JP2000158575A - Foam laminated sheet for automobile ceiling material and automobile ceiling material using the same - Google Patents

Abstract

(57) [Summary] [PROBLEMS] In addition to properties such as light weight, heat insulation properties, moldability, recyclability, etc., excellent heat resistance (heat resistance) by improving deformation due to use at high temperatures and sagging due to its own weight. It is an object of the present invention to provide an automotive ceiling material having deformability) and a foam laminated sheet for the automotive ceiling material. SOLUTION: Non-foamed layers 12 and 14 made of a thermoplastic resin as a base resin are laminated on both sides of a foamed layer 10 made of a deformed polyphenylene ether-based resin as a base resin, and an automobile ceiling material molded into a predetermined shape. , An automobile ceiling material in which the addition amount (rubber content) of the impact resistance improving material of the indoor non-foamed layer 12 was smaller than that of the outdoor non-foamed layer 14 was constructed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foamed laminated sheet for an automobile ceiling material and an automobile ceiling material using the same, and more particularly, to a heat-resistant and lightweight material which can reduce deformation and droop due to its own weight in use at high temperatures. The field relates to the field of manufacturing and using automobile ceiling materials excellent in quality.

[0002]

2. Description of the Related Art Conventionally, as a ceiling material for automobiles, a foamed laminated sheet in which a urethane foam is laminated on a base material mainly composed of a thermoplastic resin foam, or styrene-maleic anhydride copolymer foamed layers are provided on the upper and lower surfaces. A foamed laminated sheet obtained by laminating a non-foamed layer of a maleic anhydride copolymer into a desired shape is widely used. These car ceiling materials are characterized by being lightweight, having high heat insulating properties, and having excellent moldability.

However, the conventional foam laminated sheet is
When used for applications that are exposed to high temperatures for a long time, such as automotive interior materials, especially automotive ceiling materials, the heat resistance is insufficient, so the front part of the molded product hangs under its own weight (heat sag) or deforms. And other problems may occur. So, in order to solve these problems,
Conventionally, automobile ceiling materials based on composite materials of inorganic glass fibers and plastics have been used. But,
Although this composite material can maintain the quality of heat resistance, it has problems in that it is not possible to reduce the weight and that it is inferior in environmental compatibility such as recyclability due to the presence of glass fibers.

Further, foaming for automobile ceiling materials using a foamed laminated sheet in which a modified non-foamed PPE resin layer is laminated on both sides of a lightweight, environmentally compatible and heat resistant modified polyphenylene ether (PPE) resin foam layer. A laminated sheet has been proposed (Japanese Utility Model Laid-Open No. 4-1162). This modified P
A foamed laminated sheet for an automobile ceiling material using a PE resin has a non-foamed layer formed by adding an impact resistance improver to both sides of a foamed layer. This impact resistance improver is necessary to prevent the destruction of the base material when molding or mounting automotive ceiling materials, but it may lower the heat resistance and does not sufficiently satisfy the market requirements. There is a problem.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned circumstances, and in addition to characteristics such as light weight, heat insulation, moldability, recyclability, and the like, without increasing costs.
It is an object of the present invention to provide a foam laminated sheet for automobile ceiling materials having excellent heat resistance (heat-resistant deformation resistance), which has improved deformation due to use under high temperature and sagging due to its own weight, and an automobile ceiling material using the same.

[0006]

Means for Solving the Problems In order to achieve the above object, the present inventors have made intensive studies on the construction of a foam laminated sheet for automobile ceiling materials and automobile ceiling materials. In order to maintain the property, it is necessary to consider the effect of combining the skin material and the non-foamed layer, and secure the impact resistance with the skin material, and increase the rigidity by reducing the impact resistance improver of the non-foamed layer. It was found that the thermal deformation can be suppressed by increasing the size. Furthermore, it has been found that by adjusting the amount of the impact modifier added to the base resin of the outdoor non-foamed layer and the indoor non-foamed layer, thermal deformation can be suppressed by balancing the front and back sides.

That is, the gist of the foam laminated sheet for an automobile ceiling material according to the present invention is to improve the impact resistance to be added to the base resin of the indoor non-foamed layer rather than the outdoor non-foamed layer of the automobile ceiling material. By reducing the amount of additives, it is lightweight, has unprecedented heat resistance (heat deformation resistance), has good dimensional stability, moldability, impact resistance, sound insulation, heat insulation, and cost competitiveness It is possible to obtain a foam laminated sheet for automobile ceiling materials.

Further, the amount of the impact modifier added to the base resin of the indoor non-foamed layer is made to be 5% by weight or more smaller than that of the outdoor non-foamed layer. The thermoplastic resin is a modified polyphenylene ether-based resin, and the modified polyphenylene ether-based resin has a phenylene ether component content of more than 35% by weight to 75% by weight and a styrene-based component That is, the content is more than 25% by weight and 65% by weight or less.

Another feature of the automobile ceiling material according to the present invention is that an adhesive layer is laminated on the surface of the indoor non-foamed layer of the foam laminated sheet. Also,
Another aspect of the automotive ceiling material according to the present invention resides in that a skin material is joined to a surface of a non-foamed layer on the indoor side of the foam laminated sheet via an adhesive layer.

The gist of the automotive ceiling material according to the present invention is that the foamed laminated sheet for an automobile ceiling material is formed into a predetermined shape, and then the surface of the indoor non-foamed layer of the foamed laminated sheet for an automotive ceiling material is formed. In addition, a skin material is joined via an adhesive layer. Further, another point of the automotive ceiling material according to the present invention is that, after bonding a skin material to an adhesive layer laminated on a surface of a non-foamed layer on the indoor side of the foam laminated sheet for an automotive ceiling material, It is to be formed into a shape.

Another aspect of the automobile ceiling material according to the present invention is that the foamed laminated sheet for an automobile ceiling material is formed into a predetermined shape. Further, other points of the automotive ceiling material according to the present invention,
The adhesive is a hot melt adhesive.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, a foam laminated sheet for an automobile ceiling material and an automobile ceiling material according to the present invention will be described by way of an example of an embodiment. As shown in FIG. 1, the foamed laminated sheet for an automotive ceiling material according to the present invention has an indoor non-foamed layer using a thermoplastic resin as a base resin on both sides of a foam layer 10 using a thermoplastic resin as a base resin. It is obtained by subjecting a primary foamed laminated sheet formed with the outer layer 12 and the outdoor-side non-foamed layer 14 to secondary foaming and molding into a predetermined shape.
The automobile ceiling material according to the present invention is configured such that a skin material 18 is laminated on the upper surface of the non-foamed layer 12 on the indoor side via an adhesive layer 16.

The foamed layer 10 comprising a thermoplastic resin as a base resin constituting the foam laminated sheet for an automobile ceiling material is a layer serving as a base material of the automobile ceiling material, and by using a thermoplastic resin for this layer, The secondary foam laminated sheet can be easily formed. In addition, since this layer 10 is a foamed layer, it is lightweight, has excellent sound insulation and heat insulation properties, and has a low density, so that only a small amount of resin is used, and it is cost competitive.

The thermoplastic resin as the base resin constituting the foamed layer 10 includes polystyrene (PS) resin, heat-resistant PS resin, modified PPE resin, and polypropylene (P).
P) -based resins, polyethylene (PE) -based resins, polyethylene terephthalate (PET) -based resins, polyamide (nylon) -based resins, and the like. Of these, modified PPE-based resins having excellent workability and heat resistance are preferable.

The modified PPE resin includes a PPE resin (hereinafter, PPE) and a polystyrene resin (hereinafter, P
S), and copolymers (hereinafter, PPE-St) such as grafts and blocks obtained by polymerizing a styrene-based monomer (hereinafter, St) on a PPE-based resin, and the like. There is a form. (B) PPE + PS (b) PPE-St (c) PPE-St + PS (d) PPE + PPE-St (e) PPE + PPE-St + PS Among these, a mixed resin (a) of a PPE resin and a PS resin is produced. This is preferable in that it is easy.

The content of the phenylene ether component in the modified PPE resin forming the foamed layer 10 is more than 35% by weight and not more than 75% by weight, preferably more than 35% by weight and not more than 60% by weight. The components are more than 25% by weight and up to 65% by weight, preferably more than 40% by weight and up to 65% by weight. If the proportion of the phenylene ether component in the modified PPE resin is too small, the heat resistance tends to be poor. If the proportion of the phenylene ether component is too large, the viscosity at the time of heating and flowing increases, and foam molding becomes difficult. There is.

As the PPE resin, for example, poly (2,
6-dimethylphenylene-1,4-ether), poly (2-methyl-6-ethylphenylene-1,4-ether), poly (2,6-diethylphenylene-1,4-ether), poly (2 6-diethylphenylene-1,
4-ether), poly (2-methyl-6-n-propylphenylene-1,4-ether), poly (2-methyl-
6-n-butylphenylene-1,4-ether), poly (2-methyl-6-chlorophenylene-1,4-ether), poly (2-methyl-6-bromophenylene-1,
4-ether) and poly (2-ethyl-6-chlorophenylene-1,4-ether). These may be used alone or in combination of two or more. Among them, poly (2,6-dimethylphenylene-1,4-ether) is preferable from the viewpoint of versatility of raw materials and cost. When it is desired to impart flame retardancy, poly (2-methyl-6-chlorophenylene-1,4-ether) containing a halogen-based element or poly (2-methyl-6
-Bromophenylene-1,4-ether), poly (2-
Ethyl-6-chlorophenylene-1,4-ether) and the like are preferred.

The PS resin which forms a mixed resin with the PPE resin is styrene or a derivative thereof such as α-methylstyrene, 2,4-dimethylstyrene, monochlorostyrene, dichlorostyrene, p-methylstyrene, ethylstyrene and the like. It is a resin as a main component. Therefore, PS
The system resin is not limited to a homopolymer composed only of styrene or a styrene derivative, and may be a copolymer produced by copolymerizing with another monomer. Further, for example, when polymerizing styrene or a styrene derivative, such as high impact polystyrene, a polymer obtained by adding a synthetic rubber or a rubber latex may be used.

Other monomers copolymerizable with styrene or a derivative thereof which can be used for producing a PS resin forming a mixed resin with a PPE resin include, for example, acrylonitrile, methacrylonitrile, methyl (meth) A) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, maleic anhydride, itaconic acid and the like. These may be used alone,
Species or more may be used in combination.

Specific examples of the PS resin include, for example, polystyrene, styrene-α-methylstyrene copolymer, styrene / butadiene copolymer represented by high impact polystyrene, styrene / acrylonitrile copolymer and the like. . Among them, polystyrene is preferable in terms of its versatility and cost. Also, PPE
Specific examples of the styrene monomer to be polymerized, preferably graft-polymerized, to styrene resins include, for example, styrene, α-methylstyrene, 2,4-dimethylstyrene, monochlorostyrene, dichlorostyrene, p-methylstyrene, and ethylstyrene. And the like. These may be used alone or in combination of two or more. Of these, styrene is preferred in terms of versatility and cost.

When a styrene monomer is polymerized on a PPE resin, a monomer copolymerizable with the styrene monomer in a range where the styrene monomer is the main component (60% by weight or more); For example, acrylonitrile, methacrylonitrile,
Methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, maleic anhydride,
One or two or more such as itaconic acid may be contained.

A graft copolymer obtained by polymerizing a PS-based monomer on a PPE-based resin is disclosed in a conventionally known method, for example, Japanese Patent Publication No. 52-30991 and Japanese Patent Publication No. 52-38596. , A radical initiator and a styrene monomer are added to a PPE resin, and the styrene monomer is polymerized under stirring in a temperature range of 130 to 200 ° C. in the presence or absence of an organic solvent in an anhydrous state. It is manufactured by a method.

Modified P using modified PPE resin as base resin
The thickness of the primary foamed layer of the PE-based resin foamed layer 10 is preferably a primary thickness of 1 to 5 mm, more preferably 1.5 to 3.5 mm, and a foaming ratio of 3 to 20 times, more preferably 5 to 1 times.
It is preferably 5 times, and the cell diameter is 0.05 to 0.9 m.
m, more preferably 0.1 to 0.7 mm, and the closed cell rate is preferably 70% or more, more preferably 80% or more. Further, the amount of the remaining volatile components in the primary foamed layer is preferably 1 to 5% by weight, more preferably 2 to 4% by weight, based on the total weight of the foamed layer. The amount of the remaining volatile components may be measured by gas chromatography, but usually, the foamed layer sample is heated to a temperature higher than the temperature at which the modified PPE-based resin starts to soften and lower than the decomposition temperature to sufficiently volatilize the volatile components. It is measured by the weight difference before and after heating.

When the thickness of the primary foam layer 10 is less than 1 mm, the strength and the heat insulating property are poor, and it may not be suitable as a foam laminated sheet for automobile ceiling materials. On the other hand, if it exceeds 5 mm, heat is difficult to be transmitted to the center in the thickness direction of the foamed layer at the time of molding and heating, so that sufficient heating cannot be performed and moldability may be deteriorated. In addition, if the heating time is increased to perform sufficient heating, cells on the surface of the foamed layer may be broken, which may make it difficult to obtain an acceptable product. When the primary expansion ratio is less than 3 times, the flexibility is poor, the breakage due to bending or the like is likely to occur, and the effect of reducing the weight is small. If it exceeds 20 times, the strength tends to decrease and the moldability tends to decrease due to difficulty in heating to the center. Further, when the cell diameter is 0.05 mm or less, it is difficult to obtain sufficient strength, and when the cell diameter is 0.9 mm or more, the heat insulating property tends to be inferior. When the closed cell rate is 70% or less,
In addition to being inferior in heat insulation properties and rigidity, it is difficult to obtain a desired secondary expansion ratio by molding and heating, and the moldability tends to be inferior. When the residual volatile component is less than 1% by weight, the secondary expansion ratio is too low, so that molding may not be performed well. When the residual volatile component is more than 5% by weight, air pockets may be generated between the non-foamed layer and the like. In some cases, dimensional stability over time may be deteriorated.

The base resin of the foamed layer 10 used in the present invention may contain, if necessary, a cell regulator, an impact modifier, a lubricant, an antioxidant, an antistatic agent, a pigment, a stabilizer, an odor, and the like. You may add a reducing agent etc. The thermoplastic resin used for the non-foamed layers 12 and 14 is polystyrene (PS).
Resin, modified PPE resin, polypropylene (PP) resin, polyethylene (PE) resin, polyethylene terephthalate (PET) resin, polyamide (nylon)
And the like. These may be used alone or in combination of two or more. It is preferable to select the resin of the non-foamed layers 12 and 14 from the viewpoint of adhesion to the foamed thermoplastic resin layer 10. For example, when a modified PPE-based resin is used for the foamed layer 10,
It is preferable to use an S-based resin or a modified PPE-based resin.

The PS resin used for the non-foamed layers 12 and 14 is styrene or a derivative thereof such as α-methylstyrene, 2,4-dimethylstyrene, monochlorostyrene, dichlorostyrene, p-methylstyrene, ethylstyrene and the like. Is a resin containing as a main component (60% by weight or more, preferably 70% by weight or more) a derivative of Therefore, the PS-based resin is not limited to a homopolymer composed only of styrene or a styrene derivative, but may be a copolymer produced by copolymerizing with another monomer. Further, when polymerizing styrene or a styrene derivative such as high impact polystyrene (HIPS),
It may be polymerized by adding synthetic rubber or rubber latex. Known high impact polystyrene can be used, and the content of the rubber component is usually 1 to
15% by weight.

Other monomers copolymerizable with styrene or a derivative thereof which can be used in the production of PS resin include:
For example, acrylonitrile, nitrile compounds such as methacrylonitrile, methyl (meth) acrylate, ethyl (meth) acrylate, alkyl (meth) acrylate such as butyl (meth) acrylate, maleic anhydride,
Examples include unsaturated carboxylic acids such as itaconic acid and acid anhydrides thereof. These may be used alone or in combination of two or more. The other copolymerizable monomer is used in an amount of usually 0 to 40% by weight, preferably 0 to 30% by weight.

Specific examples of the PS resin used for the non-foamed layers 12 and 14 include, for example, polystyrene, styrene-α-methylstyrene copolymer, styrene-butadiene copolymer represented by high-impact polystyrene, and styrene- Acrylonitrile copolymer and the like can be mentioned.
Among them, polystyrene and high-impact polystyrene are preferable in view of their versatility, cost and impact resistance. Examples of PS resins having higher heat resistance include copolymers of styrene and a carboxyl group-containing monomer, such as styrene-maleic anhydride copolymer and styrene-itaconic acid copolymer.

The PS resins may be used alone or in combination of two or more. The PS resin may be used by blending with another thermoplastic resin. The content of the other thermoplastic resin in the blend is preferably 30% by weight or less. Examples of the thermoplastic resin to be blended include polycarbonate, polyester, polyolefins such as polyethylene and polypropylene, vinyl chloride resins such as polyvinyl chloride, polyethersulfone, polysulfone, polyamide, and copolymers thereof.
The PS resin content in the resin components of the non-foamed layers 12 and 14 is usually 70 to 100% by weight, preferably 80 to 100% by weight.

Modified PP used for non-foamed layers 12 and 14
As the E-based resin, as in the case of the foamed layer 10, PPE
A resin based on a styrene-based compound or a polymer thereof, which has been modified by polymerization or mixing. For example, a PPE-based resin and a polystyrene-based resin (P
S-based resin), copolymers such as grafts and blocks obtained by polymerizing styrene-based monomers on PPE-based resins (hereinafter referred to as PPE-St copolymers), and the copolymers and PS-based resins Alternatively, a mixture with a PPE-based resin, a mixture of the copolymer, a PPE-based resin and a PS-based resin, and the like can be given. Among these, a mixed resin of a PPE-based resin and a PS-based resin is preferred from the viewpoint of easy production and the like.

Specific examples and preferable examples of the PPE resin,
Specific examples and preferred examples of the S-based resin, specific examples and preferred examples of the styrene-based monomer, and further, specific examples of the PS-based resin and the monomer capable of being polymerized with the styrene-based monomer, the reason for using, and the like Since it is the same as the case of the primary foam layer 10, the description is omitted. However, as a preferred specific example of the PS resin, a styrene-butadiene copolymer represented by high impact polystyrene is added because the effect of improving the impact resistance of the non-foamed layer is large.

The ratio of the PPE resin and the PS resin in the modified PPE resin and the PPE resin and the styrene monomer component (other monomers copolymerizable with the styrene monomer) in the PPE-St copolymer Styrene-based polymer which is polymerized to PS-based resin or PPE-based resin with respect to 0 to 75% by weight of PPE-based resin, and more preferably 0 to 40% by weight. 10 monomer components
The content is preferably 0 to 25% by weight, more preferably 100 to 60% by weight. When a modified PPE-based resin is obtained by mixing a PPE-St copolymer with at least one of a PPE-based resin and a PS-based resin, the total of the PPE-based resin components (hereinafter referred to as a phenylene ether component) and the copolymerizable Other monomers 0-4
0% by weight of the total amount of the styrene monomer component (hereinafter, referred to as
The styrene component) is in the same range as described above, for example, a mixture of a PPE-based resin and a PPE-St copolymer, PP
In the mixture of the E-St copolymer and the PS resin, or the mixture of the PPE resin, the PPE-St copolymer and the PS resin, the phenylene ether component is 0 to 75% by weight, and further 0 to 40% by weight or less. PS resin or PPE
The styrene component polymerized in the system resin is preferably 100 to 25% by weight, more preferably 100 to 60% by weight. PPE
If the use ratio of the system resin is too large, the viscosity at the time of heating and flowing increases, and extrusion molding may be difficult.

In the foam laminated sheet for an automobile ceiling material according to the present invention, the non-foamed layer 12,
14 has a thickness of 50 to 300 μm, or even 75 to 200 μm.
m is preferred. When the thickness of the non-foamed layers 12 and 14 is less than 50 μm, the strength, rigidity, heat resistance, etc. are inferior and 30
If the thickness is larger than 0 μm, the moldability of the laminated sheet tends to be poor.

In the case of forming the non-foamed layers 12 and 14, if necessary, an impact modifier, a filler, a lubricant,
Antioxidants, antistatic agents, pigments, stabilizers, odor reducing agents, and the like may be added alone or in combination of two or more. The impact resistance improver used in the present invention is obtained by laminating thermoplastic resin non-foamed layers 12 and 14 on thermoplastic resin foamed layer 10,
It is used to prevent the non-foamed layers 12 and 14 from cracking when punching the laminated sheet that has been foamed as a car interior material, particularly as an automobile ceiling material, or when transporting the laminated sheet or molded article. It is valid.

The impact resistance improver is not particularly limited as long as it exerts its effect by being mixed with a thermoplastic resin. Examples of the impact resistance improver include rubber such as natural rubber and synthetic rubber, and those obtained by graft-polymerizing a monomer having an olefin double bond such as styrene and methyl methacrylate around rubber particles. Used for

In the case of rubber, for example, styrene / butadiene rubber, hydrogenated styrene / butadiene rubber, butadiene rubber, isoprene rubber, ethylene / propylene copolymer,
Ethylene-propylene-diene copolymer, acrylonitrile-butadiene copolymer, chloroprene rubber, butyl rubber, urethane rubber, silicone rubber, polysulfide rubber, hydrogenated nitrile rubber, polyether special rubber, fluoro rubber, ethylene tetrafluoride Propylene rubber, acrylic rubber, chlorosulfonated polyethylene rubber, epichlorohydrin rubber, propylene oxide rubber, ethylene acrylic rubber, liquid rubber, norbornene rubber, styrene-based thermoplastic elastomer, olefin-based thermoplastic elastomer, urethane-based thermoplastic elastomer, Polyester-based thermoplastic elastomer, Polyamide-based thermoplastic elastomer, 1,2-polybutadiene-based thermoplastic elastomer, PVC-based thermoplastic elastomer, Fluorine-based thermoplastic elastomer, MBS Fat, such as ethylene-vinyl acetate copolymers. These may be used alone,
Two or more kinds may be used in combination. Of these, styrene-butadiene rubber and hydrogenated styrene-butadiene rubber are preferred from the viewpoints of high compatibility with PS resins and modified PPE resins and versatility.

The impact resistance improver may be a component capable of imparting an impact resistance improvement effect by being introduced into a thermoplastic resin by modification by polymerization. For example, an impact modifier containing an impact modifier such as high impact polystyrene (impact polystyrene) may be used in the non-foamed layer 1
When used for the non-foamed layers 2 and 14, the non-foamed layers 12 and 14 can be given impact resistance.

The filler used in the present invention is a component used for improving strength, rigidity, dimensional stability and the like, and the filler used is not particularly limited. Specific examples of the filler include talc (magnesium silicate), calcium carbonate, mica, magnesium oxide, magnesium carbonate, barium sulfate, calcium sulfate, calcium sulfite, silica, clay, kaolin, white carbon, magnesium hydroxide, and carbon black. , Zeolite, molybdenum and the like. Of these, talc, calcium carbonate and mica are particularly preferred.

The amount of the filler to be added is 1 to 50 parts, preferably 5 to 40 parts, per 100 parts (parts by weight, hereinafter the same) of the non-foamed layer resin. When the addition amount is less than 1 part, a clear effect of filling with a filler (inorganic substance) cannot be obtained, while
If it is added in excess of 50 parts, the viscosity of the resin composition increases and a large load is applied to the extruder, which is not preferable.
Further, there is a problem that the impact strength of the non-foamed layers 12 and 14 is significantly reduced.

Next, the vehicle ceiling material according to the present invention will be described. Non-foamed layer 1 on the indoor side of primary foam laminated sheet
An adhesive layer 16 is laminated on the upper surface of the second member 2. Examples of the adhesive used in the present invention include a thermoplastic adhesive, a hot melt adhesive, a rubber adhesive, a thermosetting adhesive, a monomer reactive adhesive, an inorganic adhesive, and a natural adhesive. However, a hot-melt adhesive is preferable because of easy adhesion.

Examples of the hot melt adhesive include polyolefin, modified polyolefin, polyurethane, ethylene-vinyl acetate copolymer resin, polyamide, polyester, thermoplastic rubber, styrene-butanediene copolymer, and styrene-isoprene. Those containing a resin such as a copolymer system as a component are exemplified. The hot melt adhesive is used to adhere the skin material 18 to the molded body when the automobile ceiling material has a skin. By laminating the hot melt adhesive layer 16, the hot melt adhesive layer 16 is perforated due to shrinkage of the hot melt adhesive layer 16 during heating, and air between the non-foamed layer 12 and the hot melt adhesive layer 16 is heated. Poor adhesion of the skin material 18 due to accumulation or the like can be prevented. In addition, by laminating the hot melt adhesive layer 16 on the primary foam laminated sheet in advance, the step of temporarily fixing the hot melt at the time of molding is omitted, and the cost is reduced.

As described above, when the primary foamed laminated sheet is subjected to heating and secondary foaming, the primary foamed layer 10 (foaming ratio: 3)
~ 20 times, preferably 5-15 times, thickness: 1-5 mm,
(Preferably 1.5 to 3.5 mm), and usually 1.2
The secondary foaming is performed up to 4 times, but further 1.5 to 3 times.
It is preferable to perform secondary foaming (as a result, the sheet magnification after secondary foaming is 3.6 to 60 times, preferably 6 to 40 times,
The thickness is 1.2 to 10.0 mm, preferably 1.8 to
6.2 mm).

The skin material 18 can be laminated on the foam laminated sheet as needed. As the skin material 18, any skin material conventionally used for automobile interior materials can be used. Examples include, but are not limited to, woven fabrics, nonwoven fabrics, foam sheets, resin films, and the like. These may be made of synthetic resins such as polyethylene terephthalate, polypropylene, polyamide (nylon), polyacrylonitrile, modacrylic (Kanecaron) or natural materials such as wool or cotton, or may be used in combination. Further, a foamed layer of urethane, polyolefin, or the like may be laminated between the woven or nonwoven fabric and the foam laminated sheet. Further, when the automobile ceiling material of the present invention requires flame retardancy, the skin material 18 provided with flame retardancy is used.
It is preferred to use

Next, a method of manufacturing the foam laminated sheet for an automobile ceiling material and the automobile ceiling material of the present invention will be described. The thermoplastic resin foam layer 10 (primary foam layer) used in the present invention is a copolymer obtained by graft copolymerizing a styrene monomer with a mixed resin of a PPE resin and a PS resin or a PPE resin. And the like, to which various additives are added as necessary, are melted and kneaded at 150 ° C. to 400 ° C. by an extruder. Then, at 150 to 400 ° C. and at a high temperature and a high pressure of 30 to 500 atm.
The weight part is press-fitted, adjusted to the optimum foaming temperature (150 to 300 ° C.), and extruded into a low pressure zone (usually in the atmosphere) using a circular die or the like. Then, it is brought into contact with a mandrel or the like, formed into a sheet while being taken up at a speed of, for example, 0.5 to 40 m / min, cut, and then wound to produce a thermoplastic resin foam layer used in the present invention. can do.

Examples of the foaming agent used for producing the thermoplastic resin foam layer 10 include butane, propane, and the like.
Examples thereof include hydrocarbon-based blowing agents such as pentane, methyl chloride, dichloromethane, chlorofluoromethane, dichloroethane, and dichlorodifluoroethane, and halogenated hydrocarbon-based blowing agents. These may be used alone or in combination of two or more. Of these, hydrocarbon blowing agents are preferred from the viewpoint of versatility and cost.

The non-foamed thermoplastic resin layer 1 is added to the primary foamed layer 10.
As a method of laminating the layers 2 and 14, for example, a resin molded in advance into a film is foamed and supplied.
A method of bonding the upper surface and / or the lower surface of the next foam layer 10 with a hot roll or the like, a co-extrusion laminating method using a multilayer extrusion die, and the like can be given. Among these methods, the resin composition for a non-foamed layer supplied from an extruder is layered on the upper surface and / or the lower surface of the primary foamed layer 10 which has been foam-formed in advance and supplied to the plastic state. Certain non-foamed layer 1
A method of fixing the substrates 2 and 14 with a cooling roller or the like is preferable. In particular, a method of forming an extruded foam sheet of the primary foam layer 10 and extruding the non-foam layers 12 and 14 in-line and laminating them can simplify the manufacturing process and is preferably used in terms of cost.

As a method of forming a molded secondary foam laminated sheet as an automobile ceiling material from the primary foam laminated sheet obtained as described above, for example, a primary foam laminated sheet is provided at the center of a heating furnace having heaters above and below. Clamp the sheet and guide it,
After heating to a temperature suitable for molding, for example, 120 to 200 ° C. to cause secondary foaming, vacuum molding is performed in a temperature-controlled mold,
It is formed by means such as pressure forming. The heating time is usually preferably from 10 to 90 seconds.

Examples of vacuum molding and air pressure molding include, for example, plug molding, free drawing molding, plug and ridge molding, ridge molding, matched molding,
Straight molding, drape molding, reverse draw molding,
Examples of the method include air slip molding, plug assist molding, and plug assist reverse draw molding. Of these, there are both molds for automatic indoor side (convex) and automatic outdoor side (concave) molds, such as plug molding and matched mold molding. Is desirable.

It is preferable to form the foamed laminated sheet in a state before a keloid state is generated on the surface of the foamed laminated sheet by heating. As a result of the study of the present inventor, it has been found that when molding is performed in a state where a keloid state is generated on the surface during molding heating, the closed cell ratio decreases and the rigidity of the molded body decreases. The keloid state is caused by the breakage of the foam layer 10, and therefore, the closed cell rate is reduced.

Further, the thickness T of the secondary foamed laminated sheet is set to 0.5 t with respect to the free thickness t of the foamed laminated sheet at the time of secondary foaming, using a mold having a predetermined clearance. It is preferable that secondary foaming and molding be performed so as to satisfy ≦ T. In addition, t means the thickness of the foamed laminated sheet when it is heated under the same conditions as in the case of molding using a mold and cooled without performing molding by the mold.

The automobile ceiling material of the present invention is manufactured as described above. When the automobile ceiling material, which is a molded secondary foam laminated sheet, has a skin material, a method in which an adhesive layer 16 is applied to a skin material 18 in advance is applied to the primary foam laminated sheet by a hot roll. Bonding the adhesive layer 16 to the primary foam laminated sheet by a binder lamination method or a foam laminated sheet obtained by laminating the adhesive layer 16 formed in a film shape in advance by a heat lamination method. A method of bonding using a heat roll or the like, a method of temporarily fixing the skin material 18 to the primary foam laminated sheet and simultaneously performing molding and bonding at the time of heat molding, and a method of laminating the adhesive layer 16 to the primary foam laminated sheet. Skin material 1
8, but not limited thereto.

Although the embodiments of the foam laminated sheet for automobile ceiling material and the automobile ceiling material according to the present invention have been described in detail above, the present invention can be variously modified based on the knowledge of those skilled in the art without departing from the scope of the invention. The present invention can be implemented in a mode in which improvements, corrections, and modifications are added, all of which are within the scope of the present invention.

[0053]

Examples and Comparative Examples The present invention will be described in more detail with reference to the following Examples, which should not be construed as limiting the present invention. Table 1 shows the resins used in Examples and Comparative Examples, and Table 2 shows the skin material and its adhesive.

[0054]

[Table 1]

[0055]

[Table 2]

Further, evaluation methods performed in Examples and Comparative Examples are shown below. (Thickness of Foam Layer and Molded Body) The thickness of the primary foam sheet was measured at 20 places in the width direction of the foam sheet, and the average of the measured values was calculated. (Expansion ratio) The density df of the primary foam sheet is determined according to JIS K7.
The density dp of the modified PPE-based resin was measured according to JIS K7112, and determined by the following equation.

Expansion ratio = dp / df (closed cell ratio) It was determined by evaluating according to ASTM D-2859 (using a multi-pycnometer (manufactured by Beckman)). (Cell diameter (same as average cell diameter)) The cross section of the foamed layer was observed with an optical microscope, the diameters of 20 cells were measured, and the average of the measured values was calculated.

(Density) A test piece having a size of 1 mx 1 m was cut out from five places in the extrusion direction of the primary foam sheet.
After measuring their weight, the average value was calculated. (Mounting heat resistance test) As a heat resistance test of the molded body, the following mounting heat test was performed. That is, as a mounting heat resistance test method, the vehicle ceiling material shown in FIG. 2 was attached to the vehicle ceiling, and fixed to be equivalent to an actual vehicle via a sun visor, a room mirror, a room lamp, a ganish pillar. Further, six measurement points were stamped on the front part at intervals of 120 mm in symmetry with the center line of the molded body (a to a in FIG. 2).
f). A marking line was provided near the measurement point in the front part, and the vertical distance was measured. Next, after placing the car ceiling with the car ceiling material in a constant temperature room set at 100 ± 1 ° C. for 24 hours, the absolute value of the vertical dimensional change of the measurement point stamped on the front part of the molded body was measured. Was measured, and the maximum value of a to f was recorded.

[0059]

Example 1 A mixed resin 100 obtained by mixing 72.7 parts by weight of a PPE resin (A) and 27.3 parts by weight of a PS resin (B) so as to be 40% by weight of a PPE resin component and 60% by weight of a PS resin component. 2.7 parts by weight of a foaming agent containing iso-butane as a main component (iso / n = 85/15) and 0.3 part of talc were kneaded with an extruder, and the resin temperature was 201 ° C.
And extruded with a circular die, 8m /
It was wound in a roll form on a take-up roll via a take-up roll at a speed of one minute. A foam layer 10 having a primary thickness of 1.6 mm, a primary expansion ratio of 9 times, a closed cell ratio of 90%, a cell diameter of 0.15 mm, and a basis weight of 180 g / m2 was obtained. Next, the foamed layer 10 is fed out, and the PPE resin (A) 72.7 is adjusted to 40% by weight of the PPE resin component and 60% by weight of the PS resin component.
27.3 parts by weight of the PS resin (B) were melted and kneaded, and extruded using a T-die at a resin temperature of 280 ° C. to form a non-foamed layer having a thickness of 120 μm on one surface of the foamed layer 10.
Then, in the same manner, 72.7 parts by weight of the PPE resin (A) and 17.2 parts by weight of the PS resin (B) so that the other surface had 40% by weight of the PPE resin component, 54% by weight of the PS resin component, and 6% by weight of the rubber component. 3 parts by weight and 10 parts by weight of the impact modifier (C) are melted and kneaded, and extruded at 280 ° C. using a T-die to form a non-foamed layer having a thickness of 120 μm. 14 was obtained.

Further, the foamed laminated sheet is fed out, and at the same time, the hot melt film (D) is fed out to the non-foamed layer side containing no rubber component, and is fed at a speed of 10 m / min through a hot roll controlled at 120 ° C. To give a foam laminated sheet on which a hot melt adhesive was laminated. A skin material (E) is temporarily fixed on the hot melt adhesive surface of the foam laminated sheet,
The four sides are clamped, placed in an oven, and heated for 30 seconds so that the surface temperature of the foamed laminated sheet becomes 135 ° C., and then, with a mold having a mold clearance of 4.0 mm, the mold is arranged so that the skin material is on the indoor side. Plug molding, trimming and punching were performed to obtain a good automotive ceiling material. The obtained automotive ceiling material was evaluated for heat resistance.

[0061]

Example 2 2.7 parts by weight of a foaming agent mainly composed of iso-butane (iso / n = 85/15) and 100 parts by weight of PPE resin (A), which is 55% by weight of PPE resin component, 0.3 parts by weight of talc was kneaded with an extruder, cooled to a resin temperature of 215 ° C., extruded with a circular die, and wound up into a take-up roll via a take-up roll at a speed of 8 m / min. 1.6 mm primary thickness,
Primary expansion ratio 9 times, closed cell rate 85%, cell diameter 0.15
mm, a foamed layer having a basis weight of 180 g / m ² was obtained.

Next, this foamed sheet is fed out, and PPE
72.7 parts of PPE resin (A) and PS resin (B) 2 so that the resin component is 40% by weight and the PS resin component is 60% by weight.
7.3 parts are melted and kneaded, and the resin temperature is 28 using a T-die.
Extrusion was performed at 0 ° C. to form a non-foamed layer having a thickness of 120 μm on one side of the foamed layer. Then, in the same manner, 72.7 parts by weight of the PPE resin (A) and 17.2 parts by weight of the PS resin (B) so that the other surface had 40% by weight of the PPE resin component, 54% by weight of the PS resin component, and 6% by weight of the rubber component. 3 parts by weight and 10 parts by weight of the impact modifier (C) are melted and kneaded, and extruded at a resin temperature of 280 ° C. using a T die to form a non-foamed layer having a thickness of 120 μm. A foam laminated sheet was obtained.

Further, the foamed laminated sheet is fed out, and at the same time, the hot melt film (D) is fed out to the non-foamed layer side containing no rubber, and the speed is 10 m / min through a hot roll controlled at 120 ° C. To give a foam laminated sheet on which a hot melt adhesive was laminated. A skin material (E) is temporarily fixed on the hot melt adhesive surface of the foam laminated sheet,
The four sides are clamped, placed in an oven, and heated for 30 seconds so that the surface temperature of the foamed laminated sheet becomes 135 ° C., and then, with a mold having a mold clearance of 4.0 mm, the mold is arranged so that the skin material is on the indoor side. Plug molding, trimming and punching were performed to obtain a good automotive ceiling material. The obtained automotive ceiling material was evaluated for heat resistance.

[0064]

Example 3 A foamed sheet obtained in the same manner as in Example 1 was fed out, and 54.5 parts by weight of a PPE resin (A) and PS resin were adjusted so that the PPE resin component was 30% by weight and the PS resin component was 70% by weight. (B) 45.5 parts by weight are melted and kneaded, and T
The resin was extruded at a resin temperature of 280 ° C. using a die to form a non-foamed layer having a thickness of 120 μm on one side of the foamed layer. Next, in the same manner, the PPE resin component was added to the other surface so as to have 30% by weight of the PPE resin component, 64% by weight of the PS resin component, and 6% by weight of the rubber component.
Melting and kneading 54.5 parts by weight of resin (A), 35.5 parts by weight of PS resin (B), and 10 parts by weight of impact modifier (C),
Extruded at 280 ° C using a T-die, thickness 12
A non-foamed layer having a thickness of 0 μm was formed, and a foamed laminated sheet having non-foamed layers on both surfaces was obtained.

Further, the foamed laminated sheet is fed out, and at the same time, a hot melt film (D) is fed out to the non-foamed layer side containing no rubber, and the speed is 10 m / min through a hot roll controlled at 120 ° C. To give a foam laminated sheet on which a hot melt adhesive was laminated. A skin material (E) is temporarily fixed on the hot melt adhesive surface of the foam laminated sheet,
The four sides are clamped, placed in an oven, and heated for 30 seconds so that the surface temperature of the foamed laminated sheet becomes 135 ° C., and then, with a mold having a mold clearance of 4.0 mm, the mold is arranged so that the skin material is on the indoor side. Plug molding, trimming and punching were performed to obtain a good automotive ceiling material. The obtained automotive ceiling material was evaluated for heat resistance.

[0066]

Example 4 The foamed sheet obtained in the same manner as in Example 1 was fed out, and 54.5 parts by weight of the PPE resin (A) and PS resin were adjusted to 30% by weight of the PPE resin component and 70% by weight of the PS resin component. (B) 45.5 parts by weight are melted and kneaded, and T
The resin was extruded at a resin temperature of 280 ° C. using a die to form a non-foamed layer having a thickness of 120 μm on one side of the foamed layer. Then, similarly, 94% by weight of the PS resin component and the rubber component 6
90 parts by weight of the PS resin (B) and 10 parts by weight of the impact modifier (C) are melted and kneaded so as to give a weight%, and extruded at a resin temperature of 270 ° C. using a T-die to obtain a non-foamed 120 μm thick. A layer was formed, and a foam laminated sheet having a non-foamed layer on both sides was obtained.

Further, the foamed laminated sheet is fed out, and at the same time, the hot melt film (D) is fed out to the non-foamed layer side containing no rubber component, and is fed at a speed of 10 m / min through a hot roll controlled at 120 ° C. To give a foam laminated sheet on which a hot melt adhesive was laminated. A skin material (E) is temporarily fixed on the hot melt adhesive surface of the foam laminated sheet,
The four sides are clamped, placed in an oven, and heated for 30 seconds so that the surface temperature of the foamed laminated sheet becomes 135 ° C., and then, with a mold having a mold clearance of 4.0 mm, the mold is arranged so that the skin material is on the indoor side. Plug molding, trimming and punching were performed to obtain a good automotive ceiling material. The obtained automotive ceiling material was evaluated for heat resistance.

[0068]

Example 5 The foamed sheet obtained in the same manner as in Example 1 was fed out, and the PPE resin (A) 54. was prepared so that the PPE resin component was 30% by weight, the PS resin component was 64% by weight, and the rubber component was 6% by weight. 5 parts by weight, 35.5 parts by weight of PS resin (B) and 10 parts by weight of impact modifier (C) were melted and kneaded, and T
The resin was extruded at a resin temperature of 280 ° C. using a die to form a non-foamed layer having a thickness of 120 μm on one side of the foamed layer. Next, in the same manner, the other side is made such that the PPE resin component is 30% by weight, the PS resin component is 58% by weight, and the rubber component is 12% by weight.
E resin (A) 54.5 parts by weight, PS resin (B) 25.5 parts
Parts by weight, 20 parts by weight of the impact modifier (C) are melted and kneaded, and extruded at 280 ° C. using a T-die to form a non-foamed layer having a thickness of 120 μm, and a foam having a non-foamed layer on both surfaces. A laminated sheet was obtained.

Further, the foamed laminated sheet was fed out, and at the same time, a hot melt film (D) was fed out to the non-foamed layer side containing 6% by weight of rubber, and 10 m / min through a hot roll controlled at 120 ° C. To give a foam laminated sheet laminated with a hot melt adhesive. A skin material (E) is temporarily fixed on the hot melt adhesive surface of the foam laminated sheet, clamped on all sides, placed in an oven, and heated for 30 seconds so that the foam laminated sheet surface temperature becomes 135 ° C. Was molded with a mold having a mold clearance of 4.0 mm, trimming and punching were performed with a mold arranged so as to be on the indoor side, and a good automobile ceiling material was obtained. The obtained automotive ceiling material was evaluated for heat resistance.

[0070]

COMPARATIVE EXAMPLE 1 A foamed sheet obtained in the same manner as in Example 1 was fed, and the PPE resin (A) 54. was prepared so that the PPE resin component was 30% by weight, the PS resin component was 64% by weight, and the rubber component was 6% by weight. 5 parts by weight, 35.5 parts by weight of PS resin (B) and 10 parts by weight of impact modifier (C) were melted and kneaded, and T
The resin was extruded at a resin temperature of 280 ° C. using a die to form a non-foamed layer having a thickness of 120 μm on one side of the foamed layer. Next, similarly, 54.5% of the PPE resin (A) was added to the other surface so that the PPE resin component was 30% by weight and the PS resin component was 70% by weight.
Parts by weight and 45.5 parts by weight of the PS resin (B) are melted and kneaded, and extruded at 280 ° C. using a T-die to form a non-foamed layer having a thickness of 120 μm, and a foam having a non-foamed layer on both surfaces. A laminated sheet was obtained.

Further, the foamed laminated sheet was fed out, and at the same time, a hot melt film (D) was fed out to the non-foamed layer side containing 6% by weight of rubber, and 10 m / min through a hot roll controlled at 120 ° C. To give a foam laminated sheet laminated with a hot melt adhesive. A skin material (E) is temporarily fixed on the hot melt adhesive surface of the foam laminated sheet, clamped on all sides, placed in an oven, and heated for 30 seconds so that the foam laminated sheet surface temperature becomes 135 ° C. Was molded with a mold having a mold clearance of 4.0 mm, trimming and punching were performed with a mold arranged so as to be on the indoor side, and a good automobile ceiling material was obtained. The obtained automotive ceiling material was evaluated for heat resistance.

[0072]

COMPARATIVE EXAMPLE 2 A foamed sheet obtained in the same manner as in Example 1 was fed, and the PPE resin (A) 54. was prepared so that the PPE resin component was 30% by weight, the PS resin component was 58% by weight, and the rubber component was 12% by weight. 5 parts by weight, 25.5 parts by weight of PS resin (B) and 20 parts by weight of impact modifier (C) are melted and kneaded, and T
The resin was extruded at a resin temperature of 280 ° C. using a die to form a non-foamed layer having a thickness of 120 μm on one side of the foamed layer. Next, in the same manner, the other side is made such that the PPE resin component is 30% by weight, the PS resin component is 58% by weight, and the rubber component is 12% by weight.
E resin (A) 54.5 parts by weight, PS resin (B) 25.5 parts
Parts by weight, 20 parts by weight of the impact modifier (C) are melted and kneaded, and extruded at 280 ° C. using a T-die to form a non-foamed layer having a thickness of 120 μm, and a foam having a non-foamed layer on both surfaces. A laminated sheet was obtained.

Further, the foamed laminated sheet is fed out, and simultaneously, the hot melt film (D) is fed out, and
Was wound at a speed of 10 m / min through a hot roll whose temperature was adjusted to obtain a foamed laminated sheet on which a hot melt adhesive was laminated. A skin material (E) is temporarily fixed on the hot melt adhesive surface of the foam laminated sheet, clamped on all sides, placed in an oven, and heated for 30 seconds so that the foam laminated sheet surface temperature becomes 135 ° C. Was molded with a mold having a mold clearance of 4.0 mm, trimming and punching were performed with a mold arranged so as to be on the indoor side, and a good automobile ceiling material was obtained. The obtained automotive ceiling material was evaluated for heat resistance.

[0074]

Comparative Example 3 A foamed sheet obtained in the same manner as in Example 1 was fed, and 80 parts by weight of the PS resin (B) and 88% by weight of a PS resin component and 12% by weight of a rubber component were used. C) 20 parts by weight are melted and kneaded and extruded at a resin temperature of 270 ° C. using a T-die, and a thickness of 12
A non-foamed layer of 0 μm was formed. Then, similarly, 80 parts by weight of the PS resin (B) and 20 parts by weight of the impact modifier (C) are melted and kneaded so that the other surface has 88% by weight of the PS resin component and 12% by weight of the rubber component. The resin was extruded at a resin temperature of 270 ° C. using a T die to form a non-foamed layer having a thickness of 120 μm, and a foamed laminated sheet having non-foamed layers on both surfaces was obtained.

Further, the foamed laminated sheet is fed out, and simultaneously, the hot melt film (D) is fed out, and
Was wound at a speed of 10 m / min through a hot roll whose temperature was adjusted to obtain a foamed laminated sheet on which a hot melt adhesive was laminated. A skin material (E) is temporarily fixed on the hot melt adhesive surface of the foam laminated sheet, clamped on all sides, placed in an oven, and heated for 30 seconds so that the foam laminated sheet surface temperature becomes 135 ° C. Was molded with a mold having a mold clearance of 4.0 mm, trimming and punching were performed with a mold arranged so as to be on the indoor side, and a good automobile ceiling material was obtained. The obtained automotive ceiling material was evaluated for heat resistance.

Examples 1 to 3 and Comparative Examples 1 and 2
Table 3 shows the results of the heat resistance test of the ceiling materials of Table 1.

[0077]

[Table 3]

(Note) Cracking evaluation by trimming ○: No cracking. Δ: Partially cracked. From the results shown in Table 3, in the case of the example, compared to the comparative example, the amount of heat deformation of the front portion in the heat resistance test was small, and the quality as an automobile ceiling material was maintained without cracking due to trimming. You can see that.

[0079]

The automotive ceiling material and the foam laminated sheet of the automotive ceiling material of the present invention have improved heat resistance and good properties such as moldability, dimensional stability, sound insulation, impact resistance and heat insulation. It is lightweight and easy to manufacture with improved deformation due to use under high temperatures and sagging due to its own weight.
It is also useful in terms of manufacturing cost.

[Brief description of the drawings]

FIG. 1 is a diagram for explaining a configuration of an automobile ceiling material.

FIG. 2 is an explanatory plan view of an example of a trimmed molding for an automobile ceiling;

[Explanation of symbols]

 10: Foam layer 12: Indoor non-foam layer 14: Outdoor non-foam layer 16: Adhesive layer 18: Skin material 20: Assist grip mounting hole 22: Sun visor mounting hole 24: Interior mirror mounting hole 26: Interior light mounting hole

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[Procedure amendment]

[Submission date] December 7, 1998 (1998.12.
7)

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0035

[Correction method] Change

[Correction contents]

The impact modifier is not particularly limited as long as it exhibits the effect by being mixed with the thermoplastic resin. Examples of the impact resistance improver include rubber such as natural rubber and synthetic rubber, and those obtained by graft-polymerizing a monomer having an olefin double bond such as styrene and methyl methacrylate around rubber particles. Used for

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) BA10E BA13 BA15 BA16 BA27B BA27C CA01A CA30B CA30C DJ01A GB33 JB16A JB16B JB16C JH01 JJ02 JJ03 JK10B JK10C JL01 JL02 JL04 JL11D JL12D YY00A YY00B YY00C

Claims (11)

[Claims] 1. A foam laminated sheet in which a non-foamed layer having a thermoplastic resin as a base resin is laminated on both surfaces of a foamed layer having a thermoplastic resin as a base resin. A foam laminated sheet for an automobile ceiling material, characterized in that the amount of an impact resistance improver added to the base resin of the foam layer is reduced. 2. The method according to claim 1, wherein the amount of the impact modifier added to the base resin of the indoor non-foamed layer is smaller than that of the outdoor non-foamed layer by 5% by weight or more. Laminated sheet for automotive ceiling materials. 3. The foam laminate sheet for an automobile ceiling material according to claim 1, wherein the base resin of the foam layer is a modified polyphenylene ether-based resin. 4. The modified polyphenylene ether resin has a phenylene ether component content of more than 35% by weight to 75% by weight and a styrene type component of more than 25% by weight and 65% by weight or less. Claim 1
The laminated sheet for automobile ceiling materials according to any one of claims 1 to 3. 5. A foam laminated sheet for an automobile ceiling material, wherein an adhesive layer is laminated on the surface of the non-foamed layer on the indoor side of the foam laminated sheet according to any one of claims 1 to 4. 6. An automobile ceiling material, wherein a skin material is bonded to a surface of a non-foamed layer on the indoor side of the foamed laminated sheet according to any one of claims 1 to 4 via an adhesive layer. For foam laminated sheet. 7. An automobile ceiling material formed by molding the foamed laminated sheet for an automobile ceiling material according to any one of claims 1 to 4 into a predetermined shape. 8. After forming the foamed laminated sheet for automobile ceiling material according to any one of claims 1 to 4 into a predetermined shape, the surface of the indoor non-foamed layer of the foamed laminated sheet for automobile ceiling material is An automobile ceiling material in which a skin material is joined via an adhesive layer. 9. An adhesive layer laminated on a surface of a non-foamed layer on the indoor side of the foamed laminated sheet for an automobile ceiling material according to claim 5, wherein a skin material is joined to the adhesive layer and then molded into a predetermined shape. Characteristic automotive ceiling material. 10. An automobile ceiling material obtained by molding the foamed laminated sheet for an automobile ceiling material according to claim 6 into a predetermined shape. 11. The vehicle ceiling material according to claim 8, wherein the adhesive is a hot melt adhesive.