JP2005178030A - Multilayered skin material and laminate for trim material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an inexpensive multilayered skin material having good processability, excellent in lightweight properties, rigidity, heat resistance, thermoforming properties, recyclability and design properties, and reconciling high sound-absorbing capacity and interfacial adhesiveness, and an inexpensive laminate for a trim material having a high sound-absorbing capacity though using a closed cell type foamed laminated base material. <P>SOLUTION: The multilayered skin material is obtained by interposing a sheet or film, to which air permeability is imparted by providing through-holes, between an air permeable skin layer and an air permeable material. Further, the laminate for the trim material is obtained by laminating the multilayered skin material on the closed cell type foamed laminated base material. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a multilayer skin material and a laminate for interior materials. More specifically, as an interior material, it is suitable for being placed in a site that requires lightness, rigidity, heat resistance, thermoformability, recyclability, and design, and particularly for sound absorption on the high frequency side (for example, 4000 Hz or more). The present invention relates to an excellent multilayer skin material and a laminate for an interior material obtained by laminating the multilayer skin material on an closed-cell foamed laminated base material.

  In order to pursue the quietness in the room, a material provided with sound absorbing performance is widely used for interior materials. Depending on the installation location of the interior material, the required performance varies in addition to the sound absorption performance. For example, if the interior material for a vehicle is given, it has lightness, rigidity, design, heat resistance and thermoformability. . Conventionally, in order to achieve both the required performance and sound absorption performance, a sheet using urethane foam as a core base material, a sheet in which inorganic fibers and a thermoplastic resin are interconnected, and the like are widely used.

  Since these base materials are all breathable, it is necessary to provide a non-breathable layer from the viewpoint of preventing dirt on the skin material. However, if the breathability of the base material is suppressed, the sound absorption performance may be lowered. . Therefore, a decrease in sound absorption performance is suppressed by providing a non-breathable layer on the non-incident sound wave side and a breathable layer on the incident sound wave side (see, for example, Patent Documents 1 and 2).

  However, in Patent Document 1, after laminating two layers of film, arbitrary through holes are dispersed and formed with high accuracy. However, there is a problem in terms of stable formation of the through holes, and further after this step. Since there is a separate process of laminating the skin material on the surface, there is also a problem in terms of processing.

  On the other hand, in Patent Document 2, a non-breathable multilayer film is laminated on a substrate and then heat treated to provide through holes. However, it is difficult to stably and uniformly control the diameter and pitch of the through holes. In addition, not only the sound absorption performance but also the stability of the skin adhesion is lacking.

  Moreover, although examination about a breathable base material was advanced like patent document 1 and patent document 2, the present condition is that the sound absorption improvement about a non-breathable base material is not performed.

  Furthermore, the air-permeable base material contains glass fibers or is laminated with glass fiber mats in order to exhibit its rigidity and heat resistance, and there is a limit to weight reduction. Moreover, since glass fiber is contained, it is poor in recyclability and inferior to environmental compatibility.

  On the other hand, as a method for solving the above problem, there is a method using a laminated sheet in which a non-foamed layer made of a thermoplastic resin is laminated on a foamed core layer of a thermoplastic resin having heat resistance. For example, application of an automobile roof liner in which a resin-based non-foamed layer is laminated on a foamed core layer of a polyphenylene ether-based resin is disclosed (for example, see Patent Document 3).

  However, since the foamed laminated base material is a closed cell system, that is, a non-breathable base material, incident sound is almost reflected, and the sound absorbing performance is extremely low.

  For this reason, attempts have been made to impart sound absorption performance by laminating sound absorbing skin materials such as urethane slabs and ultrafine fibers on the closed cell foam laminated substrate (see, for example, Patent Document 4), but it is expensive. In addition, there are problems such as fiber settling due to thermoforming.

  In addition, interior parts and vehicle sound absorbing materials in which an inexpensive non-woven fabric is interposed between the skin material and the base material have been proposed (see, for example, Patent Documents 5 and 6), but it is hoped to provide higher sound absorbing performance. It is rare.

  Therefore, the present situation is that the non-breathable base material and the skin material have not been improved in sound absorption performance in view of cost and recyclability.

JP 2002-36405 A (1) JP 2003-225959 A (1) Utility Model 2541890 (1) JP 55-11947 A1 (pages 1 to 4) Japanese Patent Laid-Open No. 2002-127836 (1) JP 2002-215169 A (see paragraph 1)

  The present invention is a multilayer skin material that is inexpensive and has good workability, is excellent in lightness, rigidity, heat resistance, thermoformability, recyclability and design, and has both high sound absorption performance and practical interfacial adhesion, and An object of the present invention is to provide a laminate for an interior material obtained by laminating the multilayer skin material on a closed cell foam laminated substrate.

  In general, it is difficult to provide sound absorption performance with low cost, good processability, practical characteristics, excellent recyclability, and the ability to provide sound absorption performance for interior materials. It has been extremely difficult to impart sound absorption performance to such a non-breathable substrate.

  Therefore, as a result of intensive investigations for imparting sound absorbing performance to the interior material, the present inventors have determined that a pore diameter (equivalent circle diameter, hereinafter simply referred to as a pore diameter) between the breathable skin layer and the breathable material. In other words, a multilayer skin material with improved sound absorption performance can be obtained by interposing a sheet or film having air permeability by providing through holes with a pitch adjusted. In addition, by laminating the multilayer skin material on the closed cell foamed laminated base material, it was possible to obtain a laminate for an interior material that gave higher sound absorption performance even when a non-breathable base material was used.

  That is, the first multilayer skin material of the present invention is a sheet or film in which (1) a breathable skin layer and (2) a breathable material are provided and (3) a through hole is provided to impart breathability. The present invention relates to a multi-layer skin material interposed.

  The second multilayer skin material of the present invention relates to a multilayer skin material obtained by interposing a sheet or film (3) through (4) an adhesive layer in the first multilayer skin material.

  The third multilayer skin material of the present invention relates to a multilayer skin material obtained by interposing a sheet or film (3) by needle punching in the first multilayer skin material.

  The 4th multilayer skin material of this invention is related with the multilayer skin material which interposes a sheet | seat or a film (3) by thermal fusion in the 1st, 2nd or 3rd multilayer skin material.

  The fifth multilayer skin material of the present invention is a sheet, film (3), breathable skin layer (1) and breathable material (2) in the first, second, third or fourth multilayer skin material. The multi-layer skin material has an interface adhesive strength of 3N / 25 mm or more in the 180 ° peel test.

  The sixth multilayer skin material of the present invention relates to a multilayer skin material in which the sheet or film (3) is a thermoplastic resin film in the first, second, third, fourth or fifth multilayer skin material.

  The seventh multilayer skin material of the present invention relates to the multilayer skin material in which the sheet or film (3) is a polyolefin film in the first, second, third, fourth, fifth or sixth multilayer skin material. .

  The eighth multilayer skin material of the present invention is the first, second, third, fourth, fifth, sixth or seventh multilayer skin material, wherein the sheet or film (3) is a stretched film. Regarding materials.

  The first laminate for interior material according to the present invention, the first, second, third, fourth, fifth, sixth, seventh or eighth multilayer skin material is laminated on the closed cell foam laminated substrate. It is related with the laminated body for interior materials formed.

  The 2nd laminated body for interior materials of this invention is related with the laminated body for interior materials in which the closed cell type foaming laminated base material consists of polyphenylene ether-type resin in the 1st laminated body for interior materials.

  The multi-layer skin material of the present invention and the laminate for interior materials in which the multi-layer skin material is laminated on a closed-cell foamed laminated base material are excellent in sound absorption performance (particularly on the high frequency side) for ensuring indoor quietness, and inexpensive. It has good workability, is excellent in lightness, and has a sufficient design. Further, when a thermoplastic material that does not contain glass or the like is used or when a combination of different materials is not used, a multilayer skin material excellent in recyclability can be obtained. Even when the multilayer skin material of the present invention is laminated on a base material for interior material that does not have air permeability, a laminate for interior material having high sound absorption performance can be obtained.

  The multilayer skin material according to the present invention is mainly composed of a breathable skin layer (1), a breathable material (2), and a sheet or film (3) provided with a breathability by providing through holes whose pore diameter and pitch are adjusted. Consists of. Moreover, the laminated body for interior materials which concerns on this invention consists of the said multilayer skin material and a closed cell type foaming laminated base material.

  As the material for the breathable skin layer (1) and the breathable material (2) in the present invention, any material known to those skilled in the art as having breathability can be used. For example, felt, non-woven fabric, cotton, rock wool, woven fabric, glass wool, soft open-celled body and the like.

  Among these, as the breathable skin layer (1) and the breathable material (2), it is preferable to use a single-layer or multilayer fiber body. In particular, it is preferable to use a single-layer fiber body from the viewpoints of cost, practicality, lightness, and recyclability.

  The breathable skin layer (1) and the breathable material (2) may be the same or similar (therefore, regarding the materials and preferred mixing amounts described below for the breathable skin layer and the breathable material) However, since the breathable skin layer (1) is used as a skin material exposed to the indoor side or the surface side, it is more decorative and designable than the breathable material (2). Of course, it is necessary to take into consideration general practical characteristics as an interior material such as wear resistance as well as the use of an excellent material.

  The breathable skin layer (1) in the present invention may be composed of any material as long as it has practical characteristics as a general skin material for interior materials. When a fibrous body is used as the breathable skin layer (1), those conventionally used as a skin material for interior materials are preferable. For example, the fiber body which consists of a synthetic fiber, a semisynthetic fiber, a natural fiber, or a reproduction | regeneration fiber is mention | raise | lifted. More specifically, from synthetic fibers such as polyester, polypropylene, polyamide (nylon), polyurethane, polyacryl, polyacrylonitrile, modacrylic, natural fibers such as wool, cotton, hemp, cellulose, and recycled fibers such as rayon A woven fabric, knit or non-woven fabric is preferably used. Moreover, since it is a design surface, what is excellent in abrasion resistance is preferable, and when it installs in the site | part to shape | mold, the thing excellent in a moldability is so good. These may be a combination of the above materials. Among these, as the breathable skin layer (1), a nonwoven fabric made of polyethylene terephthalate fiber is particularly preferable from the viewpoint of cost and weather resistance.

  A nonwoven fabric is manufactured by the method similar to the method of manufacturing a general nonwoven fabric. Examples of the type of nonwoven fabric include a bonded binder-bonded fabric, a needle punched fabric, a spunbonded fabric, a spray fiber fabric, and a stitchbonded fabric, depending on the manufacturing method. When a nonwoven fabric is manufactured as a breathable skin layer (1) by needle punching, the number of punches and needle stroke are adjusted to increase the interlace between fibers and increase the rigidity of the fiber body, thereby improving the design and polishing resistance. Wearability can be imparted.

  In addition, an adhesive (binder resin) and / or a heat-fusible fiber (low-melting fiber) having a function as a binder between fibers is appropriately mixed with the material, and entangled by a chemical or mechanical method. Can be used.

  Examples of the binder resin include water-soluble, solvent-soluble, viscose liquid, emulsion, and synthetic resin powder. From the viewpoint of water resistance, flexibility, and workability, an emulsion type is preferable. As the emulsion type, acrylo / nitrile / butadiene latex, styrene / butadiene latex, acrylate / latex, vinyl acetate latex and the like can be used, and these can be used alone or as a mixture of two or more.

  Examples of the heat-fusible fiber (low melting point fiber) include polyethylene, polypropylene, low melting point or low glass transition point (for example, about 60 to 180 ° C., preferably 110 ° C. to 160 ° C.) polyester (hereinafter simply referred to as low melting point polyester). A core-sheath fiber having a low melting point or low glass transition point polyolefin or polyester fiber as a sheath component and a high melting point polyester fiber as a core component is preferable. From the recyclability when polyethylene terephthalate is used as the synthetic fiber, polyester fiber (including core-sheath fiber) especially has a low melting point or low glass transition point (for example, about 60 to 180 ° C., preferably 110 to 160 ° C.). preferable.

  The breathable skin layer (1) can be further provided with designability and wear resistance by resin coating on the design surface.

The basis weight of the permeable skin layer (1) is, 50 to 500 g / m ^2, 50 more 50 to 400 g / m ^2, particularly preferably from 50 to 300 g / m ^2, cost, practicality, in terms of light weight ˜150 g / m ² is particularly preferred.

The density of the breathable skin layer (1) is preferably 0.01~0.50g / cm ^3, more preferably 0.05~0.25g / cm ^3. If the density of the breathable skin layer (1) is less than 0.01 g / cm ³ , the design and wear resistance tend to be inferior. If it exceeds 0.50 g / cm ³ , the lightness, workability, moldability, etc. Tend to be inferior.

  Next, the breathable material (2) may be any material as long as it is breathable and structurally functions as a space. For example, a porous material that can be used as a part of a fibrous body or skin material can be used. More specifically, as the fibrous body, a single-layered or multilayered woven or non-woven fabric using the same material as that used in the breathable skin layer (1), and as the porous material, an open-celled body such as a flexible urethane foam is used. Can be given.

  The material can also control its sound absorption characteristics by controlling its ventilation resistance. Therefore, the fibrous body and the porous material can be improved in sound absorption performance suitable for the application by changing the internal air permeability by the manufacturing method.

  When a fibrous body is used as the breathable material (2), the fibrous body is basically the same as the breathable skin layer (1) except that it is not necessary to consider the design properties. An example can be given. Among these, when considering cost and processability as a raw material fiber, a polyester fiber is preferable, and a polyethylene terephthalate fiber having high heat resistance is particularly preferable in terms of good shape maintainability during heat molding.

  Furthermore, when exposed to a severe thermoforming press (for example, skin-integrated thermoforming), the shape maintaining property during thermoforming is improved by mixing recycled fibers such as rayon or natural fibers. Particularly in view of cost and processability, it is preferable to mix 20 to 80% by weight of regenerated fiber such as rayon or natural fiber, and more preferably 40 to 70% by weight. Moreover, you may use the shape which crimped the said fiber as a raw material which improves the shape maintenance property at the time of thermoforming.

  An adhesive (binder resin) and / or a heat-fusible fiber (low-melting fiber) having a function as a binder between fibers is appropriately mixed with the material and used by being intertwined by a chemical or mechanical method. You can also.

  Specific examples of the adhesive (binder resin) and the heat-fusible fiber include those described for the breathable skin layer (1).

  The mixing amount of the heat-fusible fiber is preferably 5 to 30% by weight in the entire fiber body. If the content exceeds 30% by weight, the cost will be high, and the formability and the overall design of the laminated skin material will be inferior due to increased binding force between fibers and the generation of fiber mass, and the thickness of the fiber body. There may be variations in thickness. If it is less than 5% by weight, the effect of mixing the heat-fusible fiber is hardly exhibited.

  The fineness of the fiber is preferably 1 to 10 denier (1.1 to 11.1 dtex). When it is less than 1 denier, the shape maintaining property of the fiber orientation tends to be impaired, and the sag of the entire fiber body tends to increase. On the other hand, when the denier is larger than 10 denier, the inter-fiber discoloration or wrinkles may be caused, and the design of the entire laminated skin material may be impaired (especially when used for a molding site). The fineness of the fiber is more preferably 2 to 7 denier (2.2 to 7.8 dtex).

Fiber basis weight constituting the fiber body, 50 to 400 g / m ^2, more preferably 50 to 300 g / m ^2, cost, practicality, 100 to 200 g / m ² from the viewpoint of light weight and high sound absorbing performance is particularly 50 to 150 g / m ² is most preferable.

  Furthermore, the thickness of the fibrous body is preferably 0.5 to 10.0 mm, and more preferably 2.0 to 4.0 mm. If the thickness of the fibrous body is less than 0.5 mm, high sound absorption performance tends not to be expected, and if it exceeds 10.0 mm, moldability, workability and the like tend to be inferior.

  In order to manufacture a fiber body using the said raw material, the method similar to manufacture of the web which is a pre-process at the time of manufacturing a general nonwoven fabric is employable. At this time, the bulkiness and flexibility can be controlled by adjusting the amount of the heat-fusible fiber and the number of needle punches.

  The breathable material (2) may be a material having any structure as long as it is breathable and structurally functions as a space, in addition to the above-described fiber body. For example, a porous material that can be used as a part of a felt or skin material. Examples of the porous material include open cells such as soft urethane foam.

  Next, the sheet or film (3) provided with a through hole to provide air permeability has a through hole to the extent that sound waves can be transmitted, and the laminated skin material including the sheet or film forms a single structure. As long as it is made of resin or metal, any material can be used. However, if the viewpoint of practical properties is taken into consideration, the interfacial adhesion strength between the breathable skin layer laminated on both sides and the breathable material (hereinafter simply referred to as interfacial adhesion) 3N / 25 mm width or more is preferable in the final form in the 180 ° peel test. More preferably, the width is 5 N / 25 mm or more as the stable adhesiveness.

  When a perforated film layer that is stably bonded on the breathable material is formed, an effect similar to a so-called Helmholtz resonator is produced, and high sound absorption performance is exhibited.

  On the other hand, when the interfacial adhesive strength is 3 N / 25 mm or less, peeling easily occurs in the laminated skin material, which causes a problem as a product.

  Here, the 180 ° peel test is performed as follows.

(180 ° peel test)
Using a tensile tester, the air-permeable skin layer and the air-permeable material of the 25 mm-width laminated skin material sample piece are each chucked, and the air-permeable skin layer is 180 ° for 10 seconds under the conditions of 23 ° C. and peeling rate of 200 mm / min. The strength when peeled in the direction of. By using this method, in the laminated skin material, the breathable skin layer and the interface with the sheet or film provided with a through hole to provide air permeability, and the air permeable material and the through hole are provided with air permeability. One of the interfaces with the sheet or film will be peeled off. The average of the peak values of the time-stress curve obtained in the test is defined as the interfacial adhesive strength.

  Moreover, the sheet | seat in this application means a thing thicker than 200 micrometers, and a film means what has a thickness of 200 micrometers or less.

  In view of lightness, workability, moldability, etc., it is preferable to use a film, among which a film of 5 to 200 μm is preferable, and 10 to 50 μm is more preferable.

  If lightness and moldability are not required, a sheet or a film may be used, and there is no upper limit to the thickness.

  As used herein, the term “through hole” means that transmission of sound waves is not inhibited at the through hole portion. Specifically, the diameter of the through hole is preferably about 0.5 to 10 mm in the final form in terms of imparting high sound absorption performance.

  Specifically, the diameter of the through hole is preferably about 0.5 to 10 mm in the final form in terms of imparting high sound absorption performance. The pitch of the through holes is preferably about 0.5 to 100 mm. When the diameter of the through-hole is less than 0.5 mm, the intervening sheet or film acts on the incident sound wave as if it were substantially non-ventilated, but as described in the section of interposing a substantially non-ventilated film. Unlike the case, the interfacial adhesive strength is 3N / 25 mm width or more in the final form in the 180 ° peel test, the air-permeable skin layer and the air-permeable material are in one structure, and the film is substantially air-impermeable. Since the vibration and sound absorption of the sheet or film as described in the section of interposing the above does not occur, high sound absorption performance cannot be expected. In addition, when the hole diameter of the through hole is larger than 10 mm, the incident sound is equivalent to complete transmission when the pitch is reduced (equivalent to no film or sheet), and high sound absorption performance cannot be expected.

  As the material of the sheet or film (3) provided with air permeability by providing a through hole, for example, when the laminate for interior material is disposed at a site to be molded, it is made of resin from the point of workability. It is preferable to use a film. Examples of the resin constituting the film include polyolefin resins such as polyethylene resins, polypropylene resins and copolymers or modified products thereof, polystyrene resins, polyester resins, polyamide resins, polycarbonate resins, or , Polyvinyl chloride resin and copolymers thereof, or a mixture of thermoplastic elastomers. These may be a single layer or a multilayer in which a plurality of them are combined. Among these, a film made of a single layer polyethylene resin, polypropylene resin, polyamide resin, polyester resin and a copolymer or modified resin thereof is preferable from the viewpoint of low cost and moldability.

  As a method of interposing the air permeable sheet or film (3) by providing a through hole between the air permeable skin layer (1) and the air permeable material (2), an adhesive is used or a nonwoven fabric is used. Examples thereof include a needle punching process that is generally used for the above-described processing, a method in which the air-permeable layer is heat-sealed, and a method in which these methods are combined.

  Examples of adhesives include epoxy adhesives, silicone adhesives and urethane adhesives, and latexes of thermoplastic resins such as polystyrene and polybutadiene. In addition, a corona treatment may be applied to a sheet or film that is appropriately provided with air permeability by providing a through hole, thereby improving the adhesion.

  When performing a needle punching process, the needle punching used when processing a nonwoven fabric is used suitably. By using this method, the breathable skin layer (1), the breathable material (2), and the sheet or film (3) can be bonded, and at the same time, the sheet or film can be provided with air permeability by providing a through hole. It becomes.

  When the film or sheet is integrated between the breathable skin layer and the breathable material by heat fusion, heat fusion using a polyethylene or polypropylene film (including a copolymer or a modified product thereof) It is preferable to make it. Since these films melt and soften at around about 100 to 160 ° C., a strong interfacial adhesion can be obtained by simple heat treatment or thermoforming together with a base material for interior materials.

  In addition, when the multilayer skin material processed by needle punching is thermoformed together with a simple heat treatment or base material for interior materials, using the film as described above, if the number and pitch of needle punches are adjusted, With the through-holes (due to needle punching) that were originally uniformly dispersed by heating shrinkage of the film as the core, the uniformly-distributed through-holes are enlarged. For this reason, even a film having only a few through holes can be changed to a through hole suitable for sound absorbing performance. Therefore, it is most preferable to use the above-mentioned film and further a stretched film because not only the improvement of the interfacial adhesion but also the reduction of the processing steps and the weight reduction can be realized.

  The above intervening methods can be used in combination. For example, by performing heat sealing after needle punching, stronger interface adhesion can be obtained, and through holes can be provided more stably and easily.

  In addition, as a method for forming the through hole, the punching process or the needle punching process described above may be performed mechanically, or a hot spot may be contacted to open the melt.

  Next, any closed cell foamed laminated substrate may be used as long as it can be applied as an interior material. Specifically, in the case of an interior material such as a vehicle interior material, it is necessary to use a closed-cell foamed laminated base material made of a thermoplastic resin in view of light weight / rigidity, heat resistance, workability, moldability, and recyclability. good. For example, on both sides of a foamed layer made of polystyrene, polypropylene, polyphenylene ether, etc., a) polystyrene (PS) resin, b) polypropylene resin, c) polyphenylene ether (PPE) resin, and Among thermoplastic elastomer-based resins, there are those in which any one or more non-foamed layers are laminated.

  Among the above, from the viewpoints of processability, heat resistance, moldability, etc., at least one of the a) PS resin and c) PPE resin is provided on both sides of the foamed layer of the polyphenylene ether resin. What laminated | stacked the non-foamed layer is preferable.

  The closed cell ratio of the foam layer is preferably 70% or more, and more preferably 85% or more. If the closed cell ratio is less than 70%, the rigidity tends to be inferior as a practical characteristic of the closed cell foamed laminated base material.

  In addition to the closed-cell foamed laminated substrate, an open-cell foamed laminated sheet, a glass fiber sheet, and the like are suitably used as the interior material base material. For example, a foam laminated sheet in which glass fiber mats are laminated on both sides of a urethane foam core layer, and a sheet in which glass fibers are integrated with a heat fusion resin (for example, polyethylene, polypropylene, low melting point polyester, polyamide resin, etc.) It is done.

  As a method for laminating the multi-layer skin material to the base material for interior material, a method suitable for each application such as required adhesive strength, presence / absence of molding after lamination, house, car interior, etc. is adopted. For example, when used as an interior material for a vehicle or the like, a general lamination method can be adopted for the interior material for a vehicle. For example, a method of heat-sealing with a vehicle substrate via a hot melt film, a method of bonding via an epoxy adhesive, a silicone adhesive, a urethane adhesive, an acrylonitrile / butadiene latex, Lamination is performed by a method of bonding via styrene-butadiene latex, vinyl acetate latex, acrylate latex, or the like.

  When laminating an integrated multilayer skin material on a closed-cell foamed laminate substrate by providing a through-hole between the breathable skin layer and the breathable material and interposing a breathable sheet or film. Is a method of heat-sealing a thermoplastic resin layer for skin adhesion such as a hot melt film, a method of laminating and integrating via a urethane-based, silicone-based, epoxy-based adhesive or thermoplastic resin latex, A frame laminating method in which a breathable material is melt-softened and laminated on a sheet is used.

  When the obtained laminate for interior material is used as a ceiling material interior material for a vehicle such as an automobile, the multilayer material is formed by thermoforming with a multilayer skin material as an inner surface.

  The present invention will be described in more detail below based on examples, but the present invention is not limited thereto.

In addition, the measured value in each Example was measured with the following measuring method.
Interfacial adhesive strength: A 180 ° peel test was performed using an autograph (DSS2000) manufactured by Shimadzu Corporation.
Normal incident sound absorption coefficient: Measured using a normal incident sound absorption coefficient measuring device defined in ASTM-E-1050.

Example 1
Non-woven skin material (manufactured by Otsuka Co., Ltd.) having a basis weight of 130 g / m ² as the skin layer (1) and polyethylene terephthalate fiber having a fineness of 2 denier (2.2 decitex) and a cut length of 51 mm as the breathable material (2) (Toyobo Co., Ltd., type 707) 35% by weight, fineness 3 denier (3.3 decitex), cut length 51mm rayon (Daiwabo Rayon Co., Ltd., CD3.3 decitex x 51mm) 50% by weight and fineness A non-woven fabric having a basis weight of 150 g / m ² and a density of 0.075 g / cm ³ consisting of 15% by weight of a low-melting-point polyethylene terephthalate fiber (Toyobo Co., Ltd., type EE7) having a denier of 4 denier (4.4 decitex) and a cut length of 51 mm. As a film (3) provided with air permeability by providing a through hole in between, a hole diameter of 3 with a pitch of about 10 mm by punching Oriented nylon film having a thickness of 15μm was drilled m through hole of (Toyobo product Co., Harden Film N1101) to obtain a multi-layer skin material through. At this time, about 14 g / m ² of urethane adhesive was used in total on both sides of the nylon film.

  Next, a closed-cell foamed laminated substrate was produced as follows.

57.1 parts by weight of modified PPE resin (Noryl EFN4230 manufactured by GE Plastics Co., Ltd .: PPE component / PS component = 70/30 weight ratio) so as to be 40% by weight of PPE resin component and 60% by weight of PS resin component And 42.9 parts by weight of PS resin (A & M Styrene Co., Ltd. polystyrene G8102: 100% PS component) were mixed. For 100 parts by weight of the mixed resin, 3.6 parts by weight of a foaming agent (isobutane / n-butane = 85/15 weight ratio) mainly composed of isobutane and 0.32 parts by weight of talc are kneaded by an extruder. Extruded with a circular die and wound into a roll on a take-up roll via a take-up roll, primary thickness 2.4 mm, primary foaming ratio 14 times, closed cell rate 88%, average cell diameter 0.15 mm, basis weight 150 g / An m ² foam sheet was obtained.

Next, methacrylic acid-modified polystyrene (polystyrene G9001: PS component / methacrylic acid = 92/8 weight ratio manufactured by A & M Styrene Co., Ltd.) 50% by weight, high impact polystyrene (HIPS) (polystyrene H8117 manufactured by A & M Styrene Co., Ltd.) : PS component / rubber component = 87.5 / 12.5 weight ratio) and 50% by weight. While feeding out the foam sheet from a roll, the mixed resin was melted and kneaded with an extruder so that the resin temperature was 245 ° C., and extruded into a film using a T-die. On the other hand, as a nonwoven fabric for preventing abnormal noise, a water needle punch nonwoven fabric (Cereth S8020 manufactured by Yuhou Co., Ltd.) having a surface weight of 25 g / m ² is supplied, and a film-like non-foamed layer is formed into a foam sheet and a water punch in a molten state. Lamination was performed by sandwiching with a non-woven fabric to form a heat-resistant PS-based outdoor non-foamed layer having a basis weight of 150 g / m ² .

Next, PPE resin (Noryl EFN4230 manufactured by GE Plastics Co., Ltd .: PPE component / PS component = 70/30 weight ratio) so as to be 20% by weight of PPE resin component and 80% by weight of PS resin component. .6 parts by weight and 71.4 parts by weight of PS resin (A & M Styrene Co., Ltd. polystyrene G8102: 100% PS component) were mixed. The mixed resin was melted and kneaded with an extruder so that the resin temperature was 265 ° C. on the back surface side of the laminated surface, and extruded into a film using a T-die. On the other hand, as the skin adhesive layer, a 30 μm hot melt film (Hirodine 7586, manufactured by Oishi Sangyo Co., Ltd.) is supplied, and a non-foamed layer in the form of a film is sandwiched between the foamed sheet and the hot melt in a molten state, A modified PPE indoor side non-foamed layer having a basis weight of 120 g / m ² was formed. Thus, the primary raw material of the closed cell type foaming lamination base material was produced.

  Laminating the multilayer skin material on the indoor side surface of the primary fabric obtained as described above, heating the skin material surface heating temperature to about 155 ° C, the outdoor surface heating temperature to about 140 ° C, A laminate for interior material was obtained by molding press.

Example 2
As a film (3) provided with air permeability by providing a through hole, a polyethylene hot melt film having a thickness of 30 μm with a hole diameter of about 10 mm and a hole diameter of 5 mm by punching (OS film manufactured by Oishi Sangyo Co., Ltd.) : A laminate for interior material was obtained in the same manner as in Example 1 except that polyethylene resin 98 / tacking agent = 98/2, surface area 30 g / m ² ) was used.

Example 3
As a film (3) in which through-holes are provided between the skin layer and the breathable material similar to those used in Example 1, the through-holes have a pitch of about 10 mm and a hole diameter of 3 mm by punching. 30 μm thick polyethylene hot melt film (OSHI manufactured by Oishi Sangyo Co., Ltd .: Polyethylene resin 98 / tack agent = 98/2, surface area 30 g / m ² ) with three layers of banok pins A three-layer skin material was obtained by temporarily fixing. By passing the obtained three-layer skin material through a heat roller, the hot melt film in the three-layer skin material was melted and softened to obtain a multilayer skin material in which the three layers were integrated.

  Next, a laminate for interior material was obtained in the same manner as in Example 1.

Example 4
Between the skin layer similar to that used in Example 1 and a breathable material, a non-vented 30 μm thick polyethylene hot melt film (OS film manufactured by Oishi Sangyo Co., Ltd .: polyethylene resin 98 / tack) By applying needle punching through the agent = 98/2, surface area 30 g / m ² ), the skin layer and the breathable material are integrated to obtain a three-layer skin material, and at the same time, the pore diameter is 1 mm in the breathable layer. Through holes with a pitch of about 10 mm were provided. Hot air was blown onto the obtained three-layer skin material, and then passed through a pressure roller to obtain a multilayer skin material.

  Next, a laminate for interior material was obtained in the same manner as in Example 1.

Example 5
A non-stretched nylon film (Toray Synthetic Film) with a thickness of 20 μm between a 130 g / m ² non-woven skin material (D01A skin material) manufactured by Otsuka Co., Ltd. and a breathable material similar to that used in Example 1 A three-layer structure interposing a product manufactured by Rayfan Co., Ltd. (type 1401) is subjected to needle punching by adjusting the number of needle punches and the needle stroke to obtain a multi-layer skin material, and at the same time, the pore diameter is about the breathable layer. A through hole of 0.5 mm and 80 holes / cm ² was provided.

  Next, the obtained multilayer skin material was left in an oven at 180 ° C. for 10 minutes for heat treatment.

Comparative Example 1
By heating and pressing the primary raw material of the closed-cell foamed laminated base material similar to that prepared in Example 1 so that the indoor and outdoor surface heating temperatures are about 140 to 150 ° C. A molded body of the closed cell foamed laminated base material was obtained.

Comparative Example 2
Only the same skin layer as used in Example 1 was laminated on the primary raw material of the closed cell foam laminated base material similar to that produced in Example 1, and the skin material surface heating temperature was about 155 ° C., It heated so that the outdoor surface heating temperature might be about 140-150 degreeC, and it press-molded, and obtained the laminated body for interior materials.

Comparative Example 3
A two-layer skin material integrated by needle punching the same skin layer and breathable material as used in Example 1 was obtained.

  Next, a laminate for interior material was obtained in the same manner as in Example 1.

Comparative Example 4
Between the same skin layer as used in Example 1 and the breathable material, a polyethylene hot melt film having a thickness of 30 μm (OS film manufactured by Oishi Sangyo Co., Ltd .: polyethylene resin 98 / tack agent = 98 / 2. The structure was integrated through a surface weight of 30 g / m ² ) to obtain a multilayer skin material. At this time, about 14 g / m ² of urethane adhesive was used in total on both sides of the hot melt.

  Next, a laminate for interior material was obtained in the same manner as in Example 1.

Comparative Example 5
Between the same skin layer as used in Example 1 and the breathable material, a polyethylene hot melt film having a thickness of 30 μm (OS film manufactured by Oishi Sangyo Co., Ltd .: polyethylene resin 98 / tack agent = 98 / 2 and a surface area of 30 g / m ² ) were interposed, and the three layers were temporarily fixed with a Bannock pin to obtain a three-layer skin material. The obtained three-layer skin material was heat-sealed by passing through a heat roller and integrated to obtain a multilayer skin material. The hot melt film in the multilayer skin material maintained a non-ventilated state.

  Next, a laminate for interior material was obtained in the same manner as in Example 1.

  Table 1 shows the structures and interfacial adhesive strengths of the samples prepared in Examples and Comparative Examples. Moreover, the measurement result of a sound absorption coefficient is shown in Table 2 and FIGS.

  In Examples 1 to 5, the sound absorption performance was superior to those of Comparative Examples 1 to 5, particularly in the middle to high frequency range of 4000 Hz or higher. Further, in Examples 1 to 4 in which the interfacial adhesive strength was 3N or more, the sound absorbing performance was particularly excellent.

It is a graph showing the sound absorption characteristic of the laminated body manufactured in Examples 1-5. It is a graph showing the sound absorption characteristic of the laminated body manufactured by Comparative Examples 1-5.

Claims (10)

(1) A multilayer skin material in which (3) a sheet or film provided with a through hole is provided between a breathable skin layer and (2) a breathable material, thereby providing breathability. The multilayer skin material according to claim 1, wherein the sheet or film (3) is interposed via (4) an adhesive layer. The multilayer skin material according to claim 1, wherein the sheet or film (3) is interposed by needle punching. The multilayer skin material according to claim 1, 2 or 3, wherein the sheet or film (3) is interposed by heat fusion. The interfacial adhesive strength between the sheet or film (3), the breathable skin layer (1) and the breathable material (2) is 3 N / 25 mm width or more in a 180 ° peel test. The multilayer skin material described. The multilayer skin material according to claim 1, 2, 3, 4 or 5, wherein the sheet or film (3) comprises a thermoplastic resin film. The multi-layer skin material according to claim 1, wherein the sheet or film (3) is a polyolefin-based film. The multilayer skin material according to claim 1, 2, 3, 4, 5, 6 or 7, wherein the sheet or film (3) comprises a stretched film. The laminated body for interior materials formed by laminating | stacking the multilayer skin material of Claim 1, 2, 3, 4, 5, 6, 7, or 8 on a closed cell foaming laminated base material. The laminate for an interior material according to claim 9, wherein the closed-cell foamed laminate is made of a polyphenylene ether resin.

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