突起等は形成されていない円滑な外周面になっている。本実施形態では、前記第２ロール３３として、常温のロールを使用するが、特に常温タイプに限定されるものではない。また、前記第２ロール３３としては、ゴムロールを用いるのが好ましい。前記ゴムロールとしては、例えば、シリコーンゴムロール等が挙げられる。
  しかして、図４に示すように、メルトフローレートが２ｇ／１０分～５００ｇ／１０分である熱可塑性樹脂を押出機の押出ダイス３１から押し出して得られた押出直後の熱可塑性樹脂膜３、及び通気性の繊維層２を重ね合わせた状態でこれらを前記一対のロール３２、３３間で挟圧する。この時、第１ロール（冷却式ロール）３２が前記押出直後の熱可塑性樹脂膜３に接触し、第２ロール３３が前記繊維層２に接触する態様で挟圧する。
　前記一対のロール３２、３３間での挟圧により、第１ロール３２の外周面の穿孔用突起部３２Ａが、少なくとも熱可塑性樹脂膜（熱可塑性樹脂層）３を厚さ方向に貫通して、複数個の貫通孔１１が設けられた熱可塑性樹脂層３が形成されると同時に、該熱可塑性樹脂層３が前記繊維層２の一方の面に積層一体化され、こうして本発明の自動車用内外装材１が得られる。
　前記一対のロール３２、３３間での挟圧の際に、第１ロール３２の穿孔用突起部３２Ａが、熱可塑性樹脂膜（熱可塑性樹脂層）３を厚さ方向に貫通し、さらに繊維層２の他方の面（非積層面；第２ロール３３に接触する表面）まで貫通するように設計して製造を行うことにより、図１に示す自動車用内外装材１を製造することができる。
　上記製造方法では、繊維層２との貼り合わせ時に同時に熱可塑性樹脂層３に貫通孔１１（及び繊維層２に通気孔１２）を形成しており、このように繊維層２との貼り合わせ時に同時に孔をあけるのが好ましいが、特にこのような製造方法に限定されるものではなく、例えば、繊維層２との貼り合わせを行った後に熱可塑性樹脂層３に貫通孔１１（及び繊維層２に通気孔１２）を形成するようにしてもよいし、或いは、後工程である裁断時に同時に熱可塑性樹脂層３に貫通孔１１（及び繊維層２に通気孔１２）を形成するようにしてもよい。
  次に、本発明の自動車用内外装材１を用いて自動車内外装用成形体４０を製造する方法について説明する。上記構成に係る自動車用内外装材１に熱成形を行うことによって所定形状の自動車内外装用成形体４０を製造する。前記熱成形の手法としては、特に限定されるものではないが、例えば、熱プレス法等が挙げられ、自動車用内外装材１を熱プレスすることにより、例えば、自動車のシャーシー形状やフェンダー形状等、使用される部位に合わせた形状に熱成形される。前記熱成形の際の加熱温度は、成形可能な温度であれば特に限定されないが、一般には１６０℃～２４０℃である。
　前記熱成形により熱可塑性樹脂層３が繊維層２の前記一方の面（積層面）側の一部に含浸されると、樹脂層３が、繊維層２の構成繊維との接触（樹脂の含浸）により、亀裂や穿孔等、部分的に破断するので、得られた成形体４０には、その熱可塑性樹脂層３（樹脂含浸繊維層２３）に厚さ方向に貫通する熱成形時穿設孔１３が形成されている（図５参照）。この熱成形時穿設孔１３の大きさ、数などは、前記熱可塑性樹脂のメルトフローレートの他、熱可塑性樹脂層３の形成量、繊維層２の構成繊維の繊度等により調整することができる。自動車内外装用成形体４０の成形形状は、図５に示すものに特に限定されるものではない。
  得られた自動車内外装用成形体４０は、前記貫通孔１１と熱成形時穿設孔１３の相乗的作用により、優れた吸音性能が得られる。即ち、貫通孔１１を介して繊維層２に入り込んだ音の吸収作用と、熱成形時穿設孔１３を介して繊維層２に入り込んだ音の吸収作用との相乗効果によって優れた吸音性能が得られる。
　なお、熱成形時の加熱温度、熱可塑性樹脂層３の形成量（ｇ／ｍ2）、熱可塑性樹脂のメルトフローレート等の各種条件の組み合わせにより、図６に示す断面形状を備えた自動車内外装用成形体４０が得られる場合もある。即ち、図６の成形体４０では、熱可塑性樹脂層３の貫通孔１１の内周面が微細凹凸形状（断面視で波線形状等）に形成されている。
  上記自動車内外装用成形体４０は、例えば、自動車用フロアーマット、フェンダライナ、アンダーカバー（自動車のシャシー下側に取り付けられるカバー）として好適に用いられるが、特にこれら例示の用途に限定されるものではない。
　次に、本発明の具体的実施例について説明するが、本発明はこれら実施例のものに特に限定されるものではない。
　＜実施例１＞
　図４に示すように、メルトフローレートが１００ｇ／１０分であるポリエチレン樹脂を押出機の押出ダイス３１から押し出して得られた押出直後のポリエチレン樹脂膜３、及び構成繊維の繊度が６．６デシテックスで目付が２５０ｇ／ｍ2の通気性のニードルパンチ不織布２を重ね合わせた状態でこれらを前項で説明した第１ロール（水冷式ロール）３２と第２ロール３３の間で挟圧した。この時、図４に示すように、第１ロール（水冷式ロール）３２が前記押出直後のポリエチレン樹脂膜３に接触し、第２ロール３３が前記ニードルパンチ不織布２に接触する態様で挟圧したので、第１ロール３２の外周面の穿孔用突起部３２Ａが、ポリエチレン樹脂膜（熱可塑性樹脂層）３およびニードルパンチ不織布２を厚さ方向に貫通し、これにより、厚さ方向に貫通する複数個の貫通孔１１が設けられたポリエチレン樹脂層３が形成されると共に、複数個の通気孔１２が厚さ方向に貫通して形成されたニードルパンチ不織布層２が前記ポリエチレン樹脂層３の片面に積層一体化され、貫通孔１１と通気孔１２が連通してなる自動車用内外装材１を得た（図１参照）。
  得られた自動車用内外装材１において、ポリエチレン樹脂層（熱可塑性樹脂層）３の形成量は１５０ｇ／ｍ2、貫通孔１１の内径が１．６ｍｍ、通気孔１２の積層面の内径が１．６ｍｍ、通気孔１２の非積層面の内径（開口径）が０．１ｍｍ～０．２ｍｍ、機械的孔（貫通孔１１と通気孔１２が連通してなる機械的孔）の配置密度が３９００個／ｍ2であった。
  上記自動車用内外装材１に１９５℃で熱プレスを行うことによって所定形状の自動車内外装用成形体４０を製造した。得られた成形体４０には、この熱成形を経て、ポリエチレン樹脂層（熱可塑性樹脂層）３を厚さ方向に貫通する熱成形時穿設孔１３が新たに形成されていた（図５参照）。
　＜実施例２＞
  メルトフローレートが１００ｇ／１０分であるポリエチレン樹脂に代えて、メルトフローレートが１５０ｇ／１０分であるポリエチレン樹脂を用いた以外は、実施例１と同様にして図１に示す自動車用内外装材１を得た。さらに、この自動車用内外装材１を用いて実施例１と同様にして熱プレスを行うことによって自動車内外装用成形体４０を製造した。
　＜実施例３＞
  メルトフローレートが１００ｇ／１０分であるポリエチレン樹脂に代えて、メルトフローレートが４００ｇ／１０分であるポリエチレン樹脂を用いた以外は、実施例１と同様にして図１に示す自動車用内外装材１を得た。さらに、この自動車用内外装材１を用いて実施例１と同様にして熱プレスを行うことによって自動車内外装用成形体４０を製造した。
　＜実施例４＞
  メルトフローレートが１００ｇ／１０分であるポリエチレン樹脂に代えて、メルトフローレートが１０ｇ／１０分であるポリエチレン樹脂を用いた以外は、実施例１と同様にして図１に示す自動車用内外装材１を得た。さらに、この自動車用内外装材１を用いて実施例１と同様にして熱プレスを行うことによって自動車内外装用成形体４０を製造した。
　＜実施例５＞
  メルトフローレートが１００ｇ／１０分であるポリエチレン樹脂に代えて、メルトフローレートが５０ｇ／１０分であるポリエチレン樹脂を用いた以外は、実施例１と同様にして図１に示す自動車用内外装材１を得た。さらに、この自動車用内外装材１を用いて実施例１と同様にして熱プレスを行うことによって自動車内外装用成形体４０を製造した。
　＜実施例６＞
  機械的孔（貫通孔１１と通気孔１２が連通してなる機械的孔）の配置密度を７８００個／ｍ2に設定した以外は、実施例１と同様にして図１に示す自動車用内外装材１を得た。さらに、この自動車用内外装材１を用いて実施例１と同様にして熱プレスを行うことによって自動車内外装用成形体４０を製造した。
　＜実施例７＞
  機械的孔（貫通孔１１と通気孔１２が連通してなる機械的孔）の配置密度を７８００個／ｍ2に設定した以外は、実施例２と同様にして図１に示す自動車用内外装材１を得た。さらに、この自動車用内外装材１を用いて実施例２と同様にして熱プレスを行うことによって自動車内外装用成形体４０を製造した。
　＜実施例８＞
  機械的孔（貫通孔１１と通気孔１２が連通してなる機械的孔）の配置密度を７８００個／ｍ2に設定した以外は、実施例３と同様にして図１に示す自動車用内外装材１を得た。さらに、この自動車用内外装材１を用いて実施例３と同様にして熱プレスを行うことによって自動車内外装用成形体４０を製造した。
　＜実施例９＞
  機械的孔（貫通孔１１と通気孔１２が連通してなる機械的孔）の配置密度を７８００個／ｍ2に設定した以外は、実施例４と同様にして図１に示す自動車用内外装材１を得た。さらに、この自動車用内外装材１を用いて実施例４と同様にして熱プレスを行うことによって自動車内外装用成形体４０を製造した。
　＜実施例１０＞
  機械的孔（貫通孔１１と通気孔１２が連通してなる機械的孔）の配置密度を７８００個／ｍ2に設定した以外は、実施例５と同様にして図１に示す自動車用内外装材１を得た。さらに、この自動車用内外装材１を用いて実施例５と同様にして熱プレスを行うことによって自動車内外装用成形体４０を製造した。
　＜実施例１１＞
  機械的孔（貫通孔１１と通気孔１２が連通してなる機械的孔）の配置密度を１１７００個／ｍ2に設定した以外は、実施例４と同様にして図１に示す自動車用内外装材１を得た。さらに、この自動車用内外装材１を用いて実施例４と同様にして熱プレスを行うことによって自動車内外装用成形体４０を製造した。
　＜実施例１２＞
  機械的孔（貫通孔１１と通気孔１２が連通してなる機械的孔）の配置密度を１１７００個／ｍ2に設定した以外は、実施例５と同様にして図１に示す自動車用内外装材１を得た。さらに、この自動車用内外装材１を用いて実施例５と同様にして熱プレスを行うことによって自動車内外装用成形体４０を製造した。
　なお、実施例２～１２で得られた各成形体４０には、熱プレスを経て、ポリエチレン樹脂層（熱可塑性樹脂層）３を厚さ方向に貫通する熱成形時穿設孔１３が新たに形成されていた（図５参照）。
　＜比較例１＞
  メルトフローレートが１００ｇ／１０分であるポリエチレン樹脂に代えて、メルトフローレートが０．８ｇ／１０分であるポリエチレン樹脂を用いた以外は、実施例１と同様にして図１に示す自動車用内外装材１を得た。さらに、この自動車用内外装材１を用いて実施例１と同様にして熱プレスを行うことによって自動車内外装用成形体４０を製造した。得られた成形体４０には、ポリエチレン樹脂層（熱可塑性樹脂層）３を厚さ方向に貫通する熱成形時穿設孔１３は形成されなかった。
　＜比較例２＞
  メルトフローレートが１００ｇ／１０分であるポリエチレン樹脂に代えて、メルトフローレートが５５０ｇ／１０分であるポリエチレン樹脂を用いた以外は、実施例１と同様にして図１に示す自動車用内外装材１を得た。さらに、この自動車用内外装材１を用いて実施例１と同様にして熱プレスを行うことによって自動車内外装用成形体４０を製造した。
　＜比較例３＞
  第１ロールとして、外周面に穿孔用突起部が設けられた水冷式ロールに代えて、このような穿孔用突起部を有しない略円柱形状の常温ロールを用いた以外は、実施例１と同様にして自動車用内外装材を得た。得られた自動車用内外装材において、機械的孔は、形成されていない。さらに、この自動車用内外装材を用いて実施例１と同様にして熱プレスを行うことによって自動車内外装用成形体を製造した。
　＜比較例４＞
  第１ロールとして、外周面に穿孔用突起部が設けられた水冷式ロールに代えて、このような穿孔用突起部を有しない略円柱形状の常温ロールを用いた以外は、実施例２と同様にして自動車用内外装材を得た。得られた自動車用内外装材において、機械的孔は、形成されていない。さらに、この自動車用内外装材を用いて実施例２と同様にして熱プレスを行うことによって自動車内外装用成形体を製造した。
　なお、比較例２～４で得られた各成形体には、熱プレスを経て、ポリエチレン樹脂層（熱可塑性樹脂層）３を厚さ方向に貫通する熱成形時穿設孔が形成されていた。
　上記各実施例、各比較例において、メルトフローレート（ＭＦＲ）が１０ｇ／１０分、５０ｇ／１０分、１００ｇ／１０分、１５０ｇ／１０分、４００ｇ／１０分、０．８ｇ／１０分、５５０ｇ／１０分のポリエチレン樹脂を用いているが、このようにＭＦＲの異なるポリエチレン樹脂は、主に分子量（数平均分子量、重量平均分子量）が異なるポリエチレン樹脂を選択することで調整できる。
Figure JPOXMLDOC01-appb-T000001
　上記のようにして得られた自動車内外装用成形体の吸音性能を下記評価法に基づいて評価した。
　＜吸音性能評価法＞
　ＫＥＳ通気性試験機（カトーテック株式会社製）を用いて各自動車内外装用成形体の通気抵抗を測定した。通気抵抗（ＡＦＲ；airflow resistance）が１０００Ｐａ・ｓｅｃ／ｍ～１６０００Ｐａ・ｓｅｃ／ｍの範囲内にあるものが吸音性能に優れていると判定できる。なお、ＫＥＳ通気性試験機は、試験片の圧力損失（標準測定で一定流量４ｃｍ3／ｃｍ2・ｓｅｃのときの試験片の抵抗による大気圧との差圧）を圧力センサーを用いて測定し、通気抵抗を直接表示するものである。
　表１から明らかなように、本発明に係る実施例１～１２の自動車用内外装材を熱成形して得られた成形体は、通気抵抗が１０００Ｐａ・ｓｅｃ／ｍ～１６０００Ｐａ・ｓｅｃ／ｍの範囲内にあり、吸音性能に優れるものであることを確認し得た。
　これに対し、熱可塑性樹脂層を構成する樹脂のメルトフローレートが本発明の規定範囲の下限より小さい比較例１の自動車用内外装材を用いると、熱成形しても熱成形時穿設孔が形成されず、熱成形して得られた成形体は、通気抵抗が１０００Ｐａ・ｓｅｃ／ｍ～１６０００Ｐａ・ｓｅｃ／ｍの範囲から逸脱しており、良好な吸音性能が得られないものであることがわかった。
　また、熱可塑性樹脂層を構成する樹脂のメルトフローレートが本発明の規定範囲の上限より大きい比較例２の自動車用内外装材を熱成形して得られた成形体は、通気抵抗が１０００Ｐａ・ｓｅｃ／ｍ～１６０００Ｐａ・ｓｅｃ／ｍの範囲から逸脱しており、良好な吸音性能が得られないものであることがわかった。
　また、熱可塑性樹脂層に貫通孔を形成せしめていない比較例３、４の自動車用内外装材を熱成形して得られた成形体は、通気抵抗が１０００Ｐａ・ｓｅｃ／ｍ～１６０００Ｐａ・ｓｅｃ／ｍの範囲から逸脱しており、良好な吸音性能が得られないものであることがわかった。
　本発明に係る自動車用内外装材は、自動車用フロアーマット、フェンダライナ、アンダーカバー等として好適に用いられるが、特にこれら例示の用途に限定されるものではない。また、通常は、自動車用フロアーマットとして使用する場合には、熱可塑性樹脂層３側を床面に配置して使用し、フェンダライナとして使用する場合には、ホイールハウス側に繊維層２を配置し、タイヤ側に熱可塑性樹脂層３を配置して使用するが、特にこのような使用態様に限定されるものではない。
１…自動車用内外装材
２…繊維層
３…熱可塑性樹脂層
１１…貫通孔
１２…通気孔
１３…熱成形時穿設孔
３２…第１ロール（冷却式ロール）
３２Ａ…穿孔用突起部
３３…第２ロール
４０…自動車内外装用成形体

Claims (10)

  1. 　通気性の繊維層と、
    　前記繊維層の一方の面に積層された熱可塑性樹脂層と、を備え、
      前記熱可塑性樹脂のメルトフローレートが２ｇ／１０分～５００ｇ／１０分の範囲であり、
    　前記熱可塑性樹脂層に該樹脂層の厚さ方向に貫通する貫通孔が複数個形成されていることを特徴とする自動車用内外装材。
  2.   前記貫通孔の内径が０．１ｍｍ～５．０ｍｍであり、前記貫通孔の配置密度が１０００個／ｍ2～３００００個／ｍ2である請求項１に記載の自動車用内外装材。
  3.   前記繊維層は、構成繊維の繊度が０．１デシテックス～１００デシテックスである不織布からなる請求項１または２に記載の自動車用内外装材。
  4.   前記繊維層は、目付８０ｇ／ｍ2～１５０ｇ／ｍ2の基布の一方の面に、目付２５０ｇ／ｍ2～２０００ｇ／ｍ2のパイルが植設されたカーペット原反であり、
    　前記基布の他方の面に前記熱可塑性樹脂層が積層されている請求項１または２に記載の自動車用内外装材。
  5.   前記熱可塑性樹脂層の形成量は、５０ｇ／ｍ2～５０００ｇ／ｍ2の範囲である請求項１～４のいずれか１項に記載の自動車用内外装材。
  6.   前記繊維層の前記一方の面から、厚さ方向の中間位置まで又は該繊維層の他方の面まで通気孔が複数形成されており、該通気孔は、前記熱可塑性樹脂層の貫通孔と連通していることを特徴とする請求項１～５のいずれか１項に記載の自動車用内外装材。
  7.   メルトフローレートが２ｇ／１０分～５００ｇ／１０分である熱可塑性樹脂を押出機から押し出して得られた押出直後の熱可塑性樹脂膜、及び通気性の繊維層を重ね合わせた状態でこれらを一対のロール間で挟圧する工程を備え、
    　前記一対のロールのうち熱可塑性樹脂膜に接触する第１ロールとして、外周面に複数個の穿孔用突起部が突設形成された冷却式ロールを用いることを特徴とする自動車用内外装材の製造方法。
  8.   請求項１～６のいずれか１項に記載の自動車用内外装材に熱成形を行うことによって成形体を得ることを特徴とする自動車内外装用成形体の製造方法。
  9.   前記熱成形の際に熱可塑性樹脂層が繊維層の前記一方の面側の一部に含浸されることにより部分的に破断して前記得られた成形体の熱可塑性樹脂層に厚さ方向に貫通する熱成形時穿設孔が形成されている請求項８に記載の自動車内外装用成形体の製造方法。
  10.   前記熱成形の際に熱可塑性樹脂層の軟化又は溶融により、前記貫通孔の両端の開口部の内径が減縮する請求項８または９に記載の自動車内外装用成形体の製造方法。
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