JP2825314B2 - Vehicle skin material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a seat cover in a vehicle interior, a door lining, a ceiling material,
The present invention relates to a vehicular skin material having a function of removing a bad smell in a vehicle cabin by being used as a floor carpet or the like.

[Conventional technology]

In recent years, as the performance of passenger cars, such as driving performance, safety, and comfort, has become more complete, interest in vehicle interior odor, which has a significant effect on passenger comfort, has increased, and odors in the vehicle interior atmosphere have been reduced. More effective measures to meet such demands have been required. The bad smell here is, for example, a smell such as a cigarette smell, a sweat smell, a musty smell, an exhaust gas smell, a solvent smell or a plasticizer smell generated from a resin interior material or an adhesive.

Conventionally, as a countermeasure to prevent these odors, there is a method of masking or sensually neutralizing the odor using an aromatic agent, and a method of spraying or volatilizing a liquid deodorant. That effect is not satisfactory. In addition, although the removal of offensive odor is also performed by an air purifying device, a small device does not provide a sufficient effect, and a large device reduces the size of the device and reduces the interior space of the vehicle, resulting in high costs. Power consumption is also large. Further, no effect can be expected while the air purification device is not operating, such as in a parked vehicle interior.

On the other hand, as a material having a deodorizing property, a sheet material to which a hydrous magnesium silicate clay mineral is added is known (Japanese Patent Application Laid-Open Nos. 62-282926 and 62-282927). As a deodorizing member having improved deodorizing performance, there is a member using a combination of sepiolite and activated carbon (JP-A-63-283649). Furthermore, while improving its deodorizing performance, as a vehicle skin material having an antistatic effect, a hydrous magnesium silicate clay mineral in a back coating layer for improving the bonding strength between the yarns constituting the fabric and A skin material for vehicles to which activated carbon is added is conceivable.

This vehicle skin material can be expected to have excellent deodorizing performance due to the adsorption properties of clay minerals and the combined action with activated carbon and the like.

However, the resin emulsion constituting the back coating agent in which the hydrated magnesium silicate clay mineral and activated carbon are dispersed has a specific resin odor. When a resin emulsion having a strong resin odor is used, some resin odor may remain even after adding a clay mineral and activated carbon to dry the resin. Although the level of the resin odor is not so high, it is a level at which odor is felt, and it is preferable that the deodorizing effect is not exerted more effectively. Furthermore, most of the resin odor of the resin emulsion is adsorbed by the deodorant in the back coating agent, so a part of the adsorption capacity that should be used for the deodorization function is used by the adsorption of the resin odor. As a result, the deodorizing ability of the deodorant cannot be fully exhibited.

[Object of the invention]

Thus, an object of the present invention is to generate almost no odor from the resin emulsion in the back coating agent, and as a result, the original deodorization of the hydrated magnesium silicate clay mineral and activated carbon added to the back coating agent as a deodorizing agent. It is an object of the present invention to provide a vehicular skin material that exhibits maximum performance.

[Configuration of the invention]

The present inventors have conducted intensive studies to solve the above conventional problems, that the resin odor after drying the resin emulsion into a resin is due to residual monomers, the strength of the resin odor and the average particle size of the emulsion. We discovered that there was a correlation in the diameter, and as a result of repeated systematic experiments, the average particle diameter was 0.25
By using a resin emulsion of μm or more as a base material and a back coating agent containing a hydrated magnesium silicate clay mineral, activated carbon and a dispersant in the fabric, there is almost no resin odor during the initial use period, and The skin material of the present invention has been completed, which is capable of effectively eliminating malodors for a long period of time.

The structure of the skin material of the present invention comprises a resin layer derived from a back coating agent comprising a polymer latex containing a hydrous magnesium silicate clay mineral, activated carbon and a dispersant, and a fabric. More specifically, a fabric, a polymer latex layer in which particles having an average particle diameter of 0.25 μm or more applied to the fabric at a rate of 15 to 135 g per square meter are fused together to form a layer, 5 to 160 parts by weight of the hydrous magnesium silicate clay mineral dispersed and fixed to 100 parts by weight of the particles of the molecular latex, and the clay mineral is added to the polymer latex layer with respect to 100 parts by weight of the particles of the polymer latex. 50-180
It is a skin material for vehicles comprising activated carbon dispersed and fixed by weight.

 Hereinafter, the configuration of the present invention will be described in detail.

The polymer latex used in the present invention is a main element of the back coating agent, and by combining the fibers constituting the fabric with the fibers, improves the dimensional accuracy of the fabric, prevents the fibers from fraying, and It is a substance that functions as a binder that holds additives such as hydrated magnesium silicate clay minerals, activated carbon, and flame retardants and fixes them to fabric.

As the polymer latex, a synthetic resin latex having an average particle diameter of 0.25 μm or more is used. The synthetic resin latex is an emulsion composed of resin colloid particles as a dispersoid and water or the like as a dispersion medium, and when dried, effectively acts as a binder by fusing the particles together.

In the present invention, the back coating agent applied to the fabric is usually obtained by mixing 50 to 180 parts by weight of a clay mineral and activated carbon in total with 100 parts by weight of polymer latex particles. If the sum of the addition amounts of the clay mineral and the activated carbon is less than 50 parts by weight, sufficient deodorizing performance cannot be expected,
If it exceeds 180 parts by weight, the polymer latex becomes relatively short, and the inherent properties of the back coating agent, namely, the improvement of the dimensional accuracy of the fabric, the prevention of yarn fraying and opening, the improvement of the strength of the fabric, the retention of flame retardants, etc. Is inadequate.

The vehicle skin material of the present invention is obtained by applying the back coating agent having the above composition to the back surface of the fabric and drying the resin to form a resin. The amount of coating should be in the range of 50 to 200 g in solid content per square meter of fabric.If it is less than 50 g / m ² , the amount of activated carbon and clay minerals is small, so the deodorizing performance will be insufficient, and the coating amount will exceed 200 g / m ² Then, the rigidity of the fabric becomes too large and the texture is impaired.

[Function of the invention]

 The operation of the present invention is considered as follows.

The clay mineral, which is one of the main components of the back coating agent in the present invention, is an aggregate of fibers having a diameter of about 0.005 to 0.6 μm, and has a thin rectangular cross section of about 1 × 0.6 nm parallel to the fibers. There are holes. Therefore, the specific surface area of the clay mineral is 150 to 400 m ² / g, and there are many pores around 1 nm due to the crystal structure and many pores around 20 nm due to the fiber diameter. It is considered that this large specific surface area and pores function as sites for receiving malodorous substances such as ammonia, amines, and fatty acids, and exhibit deodorizing properties.

On the other hand, activated carbon contained as the main component of the back coating agent along with the clay mineral has a specific surface area of 500 to 1300 m ² / g
And mainly has pores in the vicinity of 10 nm. And, due to the difference between the specific surface area and the size of the pores, the clay mineral exhibits different adsorption characteristics from the above clay minerals, such as sulfide-based odors such as hydrogen sulfide, methyl mercaptan, methyl sulfide, and methyl disulfide, and toluene and styrene. It is thought that it functions as a site for accepting hydrocarbon odors such as odors and exhibits deodorization.

 The action of activated carbon will be described in more detail.

Activated carbon is amorphous carbon in crystal structure. In its structure, the basic crystallites of graphite are irregularly arranged,
There are a myriad of pores formed after the crystallites that have been activated by a gas or a chemical, and are formed after crystallites that have disappeared or partially disappeared.

The pores are classified into three types: macropores, transitional pores, and micropores. Macropores have a radius of 20 ~
It is larger than 1000 Å, its volume is 0.2-0.5 ml / g and its surface area is 0.5-2 m ² / g. The transitional pore has a radius of 20 to 1000 angstroms, a volume of 0.02 to 1.0 ml / g and a surface area of 1 to 800 m ² / g. Micropores intended follows radius 20 Å, volume 0.25~0.9ml / g, a surface area of 500~1400m ² / g.

Since most of the odor gas molecules in the atmosphere can enter the micropores, the micropores contribute most to the adsorption capacity. The transitional pore has a great influence on the diffusion rate of the adsorbate in the pore, and in a region where the relative pressure of the adsorbate is high, the gas is trapped by vascular condensation. Macropores have little effect on gas adsorption. These pore structures vary depending on the raw materials and activation conditions.

As described above, these clay minerals and activated carbon cause the above-mentioned differences in the adsorbed substances due to the difference in specific surface area and pore size, and together with these effects, are effective in a wide variety of odors generated in the passenger compartment. Can be effectively reduced.

In addition, the polymer latex itself has almost no deodorizing property, but when a back coating agent is applied to the fabric and dried, a porous film is formed without covering the clay mineral and the activated carbon. Fixed to.

More specifically, this polymer latex is produced by emulsion polymerization. That is, a monomer of the resin is dispersed in water using an emulsifier to form an emulsion, and a polymerization initiator is added. The monomer is in the emulsifier micelle, and the polymerization reaction proceeds by the radical of the polymerization initiator penetrating into the emulsifier micelle. The particle size of the emulsion is determined by the amount of the emulsifier, and the finer the particle, the smaller the probability that the radical of the polymerization initiator meets the emulsion particle. Therefore, it is considered that the probability that the monomer is left behind increases and the resin odor increases. As shown in FIG. 1, the monomer tends to increase at a particle diameter smaller than the average particle diameter of 0.25 μm and the resin smell becomes stronger. This has not received much attention in the past.

When a resin emulsion is used for a conventional back coating agent that does not contain a deodorant, even if the particle size is increased and the resin odor is reduced to a certain extent, the resin odor still remains at a level exceeding the recognition threshold (odor intensity 2) (No. 1 FIG. A).
However, in the skin material of the present invention to which a hydrated magnesium silicate clay mineral and activated carbon are added, when a resin emulsion having an average particle diameter of 0.25 μm or more is used, FIG.
As shown in (2), the skin material has a resin odor below the detection threshold (odor intensity 1).

〔The invention's effect〕

According to the configuration of the present invention, it is considered that the excellent deodorizing performance of the clay mineral and the activated carbon can be sufficiently exhibited without hindering the deodorizing performance.

Further, in the present invention, a resin emulsion composed of latex having an average particle diameter of 0.25 μm or more is used.

Therefore, odor is hardly generated from the resin emulsion contained in the back coating agent, and as a result, the original deodorizing performance of the hydrous magnesium silicate clay mineral and activated carbon added to the back coating agent as a deodorant is maximized. It is exhibited and the deodorizing performance of the skin material is further improved.

[Other inventions]

Examples of the synthetic resin latex include latexes such as polyvinyl chloride latex, polyvinylidene chloride latex, polyacrylate latex, polyvinyl acetate latex, polyacrylonitrile latex, and modified products and copolymers thereof.

The hydrous magnesium silicate clay mineral (hereinafter, referred to as clay mineral) is a clay mineral having hydrous magnesium silicate as a main component and having a highly reactive hydroxyl group on its surface. This clay mineral is composed of fibers having a diameter of about 0.005 to 0.6 μm, and has pores (channels) having a rectangular cross section of about 1 to 0.6 nm in parallel with the fibers. It has the property of adsorbing bad smell and water vapor. In addition, in the clay mineral, magnesium or silicon may be partially replaced by aluminum, iron, nickel, sodium, or the like. Specific examples include sepiolite, white tile, laphrinite, falconite, and palygorskite. Also known as mountain cork,
This is what is called mountain leather, mountain wood, sepiolite, and attapulgite. These may be calcined in a temperature range of 400 to 800 ° C. The clay mineral may be used in the form of powder, granules, or plate, but is preferably ground to the extent that the pores of the clay mineral remain, and the length is 10 μm.
An aggregate of microcrystals having an aspect ratio of 100 or less is preferred. The pulverization at this time is performed by wet pulverization or dry pulverization using a mixer, a ball mill, a vibration mill, a hammer mill, a pin mill, a beater or the like.

As a raw material of activated carbon, any substance which is carbonized by heating is applicable, but raw materials which can be stably supplied in large quantities at low cost include sawdust, charcoal, coconut shell, lignite, peat, coal, pulp waste liquid and the like. The activation method includes a chemical activation method and a gas activation method. The chemicals used in the chemical activation method include chemicals that have a dehydrating and eroding effect on the raw materials, specifically zinc chloride,
Phosphoric acid, sulfuric acid, calcium chloride, sodium hydroxide, etc.,
An oxidizing chemical, specifically, potassium dichromate, potassium permanganate, or the like is used. In the gas activation method,
First, the raw material is carbonized, and then activated by contact with a gas at a high temperature. As the gas to be brought into contact, steam, carbon dioxide gas, air, a mixed gas thereof, or the like is used. Any of the activated carbons thus obtained can be suitably used in the present invention, but those in which micropores have been developed are particularly effective. Specifically, coconut shells were used as raw materials and activated by a gas activation method. The one that is most suitable.

These clay minerals and activated carbon are used in the form of granules or powder, and constitute a back coating agent by being dispersed in a polymer latex. The particle diameter of these clay minerals and activated carbon is not more than the same size as the thickness of the fabric when attached to the fabric, specifically, it may be about 3 mm or less, but if it is too large, the texture as the fabric deteriorates. If it is too small, the clay mineral and the activated carbon are buried in the polymer latex, and the deodorizing property is reduced. Specifically, it is desirable that the particle size is in the range of 1 to 200 μm.

In the present invention, as a dispersant used for stably dispersing the clay mineral and the activated carbon in the polymer latex, a polymer surfactant having a molecular weight of 10,000 or more is suitably used. Low-molecular surfactants penetrate the pores of clay minerals or activated carbon to reduce the deodorizing function, low-molecular surfactants themselves vaporize and become odor sources, or exist in the atmosphere It is not desirable because it may generate a bad smell due to a chemical reaction with the substance. As the dispersant, a polymer surfactant is used. The back coating agent of the present invention may contain 3 to 20 parts by weight of a dispersant for highly dispersing the polymer latex particles and other solid components in the back coating agent.
If the amount of the dispersant is less than 3 parts by weight, the stability of the back coating agent becomes insufficient, and the water resistance and weather resistance exceeding 20 parts by weight deteriorate. Examples of the polymer surfactant include a synthetic polymer and a cellulose derivative. As the synthetic polymer, for example, sodium tripolyphosphate,
Examples include polyphosphates such as sodium tetraphosphate and sodium hexametaphosphate, polyvinyl alcohol, sodium polyacrylate, polyvinylpyrrolidone, and styrene-maleic acid copolymer. Examples of the cellulose derivative include methyl cellulose, hydroxyethyl cellulose, carboxymethyl cellulose and the like.

The dispersant has an effect of stably dispersing the clay mineral and the activated carbon in the polymer latex. In particular, a molecular weight of 10,000
When a high molecular surfactant composed of the above-mentioned synthetic polymer or cellulose derivative is used, since the size of the molecule is large, it does not penetrate into the pores of the clay mineral and the activated carbon. It does not occupy or vaporize. Further, it is chemically stable and has little interaction with odorous substances.

In addition, other additives, for example, a flame retardant may be added to the back coating agent of the present invention as long as the properties are not impaired. Common flame retardants include phosphorus compounds, chlorine compounds, bromine compounds, guanidine nitrogen compounds,
There are an antimony compound, a boron compound, an ammonium compound, and the like. Specific examples include primary ammonium phosphate,
Diammonium phosphate, phosphate triester, phosphite, phosphonium salt, phosphate triamide chlorinated paraffin, dechlorane, ammonium bromide, tetrabromobisphenol A, tetrabromoethane, guanidine hydrochloride, guanidine carbonate, phosphorus Acid guanylurea, antimony oxide, sodium tetraborate decahydrate (borax), ammonium sulfate, ammonium sulfamate and the like.

The fabric to which the back coating agent is applied in the present invention is a woven fabric, a knitted fabric, or a nonwoven fabric composed of natural fibers, chemical fibers or both fibers, and specifically, woven fabrics, moquettes, towel fabrics, tricots, double raschels, Circular knitting,
Needle punch and the like can be mentioned. The fibers referred to here include natural fibers such as cotton, hemp, silk, and wool, or rayon, acetate, protein fibers, chlorinated rubber, polyamide,
Examples include chemical fibers such as polyvinyl alcohol, polyvinyl chloride, polyvinylidene chloride, polyacrylonitrile, polyester, polyethylene, polypropylene, polyurethane, polyvinylidene cyanide, and polyfluoroethylene. Alternatively, a fabric made of both fibers may be used.

Further, in the present invention, a common liquid deodorant or powdered deodorant, for example, plant extraction oil, oxidizing agent, organic acid,
It is also possible to use a metal salt or the like in combination. In this case, these deodorants are used, for example, by adding them to the fibers constituting the mixed resin emulsion or the fabric, or by directly applying them to the fabric using a spray or a brush.

The vehicular skin material of the present invention reduces the bad smell in the vehicle quality and provides a comfortable living space due to its excellent deodorizing performance. However, the back coating agent contains activated carbon having a small electric resistance. Therefore, it has a characteristic of effectively dissipating static electricity as a secondary effect. Therefore, by combining this with a fabric provided with conductivity, it is also effective in preventing static electricity.

The conductive fabric referred to here is a material in which conductive materials such as copper, aluminum, stainless steel, carbon, and a conductive polymer are mixed into organic fibers in a particulate form, or a vacuum evaporation method is applied to the surface of the organic fibers. Woven fabric, knitted fabric, non-woven fabric which is coated with or coated with the organic fiber, or contains 0.1 to 20% by weight of a conductive fiber consisting of a conductive substance itself with respect to the fabric. Include woven fabric, moquette, toweling, tricot, double raschel, circular knitting, needle punch and the like. In this case, as fibers mainly constituting the fabric, natural fibers such as cotton, hemp, silk, wool, rayon, acetate, protein fibers, chlorinated rubber, polyamide, polyvinyl alcohol, polyvinyl chloride, polyvinylidene chloride, polyacrylonitrile, Examples thereof include chemical fibers such as polyester, polyethylene, polypropylene, polyurethane, polyvinylidene cyanide, and polyfluoroethylene, or may be composed of both fibers. When the content of the conductive fiber is less than 0.1% by weight, static electricity is not sufficiently dissipated due to the poor conductivity of the fabric, and when the content exceeds 20% by weight, the effect of the color of the conductive fiber itself on the color of the entire fabric is applied. This impairs the original appearance and texture of the fabric. In addition, the effect of suppressing static electricity does not increase while the cost is high.

As a method for adding conductive fibers to the fabric, mixing in a fiber state, mixing in a sliver state, twisting in a thread form,
Any of a mixture in the form of a filament, a twisted yarn, and an arrangement on a texture may be used.

In this case, the content of the activated carbon contained in the back coating agent is preferably set to 40 to 90% by weight of the total amount of the clay mineral and the activated carbon. Activated carbon content is 40% by weight
If less, the effect of dissipating static electricity is not sufficient,
On the other hand, when the content exceeds 90% by weight, the deodorizing performance is impaired because the clay mineral adsorption properties are not sufficiently exhibited as described above.

The static electricity removing function of the skin material of the present invention is considered as follows.

The static electricity generated by the friction between the clothing and the skin material for the vehicle is charged on the surface of the skin material and the clothing when the normal skin material is used, and the human body is charged by the static electricity charged on the clothing. On the other hand, in the skin material of the present invention, since both the fabric constituting the skin material and the resin layer derived from the back coating agent are conductive, the static electricity generated by the friction between the clothing and the vehicle skin material is limited to the skin. The current is collected by the conductive fibers contained in the material and corona discharge occurs in the air, or the collected static electricity is diffused throughout the skin material by the activated carbon in the back coating agent, and local high voltage is generated. It is suppressed and gradually discharged into the air. Therefore, no high-voltage static electricity is generated in the human body due to electrostatic induction. In this way, static electricity is effectively removed, and an unpleasant discharge phenomenon when the vehicle gets off the vehicle is prevented.

〔Example〕

Hereinafter, the present invention will be described based on examples, but the present invention is not limited by these examples unless it exceeds the gist thereof.

35 parts by weight of sepiolite with a particle size of 150 mesh or less, 250
35 parts by weight of coconut shell activated carbon with a particle size of less than mesh, molecular weight 10
5 parts by weight of 0,000 carboxymethylcellulose were dry-mixed to obtain a mixed powder. Next, 75 parts by weight of the mixed powder and 390 water
Parts by weight were mixed to form a slurry. Next, the above slurry was mixed with 100 parts by weight of a polyacrylate latex having a solid content of 55% and an average particle diameter of 0.36 μm to prepare a back coating agent. Next, 27.4 kg (solid content: 6.3 kg) of the above back coating agent was applied to 42 m ² of a moquette fabric made of polyester fiber using a doctor blade, dried at 140 ° C. for 6 minutes, and a 4.2 mm thick vehicle skin material was obtained. Obtained.

A seat assembly for three vehicles was produced using the vehicle skin material thus produced, and was mounted on three four-door sedans. After mounting, the window glass, the door, and the ventilator were closed and left for one day. After that, 12 panelists got into the car alternately, and the odor intensity in the passenger compartment was evaluated by a six-stage odor intensity display.

Further, for comparison, a skin material for a vehicle was produced by the same materials and processes as described above, except that an acrylate emulsion having an average particle diameter of 0.18 μm was used (Comparative Example 1).

Further, a vehicle skin material was produced using exactly the same materials and steps as in the example except that no deodorant was contained (Comparative Example 2).

The skin materials of these comparative examples were mounted on an actual vehicle in the same manner as in the examples, and the odor intensity was evaluated under the same conditions by a six-stage odor intensity display.

The intensity of the odor remaining in the passenger compartment was 0.5 in this example, 1.6 in Comparative Example 1, and 2.4 in Comparative Example 2, and the residual odor was increased by setting the particle size of the polymer latex to 0.25 μm or more. The amount of odor was significantly reduced.

In addition, in the evaluation by the odor intensity display of 6 levels of odor, 0 is “odorless”, 1 is “odor that can be finally sensed”,
2 indicates "a weak smell that tells what the smell is", 3 indicates "a smell that can be easily sensed", 4 indicates "a strong smell", and 6 indicates "a strong smell".

[Brief description of the drawings]

FIG. 1 is a diagram showing a correlation between the average particle diameter of a polymer latex and the odor intensity in a vehicle cabin equipped with a vehicular skin material coated with a back coating agent using the latex. (A) shows the case where the back coating agent does not contain the hydrated magnesium silicate clay mineral and the activated carbon, and (b) in the figure shows the case where the back coating agent contains the hydrated magnesium silicate clay mineral and the activated carbon.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI D06M 23/00 D06M 11/06 11/00 Z (72) Inventor Takatoshi Sekihara 1-1-1 Toyota-cho, Kariya-shi, Aichi Pref. In-company (72) Inventor Akihiro Matsuyama 1-1-1 Toyota-cho, Kariya-shi, Aichi Prefecture Inside Toyota Boshoku Corporation (72) Inventor Osamu Araki 1-Toyota-cho, Toyota-shi, Aichi Prefecture Toyota Motor Corporation (72) Inventor Yoshio Yamada 1 Toyota Town, Toyota City, Aichi Prefecture Examiner, Kenji Sano, Toyota Motor Corporation (58) Field surveyed (Int. Cl. ⁶ , DB name) D06N 7/00 D06M 15/693 D06M 11/06 D06M 11 / 00 D06M 21/00

Claims (1)

(57) [Claims] 1. A fabric, a polymer latex layer coated with 15 to 135 g per square meter of particles having an average particle diameter of 0.25 μm or more and fused together to form a layer; Hydrous magnesium silicate clay mineral dispersed and fixed to 5 to 160 parts by weight with respect to 100 parts by weight of polymer latex particles, The polymer latex layer, 100 parts by weight of the polymer latex particles, the clay mineral A skin material for vehicles comprising a total of 50 to 180 parts by weight of activated carbon dispersed and fixed.