JPS6023982B2 - Laminated interior material and its manufacturing method - Google Patents

Description

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

Interior materials using thermoplastic resins such as polyethylene pyrene, vinyl chloride resin, Ao resin, and polystyrene, or their foams, are used in automobiles because of their excellent physical properties such as productivity and moisture resistance. It is often used as

This interior material is manufactured by laminating a skin layer with a cushion layer such as urethane foam on these base materials.
In this regard, the present inventor previously registered a utility model in 1974-
No. 21052 proposed an interior material in which a base material and a skin material with a cushion layer are attached using an olefin-based hot melt adhesive, and the base material and skin material are simultaneously molded. FIG. 1 shows a cross section of an interior material according to an example of the above-mentioned utility model registration application, in which the base material 8 is a foamed polystyrene sheet 2 and impact polystyrene films are laminated on both sides of the skin material 7. A cushion layer 5 made of a foam such as polyurethane foam is adhered to a skin layer 6 of a textile fabric or a polyvinyl chloride sheet.

After temporarily fixing a layer formed by melting and applying the hot melt adhesive 3 to one surface of the base material 8 or the skin material 7, the skin material 7 and the base material 8 are placed in separate heating furnaces and heated to the respective required temperatures. Heat. After heating, the skin material 7 and the base material 8 are superimposed and molded into a desired shape using molds on both sides. The above-mentioned interior material has characteristics such as good productivity and ability to be deep drawn during molding.

However, this interior material also had the following problems. That is, when the pressing pressure of the mold is increased in order to accurately obtain the molded shape or the thickness after molding of the base material 8 using foam, the hot melt adhesive 3 penetrates into the cells of the foam of the cushion layer 5. As a result, the cells were set in a collapsed state, and this state did not recover even after the mold was released, so that when viewed from the skin layer 6 side, the overall thickness of the remaining cushion layer 5 became thin as an avatar. The present invention is based on the utility model registration filed by the present inventor in 1986-2105.
2, and its purpose is to prevent avatars from occurring even if the presser pressure of the mold is increased during molding, so that it is easy to obtain an accurate molded shape and molded thickness of the base material, and to reduce the An object of the present invention is to provide a laminated interior material with a smooth surface and a method for manufacturing the same.

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

FIG. 2 is a sectional view of an embodiment of the laminated interior material according to the present invention. The difference from the conventional laminated interior material shown in FIG. 1 is that a nonwoven fabric 4 is attached to the side surface of the base material of the cushion layer 5. The third method for manufacturing the laminated interior material of the present invention having such a configuration is as follows.
This will be explained based on the diagram. The upper row of the figure shows the process of manufacturing the base material, and the lower row shows the process of manufacturing the skin material. First, the manufacturing method of Motomura 8 will be explained.

In addition to the above-mentioned polystyrene film, 1 also includes a film made of a copolymer of polystyrene and another resin, such as maleic anhydride.

2 is a foam sheet made of the same resin as the film.

The sheet 2 and the film are laminated by means such as thermal adhesion to form a base material 8 having a three-layer structure. The base material 8 is not limited to the above configuration, and may include general polypropylene,
Thermoplastic resins such as polyethylene, polypinyl chloride, ABS resin, polycarbonate, polystyrene, acrylic resin, copolymers of these resins and other thermoplastic resins, calcium carbonate, barium sulfate, mica, wood powder, talc (talc), etc. ) etc. as a filler can also be used. Foamed sheets of these resins can also be used. In short, any sheet that can be softened by heating and molded into a certain shape, then hardened again by cooling and maintains that shape can be applied. Next, hot melt adhesive 3 is applied or temporarily fixed on one side of base plate 8. Materials for the hot melt adhesive 3 include olefin, polyamide, polyester, SBR, polyurethane, etc., and these are selected depending on the ability to later adhere to Motomura 8 and the like. For example, in the case of the three-layer polystyrene sheet, a polyester-based material is preferable.
These hot melt adhesives 3 can be applied directly onto the base material 8 using a roll coater, spray, etc., or only the hot melt adhesives 3 can be made into a film or a nonwoven fabric using a spunbond method. The hot melt adhesive 3 is temporarily fixed onto the base plate 8 by means of hot rolling or hot rolling. In this case, the non-woven hot melt adhesive 3 is particularly suitable because it is air permeable and does not generate bubbles at the interface with the base material during adhesion.
Even if it is in the form of a film, it can be treated equally if it has numerous small holes to give it breathability. Next, the steps of the method for manufacturing the skin material 7 will be explained.

5 is a cushion layer which, in addition to the above-mentioned polyurethane foam, is made of polyvinyl chloride foam, polypropylene foam,
Polyethylene foam, polybutadiene foam, etc. can be used.

6 is a skin layer made of a polyvinyl chloride sheet or knitted fabric such as raised knit.

These cushion layer 5 and skin layer 6 are layered in advance by means of an adhesive or frame lamination. Next to the cushion layer 5 side of the skin material 7 is a nonwoven fabric 4.
Paste. The nonwoven fabric 4 is made from synthetic fibers such as silica or polyester or polyamide by a wet method, a dry method, a spunbond method, or the like. The nonwoven fabric needs to have as uniform a layer as possible, be hard to tear, and have excellent physical properties such as water resistance. The basis weight of the non-woven fabric 4 is preferably from 15 to 120 tan. If the basis weight is low, sushi tends to form on the skin layer when the presser pressure of the mold is increased, and if the basis weight is too high, it will be difficult to spread and the sushi will become stale or break. The nonwoven fabric 4 is adhered to the cushion layer 5 by conventional means. For example, lamination with adhesive can be used, and if the material of the cushion layer 5 is polyurethane foam, frame laminate can also be used. The nonwoven fabric 4 is made of a material that does not melt at the heating temperature during bonding. Next, the rhombus material 8 to which the hot melt adhesive 3 is temporarily attached and the skin material 7 to which the nonwoven fabric 4 is attached are individually heated in a base material heating furnace 9 and a skin material heating furnace 10, and when softened, the heating furnace It is taken out, compressed using molds 11 and 12, and taken out after cooling.

The base material 8 and the skin material 7 are firmly adhered during molding by the hot melt adhesive 3 softened by heating. In this case, since the nonwoven fabric 4 is interposed between the hot melt adhesive 3 and the foam of the cushion layer 5, it is possible to prevent the hot melt adhesive 3 from melting and penetrating into the cells of the foam. Therefore, the epidermal layer 6 is less likely to become an avatar. Furthermore, due to the heat insulating effect of the nonwoven fabric 4, the heat generated when the hot melt adhesive 3 is melted is delayed in being transmitted to the cushion layer 5, and therefore the foam of the cushion layer 5 can be prevented from being damaged by the heat. Furthermore, by setting the foam of the cushion layer 5 and the compressive elastic modulus of the nonwoven fabric 4 to different values, the feeling of bottoming out when pressed can be reduced. This is shown in FIG. A comparison is made between the conventional product and the product of the present invention, with the compression ratio on the horizontal axis and the compression cart on the vertical axis, where the solid line is the product of the present invention and the broken line is the conventional product. Hereinafter, interior materials were manufactured and tested under the following conditions for Examples and corresponding control examples, and the results shown in Table 1 were obtained.

Example 1 A heat-resistant polystyrene film with a thickness of 0.2 is laminated on both sides of a foamed sheet made of the same resin to form a base material 8 of a 3-sail thickness with a basis weight of 680 mm. A polyester spunbond non-warp fabric 4 having a basis weight of 30 g/force and a softening temperature of 12,000 was partially temporarily fixed with a hot melt adhesive 3 using a hot rod.

Next, the ether-based urethane foam having a thickness of 2.5 ribs and a density of 28 mm was laminated on the back side of a polyvinyl chloride sheet having a thickness of 0.25 ribs by a frame lamination method. Further, on the other side of this urethane foam, a wet-processed nonwoven fabric 4 of polyester having a basis weight of 25 mm was laminated by frame lamination. The base material 8 and the skin material 7 were placed in a heating furnace and heated until their surface temperatures reached 1300C and 50C, respectively.

Thereafter, it was taken out and compressed using a double-sided mold at a press pressure of 2k9/m. After cooling, it was taken out and the appearance was observed and the epidermis was pressed with a finger to feel the sensation. Example 2 ABS resin with a thickness of 2 was used as the material 8.

The rest was carried out in the same manner as in Example 1. Example 3 Instead of temporarily fixing the spunbond nonwoven fabric hot melt adhesive 3 to the base material in Example 1, a hot melt adhesive with a softening point of 120 oo was applied to the substrate 8 using a roll coater.
Evening/I applied it on my pillow.

In this case, the hot melt adhesive 3 was applied onto the base layer 8 in the form of a bead. Others are the same as in Example 1. Example 4 In Example 1, polybutadiene foam was used instead of urethane foam.

An acrylic ecocolsion type adhesive was used to laminate the cushion layer 5 with the polyvinyl chloride sheet of the skin layer 6 and the nonwoven fabric 4. Others are the same as in Example 1. Control example 1
In Example 1, the single-sided nonwoven fabric 4 of urethane foam was not used.

Others are the same as in Example 1. Control Example 2 In Control Example 1, the press pressure of the mold was 0.2 k9/m.

Control Example 3 In Example 4, the single-sided nonwoven fabric 4 of polybutadiene foam was not used.

Others are the same as in Example 4. Table I Under normal conditions, <marrow strength: Collect a sample of 25 pieces in width and 120 pieces in length, then use a knife or the like at the interface between the base material and the nonwoven fabric or foam to leave 50 ribs. Peel off.

Next, the base material and the skin material are peeled off using a large chuck at a speed of 50 parts/min. After heat aging, the same material as Hina Strength Mikami is used.
The sample was left in an atmosphere at 20°C for -1 week, then taken out, and left at normal temperature (20-22°C) for 24 hours, after which the same test as above was carried out. As explained above, in the laminated interior material of the present invention, a nonwoven fabric that does not melt at the heating temperature during adhesion is attached to the surface of the cushion layer facing the base material, and the base material and the skin material are heated and softened separately. After that, the two are molded into the desired shape using an overlapping mold, so the bonding agent between the base material and the skin material does not penetrate into the cushion layer during molding, and avatars do not occur on the skin layer. This has the effect that the thickness of the cushion layer does not become thinner, and furthermore, the insulation effect of the nonwoven fabric prevents the cushion layer from being damaged by the heat generated when the adhesive is melted.

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view of a subordinate interior material, FIG. 2 is a cross-sectional view of an embodiment of the interior material according to the present invention, FIG. 3 is a process diagram of the method for manufacturing the interior material according to the present invention, and FIG. The figure shows the results of a comparison between the conventional product and the product of the present invention in terms of bottoming feeling when the skin layer side is pressed down. 3...Hot melt adhesive, 4...Nonwoven fabric, 5...
・Cushion layer, 7... Skin material, 8... Base material, 9.
...Heating furnace for base material, 10...Heating furnace for surface layer, 11,
12... Molding mold. Figure 1 Figure 2 Figure 4 Figure 3

Claims (1)

[Scope of Claims] 1. In a laminated interior material having a structure in which a skin material with a cushion layer is present on a hard base material, the surface of the cushion layer facing the base material does not melt at the heating temperature during bonding, A hot melt for bonding a skin material with a nonwoven fabric having a basis weight of 15 g/m^2 to 120 g/m^2 and bonding the nonwoven fabric between the nonwoven fabric and the base material and the base material. In addition to providing an adhesive layer, each of the skin material, hot melt adhesive, and base material was heated to a desired temperature and then molded using a mold to form a three-dimensional shape, and at the same time the skin material and base material were bonded. A laminated interior material characterized by: 2. The process of manufacturing the base material by pasting films on both sides of the sheet, and the skin layer on one side of the cushion layer, which does not melt at the heating temperature during adhesion on the other side and has a basis weight of 15
g/m^2 to 120 g/m^2 of nonwoven fabric to produce a skin material, and a step of temporarily fixing or applying hot melt adhesive to one side of the base material or the surface of the nonwoven fabric side of the skin material. and a step of placing the thus obtained base material and skin material in a heating furnace and heating them to a predetermined temperature,
A method for manufacturing a laminated interior material comprising the steps of molding the base material and skin material heated in the above step into a three-dimensional shape using a mold, and simultaneously joining the skin material and the base material.