JP6492364B2 - Interior material for automobile and manufacturing method thereof - Google Patents

Description

  The present invention relates to an automobile interior material. More specifically, the present invention relates to an automotive interior material having a hook-and-loop fastener attached on the back surface side, and a manufacturing method thereof. Specifically, the interior of an automobile has a hook-and-loop fastener attached to the back surface when the interior material is molded with a mold. Regarding materials.

  Conventionally, as a method of fixing automotive interior materials such as ceiling materials, door trims, trunk room materials, etc. to the vehicle body, surface fasteners are attached to a plurality of predetermined positions on the back surface of the automotive interior material, while also on the vehicle body side, There is known a method of fixing an interior material to a vehicle body by attaching another hook-and-loop fastener and engaging both hook-and-loop fasteners close to each other.

  As a method for manufacturing an interior material having a hook-and-loop fastener attached to the back surface used in such a method, a method of attaching a hook-and-loop fastener to the back surface of an automobile interior material molded into a predetermined shape is known. (Patent Document 1). However, in the case of this known method of attaching using an adhesive, the adhesive has a problem that the adhesive strength decreases as the temperature of the vehicle body rises. Since the temperature of the vehicle body rises considerably due to the strong sun, the adhesive strength is greatly reduced, and in some cases, it may cause a serious problem such as peeling.

  Instead of using such a pressure-sensitive adhesive, a hot melt adhesive is applied to the back surface of the surface fastener, the hot melt adhesive is heated and melted immediately before the surface fastener is attached, and There are also known a method of attaching to a predetermined position, and a method of applying a molten hot melt adhesive to a predetermined place on the back surface of the interior material and attaching a hook-and-loop fastener at the same time.

If this method using a hot melt adhesive is used, the problem of decrease in adhesive strength due to heat as in the above method using an adhesive can be solved. However, in this method, it took time to install. In this case, the hot melt adhesive is solidified and sufficient adhesive force cannot be obtained. To prevent this, the surface fastener is quickly pressed and attached to a predetermined position of the interior material while the hot melt adhesive is in a molten state. In this case, the hook-and-loop fastener is easily detached or displaced from the predetermined position. Since it is attached, there is a problem that sufficient engagement force cannot be obtained.
Furthermore, in the interior material production line, the conventional process of hot-melting the adhesive on the back surface of a plurality of surface fasteners at a predetermined position on the back surface of the manufactured interior material and attaching it within a predetermined period of time adds time. Therefore, the mounting operation must be complicated, and it is extremely difficult to mount accurately and firmly.

JP 11-179813 A (Claim 1)

  The present invention is a technique for fixing the interior material for automobiles to the vehicle body using the hook-and-loop fastener, and there is no problem that the adhesive force decreases due to heat as in the technique for fixing using an adhesive. In addition, the present invention provides a technique that does not cause a problem that the adhesion is insufficient due to time or the problem of being attached with a deviation from an accurate position, such as a technique of attachment using a hot melt adhesive.

That is, the present invention relates to an automotive interior material in which a hook-and-loop fastener is fixed at a predetermined position on the back surface side of the automotive interior material. The nonwoven fabric layer is formed on the surface on which the surface fastener is fixed, and the surface fastener of the nonwoven fabric layer. A laminated film layer having both sides covered with a hot-melt adhesive layer is superimposed on the surface opposite to the surface on which the surface is fixed, and a depressed portion is formed at a predetermined position on the back surface side. A hook-and-loop fastener is fitted and fixed with a hot-melt adhesive without any gap with the engaging element surface facing outside.

  Preferably, in the present invention, the automotive interior material includes the foamed resin layer or the nonwoven fabric layer, and the automotive interior material includes the foamed resin layer and at least one surface thereof. The above-mentioned automotive interior material comprising a nonwoven fabric layer covering the laminate, wherein the automotive interior material is a skin material, a foamed resin layer I, a nonwoven fabric layer I, a foamed resin layer II and a nonwoven fabric layer II laminated in this order. And it is invention of the said interior material for motor vehicles by which the surface fastener is being fixed to the surface on the opposite side to the foamed resin layer II of the nonwoven fabric layer II.

  In the present invention, it is preferable that the hook-and-loop fastener includes a resin substrate and an engagement element made of the same resin standing upright from the substrate, and the engagement element is a side from the stem portion standing upright from the substrate and the top of the stem portion. The automotive interior material is a molded male surface fastener composed of a protruding protrusion for engagement that protrudes into the surface, and more preferably, the molded surface fastener has a height (H) of the engagement element from the substrate. A molded male in which the ratio (D / H) of the length (D) from the top to the lower end of the protrusion is 0.35 to 0.75, and the substrate coverage of the engagement element is 25 to 45% It is invention of the said interior material for motor vehicles which is a type | mold surface fastener.

Further, in the present invention, the hook-and-loop fastener has a loop element made of a multifilament on the surface of a base fabric made of a woven fabric, and the multifilament is a female hook-and-loop fastener made of a polybutylene terephthalate resin. It is an invention of an interior material.
And as the use of the interior material for automobiles, when it is a ceiling material for automobiles, the interior material for automobiles is a trim for automobile doors, the interior material for automobiles is a trunk room material, or the automobile This is a case where the interior material for the interior is an interior material with a wire harness.

Further, according to the present invention, a nonwoven fabric layer is present on the surface to which the surface fastener is fixed, and both surfaces of the nonwoven fabric layer are opposite to the surface to which the surface fastener is fixed with a hot melt adhesive layer. When a sheet for automobile interior material with a laminated film layer covered is inserted into a mold and heated and pressed into a predetermined shape, the hot melt adhesive is placed on the back surface in advance at a predetermined position of the mold. The hook-and-loop fastener is set so that the engagement element surface is on the mold surface side, and the sheet is inserted and molded in that state, and then removed from the mold to fix the hook-and-loop fastener in place. This is a method for manufacturing an automobile interior material. And it is said manufacturing method with which the hollow which can fix a hook_and_loop | surface fastener is provided in the predetermined position of a metal mold | die, and the magnet is embedded in the predetermined position of a metal mold | die, On the other hand, a magnetic material is used for a hook_and_loop | surface fastener In the above manufacturing method, the hook-and-loop fastener is magnetically attached to a predetermined position of the mold by the magnet and the magnetic material.

  The present invention is not a technique for attaching a hook-and-loop fastener to a predetermined position on the back surface of an automobile interior material after being molded by using an adhesive or an adhesive as in the prior art, but an automobile interior material (hereinafter simply referred to as an interior material). When molding with a mold, set the hook-and-loop fastener at a predetermined position in the mold, and use the heat and pressure to make it exist on the back of the hook-and-loop fastener at the time of molding. This is a technology that melts the hot melt adhesive and attaches a surface fastener to the back of the interior material, and simultaneously molds the interior material and fixes the surface fastener to the back of the interior material. Like the conventional technology for attaching hook-and-loop fasteners with hot-melt adhesive, if it takes time to attach hook-and-loop fasteners to the back, the adhesive will solidify and sufficient adhesive strength will be obtained. It does not cause the problem have.

  In addition, the interior material of the present invention has a problem of lowering of adhesive strength due to heat like the conventional technology of attaching with an adhesive because the surface fastener is bonded and fixed to a predetermined place on the back surface of the interior material by a hot melt adhesive. Does not occur. Furthermore, since it is not necessary to newly attach a hook-and-loop fastener to the manufactured interior material, there is no problem that the hook-and-loop fastener attaching work becomes complicated due to time.

  In particular, in the case of the present invention, the hook-and-loop fastener is used as an interior material by fitting the hook-and-loop fastener into a recess provided at a predetermined position of the mold or by using a magnetic force to set the predetermined position of the mold. It can be accurately and firmly attached to a predetermined position. Therefore, there is no problem that the mounting position is shifted or the mounting force is insufficient as in the prior art.

  In the case of the prior art, the predetermined position on the back surface of the interior material is recessed at the time of molding so that the predetermined position where the surface fastener on the back surface of the interior material should be attached is easy to understand. In order to improve workability when attaching the hook-and-loop fastener, the depression provided on the back surface of the interior material is provided so as to be considerably larger than the size of the hook-and-loop fastener. However, there is a wide gap around the hook-and-loop fastener, and the hook-and-loop fastener is not fitted in the depressed portion without a gap as defined in the present invention.

  In the case of the present invention, since the hook-and-loop fastener is fitted without a gap, the side surface of the hook-and-loop fastener substrate and the interior material are brought into contact with each other, thereby making it possible to bond more firmly. In addition, the recesses and the hook-and-loop fastener that are provided on the back surface of the interior material are fitted with no gap, thereby facilitating alignment between the interior material and the vehicle body, and can be attached at a more accurate position without subtle displacement.

It is sectional drawing of an example at the time of shape | molding the interior material with a surface fastener of this invention with a metal mold | die, and the sheet | seat for interior materials inserted in the metal mold | die. It is a perspective view of an example of the interior material with a hook-and-loop fastener of the present invention taken out from a mold. It is a perspective view of an example of a molding male surface fastener used suitably for the present invention. It is a perspective view of an example of the engagement element of the shaping | molding male surface fastener used suitably for this invention. It is a top view of an example of a molding male surface fastener suitably used for the present invention. It is sectional drawing which showed typically the surface fastener attachment part of an example of the interior material with a surface fastener of this invention. It is sectional drawing which showed typically the hook-and-loop fastener attachment part of another example of the interior material with a hook-and-loop fastener of this invention. It is sectional drawing which showed typically the hook-and-loop fastener attachment part of an example of the conventional interior material with a hook-and-loop fastener. It is sectional drawing which showed typically a part of example of the interior material with a hook_and_loop | surface fastener obtained by this invention.

The present invention will be described below with reference to the drawings.
As shown in FIG. 1, the automotive interior material with a hook-and-loop fastener according to the present invention has a hook-and-loop fastener (2) set at a predetermined position in a mold for molding the interior material, and then the mold. The interior material sheet (1) is inserted between the upper mold (3) and the lower mold (4), and the sheet is heated and pressed in the mold to obtain a predetermined shape. The hook-and-loop fastener (2) is fixed at a predetermined position on the back side of the interior material for automobiles as shown in FIG. 2 by fixing the hook-and-loop fastener at a predetermined position on the back side and removing it from the mold. Interior material (5) is obtained.

First, the surface fastener used in the present invention will be described in detail.
The hook-and-loop fastener used in the present invention may be a male hook-and-loop fastener having a hook-type engagement element such as a hook type, a mushroom type or a hook type on the surface, or a female type having a loop-type engagement element on the surface. Any of hook-and-loop fasteners may be used. In addition, the engagement of male surface fasteners that have columnar elements on the surface and cause engagement by frictional force etc. when the columnar elements are fitted in the gap when the engagement element surfaces are overlapped. Engagement between male surface fasteners in which an engagement force is generated by engagement of mushroom-shaped engagement elements may be used.

  Preferably, it is preferable that the engaging element is not easily defeated by the pressing force under the heating conditions during molding. Specifically, the hook-and-loop fastener includes a resin substrate (B) and the same as shown in FIGS. The engaging element (E) is made of the same resin upright from the substrate, and the engaging element is formed from a stem portion (S) standing upright from the substrate and an engaging protrusion (T) protruding sideways from the top of the stem portion. A molded male surface fastener is preferable because the engaging element is unlikely to fall. More preferably, in such a molded male surface fastener, the ratio of the length (D) from the top of the engaging element to the lower end of the protrusion with respect to the height (H) of the engaging element from the substrate The molded male surface fastener has a (D / H) of 0.35 to 0.75 and a substrate coverage of the engagement element of 25 to 45%.

  In the case of a normal molded male surface fastener, D / H is 0.15 to 0.25, and considering that the substrate coverage is in the range of 10 to 15%, a molded male mold suitable for the present invention. It can be said that the hook-and-loop fastener is very special. The height (H) of the engaging element is also preferably in the range of 1.2 to 4.0 mm in terms of engaging force.

  In the molded male surface fastener suitably used in the present invention, a plurality of engaging elements as described above are arranged in a row at regular intervals in the vertical direction (Y direction shown in FIG. 3) (that is, There are a plurality of such rows in parallel in the horizontal direction (X direction shown in FIG. 3).

  Both the substrate (B) and the male engagement element (E) of such a molded male surface fastener are made of plastic, and the substrate (B) and the male engagement element (E) are formed of different resins. However, from the viewpoint of productivity, it is usually preferable to be composed of the same resin.

The resin used is not particularly limited, and examples thereof include thermoplastic resins used for normal molding. For example, polyolefin resins represented by polypropylene, nylon resins such as nylon 6 and nylon 66, polyethylene terephthalate, poly Examples thereof include polyester resins such as butylene terephthalate and polylactic acid, polyvinyl chloride resins, styrene resins, acrylic resins, and the like, and polyester elastomer resins and polyurethane elastomer resins may be used. Of these, polypropylene, polyethylene terephthalate, polybutylene terephthalate, and polyester-based elastomer are particularly preferable because the engaging element is unlikely to fall during molding with a mold and easily rises even if it falls.
However, a resin that does not melt or soften at the temperature when molding the interior material in a mold is preferable.

  In the molded male surface fastener suitably used in the present invention, as described above, the male engagement element has the engagement protrusion (T) protruding from the same side as the stem (S), Usually, it is preferable that the engaging protrusions (T) protrude symmetrically from the stem on both sides in that the mating surface fastener can be engaged at the correct position. The stem (S) usually stands upright from the substrate (B). In order to increase the engagement force, the engagement protrusion (T) protrudes in parallel with the substrate or in a direction in which the tip portion is lowered to the substrate side from the parallel as shown in FIGS. That is, the protrusion protrudes in a direction in which the loop-like engagement element can be firmly held under the engagement protrusion (T), and the protrusion shape is easily engaged with the loop-like engagement element, and the engagement is difficult to disengage. Is preferred.

  As described above, the molded male surface fastener used in the present invention has a D / H of 0.35 to 0.75 and a substrate coverage of the engagement element of 25 to 45%. When satisfying such D / H and substrate coverage, when attaching the interior material to the vehicle body, it is necessary to confirm that it is overlaid at a position where it can be attached to an accurate position. When the interior material is overlapped close to the vehicle body, the surface fastener on the back of the interior material easily engages with the surface fastener attached to the vehicle body, making it difficult to peel off, and it is difficult to attach the interior material to the correct position. Can be prevented.

  Generally, interior materials for automobiles have a large area, and when attaching, it is not possible to visually confirm the positions of the hook-and-loop fasteners. In the case of a fastener, unnecessary engagement occurs at this alignment stage, and when it is found that it is not the correct position, it is necessary to disengage the engagement and reattach it to the correct position. In the conventional male surface fastener, a strong engagement is generated at the time of alignment, and a great deal of labor and time is required to disengage the engagement. When the hook-and-loop fastener is newly engaged or peeled off, the molded interior material may be bent and the interior material may be damaged.

  Therefore, when attaching the automotive interior material to the vehicle body, it is extremely important that the engagement is difficult to occur at the time of alignment, but in the case of a molded male surface fastener suitably used in the present invention, When D / H is 0.35 to 0.75 and the substrate coverage of the engagement element is 25 to 45%, unnecessary engagement is rarely caused during alignment.

  FIG. 3 and FIG. 4 are perspective views of an example of an engagement element constituting a male surface fastener suitably used in the present invention. In the engagement elements of these drawings, the value of D / H is increased. Therefore, a sticking prevention projection is provided on the top of the engagement element. Conventional male surface fasteners do not have such sticking prevention projections, and the tops of the engagement elements often have a flat or mushroom-like gentle roundness.

  Of course, the sticking prevention protrusion does not need to be provided on the top of the engagement element, and may protrude from the engagement protrusion (T) in a direction away from the substrate. Furthermore, the number of sticking prevention protrusions does not have to be one for each engagement element, and a plurality of sticking prevention protrusions may exist, or about one for two to three engagement elements. Further, the engagement protrusion itself may be thickened so that the D / H value is 0.35 or more.

  Further, in the male surface fastener used in the present invention, it is preferable that the substrate coverage of the engagement element is 25 to 45% in order to prevent unnecessary engagement at the time of alignment, that is, erroneous attachment. The substrate coverage referred to here is the ratio of the area of the head portion of the male engagement element viewed from the top to the area of the substrate portion where the male engagement element is erected, specifically, the male type The portion where the engaging element is present is photographed from above with an optical microscope, and an arbitrary substrate portion where 50 male engaging elements are present is enclosed from the photograph, and the area (s1) of the enclosed portion is enclosed. ) And the total area (s2) of the upper surfaces of the 50 male engaging elements existing in the same portion, and calculating [(s2) / (s1)] × 100 to obtain the substrate covering of the engaging elements The rate (%) is obtained.

  FIG. 5 is a schematic view of a portion where engaging elements are continuously present taken from the upper surface with an optical microscope. In FIG. 5, S is a stem, T is an engaging protrusion, and B is a substrate. Represent. The X direction and the Y direction in the figure coincide with the Y direction and the Y direction in FIG. As shown in FIG. 5, when the engagement elements are regularly erected on the substrate, as shown in FIG. Draw a quadrilateral with a side (a quadrilateral shown by a one-dot chain line in FIG. 5), and determine the ratio of the area (S + 2T) of the engagement element as seen from the top of one engagement element to the area. The substrate coverage of the element is required.

In the present invention, the thickness of the substrate (B) is not particularly limited, but a range of 0.2 to 0.8 mm is appropriate. The density of the engaging elements is preferably in the range of 20-50 pieces / cm ² , and more preferably in the range of 30-40 pieces / cm ² .

  As a method for manufacturing such a male surface fastener, the following method is used. That is, a male mold in which a thermoplastic resin is melt-extruded from a nozzle having a male engaging element and a slit having a shape corresponding to the substrate, cooled, and is continuous from the substrate to the tape length direction on the substrate surface. First, a tape-like object having a plurality of engagement element rows having engagement element cross sections is formed.

  Next, the engagement element rows existing on the surface of the obtained tape-like material are arranged at the tips of the rows at small intervals in the direction transverse to the row length direction (Y direction), preferably in the orthogonal direction. Make a cut from to the base. The interval between the cuts is suitably in the range of 0.2 to 0.6 mm.

  Next, the tape-like material is stretched in the length direction. As the draw ratio, a degree in which the length of the tape-like material after stretching is 1.3 to 3.5 times the length of the original tape-like material is employed. By this stretching, the cuts formed in the rows are widened, and the rows become rows made up of a large number of independent male engaging elements. In addition, a cut | interruption may be made in the direction orthogonal to the line length direction, and may be put in the diagonal direction. FIG. 5 shows a case where a cut is made in the orthogonal method.

  In the present invention, the surface fastener used is preferably a molded male surface fastener as described above, but may be a male surface fastener having a woven fabric as a substrate, and a female surface fastener having a woven or knitted fabric as a substrate. But you can.

  However, in the case of a hook-and-loop fastener made of woven fabric or knitted fabric, the engaging element is made of monofilament in the case of a male hook-and-loop fastener, and the engaging element is made of multifilament in the case of a female hook-and-loop fastener. In the case of such a hook-and-loop fastener, in general, the engaging element is easily tilted by heat and pressure when the interior material is molded with a mold, and the engaging force is reduced. In order to prevent this, it is preferable to use a monofilament or multifilament made of an elastic resin such as an elastomer resin or polybutylene terephthalate as the engaging element. In particular, when a female surface fastener is used, a multifilament made of polybutylene terephthalate is used as an engaging element of the female surface fastener, and the engaging element falls down due to heating and pressurization during molding. However, it is preferable because it stands up easily.

  The size of the hook-and-loop fastener when set in the mold is preferably about 10 to 40 mm × 20 to 80 mm, more preferably 15 to 30 mm × 30 to 60 mm, for example, in the X direction × Y direction or the opposite direction. It is about. If it is smaller than this size, a large number of hook-and-loop fasteners are required to obtain the required engagement force, and it takes time and effort to set a large number of hook-and-loop fasteners in the mold. On the other hand, if it is larger than this, it will be difficult to set in the mold, or labor will be required to prevent the surface fastener from peeling off from the mold surface during molding.

  And a hot-melt-adhesive agent layer (6) exists on the back surface side of a board | substrate (B). As the hot-melt adhesive, it is preferable that the hot melt adhesive can be melted at a temperature at which the interior material is molded with a mold to fix the hook-and-loop fastener at a predetermined position of the interior material and has durability. Specific examples include general rubber-based, polyolefin-based, and polyamide-based materials, and the hot melt temperature is preferably about 100 to 160 ° C.

Prior to setting in the mold, a hot melt adhesive is applied to the back side of the surface fastener. The amount to be applied is preferably 100 to 400 g / m ² . In addition, in order to increase the adhesive force with the hot melt adhesive, the back surface of the hook-and-loop fastener may be provided with irregularities to be an anchor material on the back surface, a protrusion, or a corona discharge on the back surface. It may be performed to increase the adhesive force, or a primer may be applied to the back surface to increase the adhesive force.

Next, an automotive interior material that is an object to which a hook-and-loop fastener is attached will be described.
The automotive ceiling material will be described as a representative interior material. The automotive ceiling material is preferably a laminated structure including a foamed resin layer or a nonwoven fabric layer, and particularly preferably a foamed resin layer and a nonwoven fabric layer covering at least one surface thereof. In particular, a multilayer laminated structure as shown in FIG. 9 is preferred. Of course, the present invention is not limited to such a laminated structure.

For the interior material, first, an interior material base material composed of a foamed resin layer and a non-woven fabric layer covering at least one surface of the interior material is put in a mold and heated and pressed to perform the first molding, and then the first molded product is covered with a skin material. Is put in the mold again, and heated and pressed to perform the second molding that integrates the skin material, which is produced by the so-called two-stage molding method, and all the materials are superimposed on the mold. There are two cases of manufacturing by a one-stage molding method of molding by heating and pressurizing, and the present invention may be any.
In the case of the two-stage molding method, the method of the present invention may be used during the first molding, or the method of the present invention may be used during the second molding.

  In the present invention, a laminated structure (5) as shown in FIG. 9 is a preferred example of an automobile ceiling material, but the structure of FIG. 9 includes a skin material (51) and a foamed resin layer I (52). ), Non-woven fabric layer I (53), foamed resin layer II (54), and non-woven fabric layer II (55) are laminated in this order, and both sides of the foamed resin layer II are glass fiber mat layers (56 and 57). The film layer (58) is inserted between the glass fiber mat layer (57) and the nonwoven fabric layer II (55).

  Among these, the foamed resin layer II (54) is a foamed layer made of a resin such as polypropylene, polyethylene, or polyurethane, and is usually a hard foamed resin layer. The foamed resin layer is greatly pressed during the molding of the ceiling material, and as a result, the thickness is reduced to a fraction. The thickness of the foamed resin layer after molding is preferably 3 to 10 mm in terms of heat insulation and soundproofing, and the foaming ratio is preferably 10 to 30 times, particularly preferably 15 to 25 times.

And in order to raise the intensity | strength of this foamed resin layer II (54) and to obtain moderate hardness, the glass fiber mat layer (56, 57) has covered the both surfaces. The glass fiber mat layer is a non-woven fabric layer made of glass fibers. The non-woven fabric is impregnated with a thermosetting adhesive typified by an isocyanate compound, thereby fixing the shape of the non-woven fabric and bonding and integrating the upper and lower layers. Has been achieved. As the basis weight of the glass fiber mat layer is preferably 50 to 150 g / ^{m 2.}

  In addition, it is also possible to make a glass fiber mat layer unnecessary by mixing glass fiber into the foamed resin layer II. Of course, other high-strength and high-elasticity fibers can be used instead of glass fibers. Furthermore, the layer which consists of a normal synthetic fiber, a natural fiber, and a pulp-like thing may be impregnated with the adhesive agent.

A skin material (51) is integrated on the surface side of the ceiling material. As the skin material, a sheet having a high-quality appearance such as a woven or knitted fabric, natural leather, artificial leather, or a decorative resin sheet is used. On the back side of the skin material, a soft foamed resin layer I (52) such as polyurethane is affixed in order to correct the wrinkles and looseness of the skin material to adjust the surface shape and give a soft and high-class feeling. Yes. The thickness of the soft foamed resin layer I (52) is preferably 0.2 to ² mm, the basis weight is preferably 100 to 300 g / m ² , and the foaming ratio is preferably 5 to 30 times. The skin material and the foamed resin layer I are usually integrated by an adhesive.

A non-woven fabric layer I (53) made of synthetic fibers is laminated on the back side of the soft foamed resin layer I (on the side opposite to the skin layer) in order to enhance strength, soundproofing and heat insulation. As a fabric weight of this nonwoven fabric layer, 20-100 g / m < ² > is preferable, More preferably, it is a bulky nonwoven fabric layer of 30-80 g / m < ² >. As the nonwoven fabric used for this nonwoven fabric layer, a nonwoven fabric in which the constituent fibers are three-dimensionally entangled by water entanglement or needle punch is used. In order to achieve adhesion between the layers, a hot melt adhesive may be generally used, but as a part of the fibers constituting the nonwoven fabric, a heat-fusible fiber is used and the fibers are melted by melting the fibers. Bonding is also a suitable method.

  A film layer (58) may be overlaid on the back side of the glass fiber mat layer (57) (that is, the side away from the skin layer) in order to block ventilation and improve condensation prevention and heat insulation. . This film layer also has a purpose of preventing glass fibers mixed in the glass fiber mat layer (57) and the foamed resin layer II from being scattered or stabbed during operation. Examples of the resin constituting the film layer (58) include polyolefins such as polyethylene and polypropylene, polyamide resins, and polyester resins. A laminated film in which both surfaces of a layer made of nylon or polyolefin are covered with a hot melt adhesive layer is also a preferred example. The thickness of the film layer is preferably 30 to 150 μm.

And it is preferable from points, such as heat insulation, adhesiveness, and soundproofing, that the nonwoven fabric layer II (55) exists in the surface which affixes a hook_and_loop | surface fastener in a metal mold | die. Usually, as this nonwoven fabric layer II, a bulky nonwoven fabric layer made of polyester fibers or polyolefin fibers is used. As the basis weight, 15 to 60 g / ^{m 2,} in particular 20 to 50 g / ^{m 2} is preferred. In the case where a hot melt adhesive can be used for adhesion of the nonwoven fabric layer II and the hot melt adhesive layer is present on the surface of the film layer (58), it is not necessary to newly use an adhesive.

In addition to the above-described automotive ceiling materials, there are various automotive ceiling materials, but the present invention can also be applied to them, that is, a ceiling material sheet is bent into a desired shape using a mold. Thus, the present invention can be applied if it is manufactured in the shape. And this invention is applicable also to the interior material which covers the door trim for motor vehicles, and a trunk room other than the ceiling material for motor vehicles.
Furthermore, it is fixed to a part of the hook-and-loop fastener of the interior material with the hook-and-loop fastener with the other hook-and-loop fastener attached to the wire harness, and the remaining portion of the hook-and-loop fastener of the interior material with the wire harness is used, By engaging the other surface fastener attached to the vehicle body, the wire harness-attached interior material can also be fixed to the vehicle body. Of course, this method can also be applied to automobile door trims and trunk room interior materials.

  The present invention can be applied when such an interior material is molded by a mold. That is, a hook-and-loop fastener is set in advance at a predetermined position of the mold so that the engaging element surface of the hook-and-loop fastener is on the mold side, and the interior material sheet is inserted into the mold and heated and pressed. The interior material sheet is bent into a desired shape and molded. And an interior material is obtained by taking out from a metal mold | die. At that time, a hook-and-loop fastener is fixed to a predetermined location of the interior material by a hot melt adhesive that is present on the back surface.

In order to set the hook-and-loop fastener at a predetermined position in the mold, a depression is preferably provided at the predetermined position in the mold so that the hook-and-loop fastener can be fitted without a gap.
Also, a magnet is embedded in a predetermined position of the mold, while a magnetic material is applied to the surface fastener, and the surface fastener is set by magnetic attachment at a predetermined position of the mold by the magnet and the magnetic material. Also preferred is. Specifically, the magnetic powder is added to the resin constituting the surface fastener, or the resin containing the magnetic powder is present between and around the engagement elements on the back and front sides of the surface fastener. To achieve this.

  Furthermore, another heat-resistant surface fastener can be embedded at a predetermined position of the mold, and the surface fastener can be set in the mold by engaging the surface fastener to be attached to the interior material.

  In this manner, the surface fastener is set in the mold, and in this state, the automobile interior material sheet is inserted between the molds, and is molded by heating and pressing. As a molding condition, a pressure at which the thickness of the foamed resin layer II is 40 to 80% of the thickness before molding is usually preferable at a temperature of 120 to 170 ° C. for 20 to 200 seconds.

  By this molding, the surface fastener is depressed into the foamed resin layer II and the nonwoven fabric layer II, and “the interior material portion to which the surface fastener is fixed is depressed, as defined in the present invention, and the surface fastener is formed in the depressed portion. It is in a state of being “fitted with no gap” with the engaging element surface on the outside. And the hook_and_loop | surface fastener inserted in this way is being fixed to the interior material main body with the hot-melt-adhesive agent which exists in the hook-and-loop fastener back surface side. And since the hook-and-loop fastener is being fixed in such a state, the hook-and-loop fastener is firmly attached to the interior material at an accurate position.

  As shown in FIGS. 6 and 7, the interior material with the hook-and-loop fastener obtained by the present invention has a recessed portion of the interior material to which the hook-and-loop fastener is fixed, and the hook-and-loop fastener is engaged with the surface of the engaging element. It is fitted with no gaps on the outside. In FIG. 6, the interior material in a portion where the surface fastener exists is depressed vertically, and the surface fastener is fitted into the depressed portion without a gap. On the other hand, although the location of the interior material to which the hook-and-loop fastener is fixed is depressed in FIG. 7, the periphery is sloped.

  When the back surface of the interior material is covered with a non-woven fabric made of a fiber that is not easily changed by heat, the cross-sectional shape shown in FIG. 7 is obtained. On the other hand, the back surface of the interior material is easily softened by heat and is easily depressed. In the case of a foam layer, a cross-sectional shape as shown in FIG. 6 is formed.

  On the other hand, FIG. 8 shows a conventional case where a hook-and-loop fastener is attached to the back surface of the molded interior material with an adhesive or an adhesive after molding the interior material. As you can see, there is a dent on the back of the interior material, but the dent is considerably wider than the surface fastener in terms of workability when attaching a hook-and-loop fastener, and there is an extension of the dent around the hook-and-loop fastener. Yes. In this respect, the interior material with a hook-and-loop fastener of the present invention is different from the conventional one. The difference in effect based on this difference is as described above.

  The automotive interior material with a hook-and-loop fastener of the present invention is fixed to the vehicle body by engaging with a hook-and-loop fastener attached to a predetermined location of the vehicle body. The hook-and-loop fastener attached to the vehicle body side is not particularly limited as long as it can be engaged with the hook-and-loop fastener attached to the interior material. When the hook-and-loop fastener attached to the interior material is a male surface fastener, The hook-and-loop fastener to be attached is a female hook-and-loop fastener, that is, a hook-and-loop fastener having a loop-shaped engaging element. On the other hand, when the hook-and-loop fastener attached to the interior material is a female hook-and-loop fastener, It becomes a male hook-and-loop fastener.

  Further, when the male surface fastener is a surface fastener capable of engaging between males and males, both of them can be male surface fasteners. Furthermore, it may be a combination of male surface fasteners that have columnar elements on the surface and cause engagement by frictional force or the like when the columnar elements fit into the gap when the engagement element surfaces are overlapped. Further, as the female surface fastener, a nonwoven fabric in which a large number of napped fibers having crimps at the tip are present on the surface can also be used as the female surface fastener. Therefore, such a nonwoven fabric may be attached to the vehicle body.

  The number of hook-and-loop fasteners attached to the interior material with hook-and-loop fasteners depends on the size of the interior material, but in general, it should be distributed and attached so that the end and center of the interior material can be firmly fixed. What is necessary is just about 5-20 places on the interior material back surface.

  The automotive interior material with the hook-and-loop fastener of the present invention, since the hook-and-loop fastener is firmly attached at an accurate position, the interior material can be firmly attached to an accurate position, and workability is improved. The product looks good and gives a high-class feel. The automotive interior material with a hook-and-loop fastener according to the present invention can be used for fixing a wire harness to an automotive ceiling material, an automotive door trim, a trunk room interior material, or an interior material.

  Hereinafter, the present invention will be described with reference to examples.

Example 1
The both sides of the 8 mm thick layer made of foamed polyurethane are covered with a glass fiber mat impregnated with a thermosetting isocyanate compound (basis weight: 100 mm / m ² ), and one side (referred to as the surface side surface) is polyester fiber. 2 mm thick entangled nonwoven fabric, the opposite side (referred to as the back side), a 1 mm thick polypropylene layer on both sides of a laminated film consisting of a hot melt polyolefin layer and a polyester fiber 1 mm thick The sheet | seat for ceiling materials for motor vehicles laminated | stacked so that the entangled nonwoven fabric side might become the outer side by the laminated body which consists of a entangled nonwoven fabric of this.

On the other hand, as a molded male surface fastener, a molded male surface fastener manufactured by Kuraray Fastening Co., Ltd. (L20740 engaging element protrudes from a substrate having a thickness of 0.33 mm, and an engaging protrusion that protrudes from the stem to both sides. D / H = 0.54, element substrate coverage = 35.7%, engaging element height (H) = 2.85 mm, engaging element density = 31 / cm ² , constituent resin: After the corona treatment on the back side of the substrate (polypropylene) and primer treatment, a surface fastener coated with a polyamide-based hot melt adhesive (melting point 110 ° C.) is cut into a length of 40 mm × width of 20 mm. did. This hook-and-loop fastener had a thickness of 3.5 mm including the hot melt adhesive layer applied to the back surface.

  This molded male surface fastener is provided with recesses of width 20 mm × length 40 mm × depth 1.2 mm in the vicinity of the end portion of the lower mold of the ceiling mold for automobiles and in the vicinity of the center portion of 4 places, The molded male surface fastener was inserted into this recess so that the engaging element side was the bottom of the mold recess. The molded male surface fastener could be inserted and fixed in the recess without any gap.

Then, the ceiling material sheet is inserted between the upper mold and the lower mold of the mold set with the molded male surface fastener so that the back side is the lower mold side, and the sheet is held by the upper mold and the lower mold. And then heated and pressurized to 140 ° C., kept in this state for 40 seconds, cooled, and then the sheet was taken out from the mold. The obtained sheet (base material for ceiling material) is bent so as to match the shape of the ceiling material for automobiles, and a hook-and-loop fastener is firmly fixed to the end portion and the center portion by a hot melt adhesive. It was. The size of the ceiling material base material was 1.8 m ² , and the foamed polyurethane layer constituting the base material was reduced from 8 mm thickness before molding to 5 mm thickness by heat compression. And the hook_and_loop | surface fastener was inserted and fixed without the clearance gap in the hollow formed in the ceiling material back surface.

Next, a skin layer in which a foamed polyurethane layer having a thickness of 2 mm is bonded to the back surface of a black knitted fabric having a thickness of 1 mm and a basis weight of 150 g / m ² made of polyester fiber is prepared, and the surface fastener is attached to the back surface of the skin layer. Overlay the opposite surface of the base material for ceiling material with the surface fastener attached, and insert it again into the mold, this time heating and pressurizing for 30 seconds at a temperature 20 ° C lower than the previous time, and bonding . As an adhesive, polyolefin-based adhesive fibers are blended in the entangled nonwoven fabric.

  In the obtained ceiling material for automobiles, all of the surface fasteners are firmly attached to the ceiling material base material, and when engaged with the loop surface fastener attached to the vehicle body, the engagement occurs at the stage of alignment. The ceiling material could be firmly attached to the correct position. When the ceiling material attached to the vehicle body was heated to 75 ° C., the engagement force of the ceiling material did not decrease at all. Moreover, the knit layer on the surface is flexible, has no wrinkles or bangs, and has a high-grade appearance.

Example 2
A ceiling material was manufactured by using a one-stage molding method in which the following skin layer was stacked on the ceiling material sheet used in Example 1 and inserted into a mold in this state.
That is, as an outer skin layer, a polyurethane solution is impregnated with an entangled nonwoven fabric composed of sea-island composite spun fibers containing polyester as an island component, the solution is wet-coagulated, and the sea component in the sea-island fibers is extracted and removed from the obtained sheet. The surface of the resulting sheet is fluffed with sandpaper, and a 1.2 mm thick suede-like artificial leather dyed in brown is attached to the back of a 2 mm thick polyurethane foam layer. It was.

  The molding conditions for the ceiling material are the same as the molding conditions for the first stage of Example 1. As in the case of Example 1, in the obtained ceiling material for automobiles, all the surface fasteners are firmly attached to the ceiling material base material, and the surface fasteners are inserted into the recesses formed on the back surface of the ceiling material without any gaps. And was fixed in that state.

When the obtained ceiling material is engaged with the loop hook-and-loop fastener attached to the car body and the car body is fixed, the engagement does not occur at the stage of alignment, and the ceiling material can be attached at a precise position. It was.
When the ceiling material attached to the vehicle body was heated to 75 ° C., the engagement force of the ceiling material did not decrease at all. The obtained ceiling material was dignified and elegant, without any wrinkles or sagging, and without impairing the suede-like luxury feeling at all.

1: Automotive interior material sheet 2: Hook fastener 3: Mold upper mold 4: Mold lower mold 5: Automotive interior material 6: Hot melt adhesive layer B: Hook fastener substrate E: Engagement element stem T : Engaging protrusion S: sticking preventing protrusion 51: skin material 52: foamed resin layer I
53: Nonwoven fabric layer I
54: Foamed resin layer II
55: Nonwoven fabric layer II
56: Glass fiber mat layer 57: Glass fiber mat layer 58: Film layer

Claims (8)

In a vehicle interior material in which a hook-and-loop fastener is fixed at a predetermined position on the back side of the automotive interior material, a surface on which the surface fastener is fixed is a nonwoven fabric layer, and a surface on which the surface fastener of the nonwoven fabric layer is fixed A laminated film layer with both sides covered with a hot-melt adhesive layer is overlaid on the opposite surface , and a recessed portion is formed at a predetermined position on the back surface , and a hook-and-loop fastener is engaged with the recessed portion. An automotive interior material characterized by being fitted and fixed with a hot-melt adhesive with no gap between the element surfaces. Automotive interior materials are at least a skin material, a foamed resin layer I, a non-woven fabric layer I, a glass fiber mat layer , a foamed resin layer II, a glass fiber mat layer, a laminated film layer and a non-woven fabric whose both surfaces are covered with a hot melt adhesive layer The automotive interior material according to claim 1, wherein the automotive interior material comprises a layer II and is laminated in this order, and a surface fastener is fixed to a surface of the nonwoven fabric layer II opposite to the foamed resin layer II. The hook-and-loop fastener is composed of a resin substrate and an engaging element made of the same resin upright from the substrate, and the engaging element is composed of a stem portion standing upright from the substrate and an engaging protrusion protruding from the top of the stem portion to the side. automobile interior material according to claim 1 or 2 is a molded male surface fastener. In the molded male surface fastener, the ratio (D / H) of the length (D) from the top of the engaging element to the lower end of the protrusion with respect to the height (H) of the engaging element from the substrate is 0.35. The automotive interior material according to claim 3 , wherein the engagement element has a substrate coverage of 25 to 45%. Surface fastener woven into the surface of the base fabric made of knitted fabric has a loop element formed of a multifilament, the multifilament according to claim 1 or 2 is a female surface fastener composed of a polybutylene terephthalate resin Automotive interior materials. A laminated film layer in which a nonwoven fabric layer is present on the surface to which the surface fastener is fixed, and a surface opposite to the surface to which the surface fastener is fixed of the nonwoven fabric layer is covered with a hot melt adhesive layer. A surface fastener in which a hot melt adhesive is applied in advance to a predetermined position of a mold when a sheet for an interior material for automobiles, on which is laminated, is inserted into a mold and heated and pressed into a predetermined shape Automotive interior in which a hook-and-loop fastener is fixed at a predetermined position by setting the engagement element surface to be on the mold surface side, inserting the sheet in that state, molding, and taking out from the mold A method of manufacturing the material. The manufacturing method of Claim 6 with which the hollow which can fix a surface fastener is provided in the predetermined position of the metal mold | die. A magnet is embedded at a predetermined position of the mold, while a magnetic material is applied to the hook-and-loop fastener, and the hook-and-loop fastener is set at a predetermined position of the mold by magnetic attachment. Item 8. The production method according to Item 6 or 7 .