JP2007301774A - Base material for car trim material and car trim material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a base material for a car trim material excellent in glass free lightweight properties, recyclability and heat resistance, further improved in combustibility or sound absorbing characteristics and excellent in high temperature adhesion stability using a foamed laminated sheet based on a modified PPE resin, and a car trim material produced by molding the base material for the car trim material. <P>SOLUTION: A single-layer skin material as a skin material becoming a design surface or a multilayered fiber on the back of an air permeable skin material is arranged on the foamed laminated sheet, which is produced by laminating a non-foamed layer comprising a thermoplastic resin on both sides of a foamed layer based on a modified polyphenylene ether resin, to obtain a base material for the car trim material and a car trim material having the above mentioned characteristics. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a vehicle interior material and a vehicle interior material based on a modified polyphenylene ether resin foam layer obtained by laminating a single layer skin material or a laminated skin material having excellent sound absorption characteristics.

  In the field of interior materials used for vehicles such as automobiles, it is desired to provide sound absorption characteristics in pursuit of comfort in the vehicle. On the other hand, inexpensive non-woven fabric skin materials are frequently used for the design of interior materials, but it is technically difficult to impart sound absorption characteristics to the non-woven fabric skin materials.

  Then, although it is expensive, the laminated body which consists of porous materials, such as a slab urethane, and a breathable skin material is used (patent document 1). However, since it is a dissimilar material as described above and a thermosetting resin, the laminate is not only expensive but also difficult to recycle.

  Furthermore, in recent years, development of a sound absorbing material having an improved fiber structure has been promoted. For example, sound absorption is imparted by reducing the fiber diameter (Patent Document 2). However, by reducing the fiber diameter, there is a problem that processability is lowered and coloring by coloring is difficult.

  Moreover, in order to improve the performance as a sound-absorbing material for vehicles, the technique which laminates | stacks the low density nonwoven fabric material which is bulky and flexible on an outer skin is disclosed (patent document 3). However, it is not possible to obtain sufficiently satisfactory sound absorption characteristics by simply laminating a low-density nonwoven fabric in which fibers are randomly oriented on a skin material such as tricot cloth, so further improvement is desired.

However, the term “random orientation” as used herein means that the plane rate and cross rate defined below are not adjusted.
The plane rate is the ratio of fibers arranged in multiple layers in the plane direction. As the measurement method, cut the laminated skin material, take a SEM photograph in the cross section of the multilayer fiber part, and place the vertical line on the plane with the thickness direction up and down at an arbitrary place of the square with the thickness of the multilayer fiber part as one side. A horizontal line is drawn in a cross, the number of fibers intersecting the vertical line and the horizontal line is counted (a is the number of fibers intersecting the vertical line, and b is the number of fibers intersecting the horizontal line), and the following formula is calculated. (However, when calculating, measure at five or more locations and take the average value.)

  The cross rate is the ratio of fibers arranged crossing the fibers in the length direction of the skin material, and the fiber amount Q supplied in the flow (longitudinal) direction of the fiber laminate forming the multilayer fiber body, The fiber crossing state was defined as a ratio to the fiber amount P supplied from the direction (width direction) perpendicular to the flow direction. (However, in the case where all the fiber supplies differed from the flow direction, Q was the closest to the length direction of the multilayer fiber body, and P was the other).

  Moreover, although patent document 3 is content to combine the dissimilar material of skin materials, such as a tricot cloth, and a low density nonwoven fabric, the combination of a dissimilar material inevitably raises cost.

  For this reason, it is desirable to combine the same kind of materials as much as possible to reduce the cost and to further improve the sound absorption characteristics.

  For these purposes, when combining a non-woven skin material and the same type of non-woven fabric, considering the dimensional stability, structural rigidity, cost, etc. Inevitably, needle punching without adjusting the flatness is often performed. However, if this needle punching process is performed, the fibers will stand in the thickness direction as a result, resulting in an increase in the vertical transmission of incident sound. Furthermore, even in the laminating process in which these two types of non-woven fabrics thus produced are laminated to produce a laminated skin material having excellent sound absorption characteristics, this laminating process is also considered in view of its adhesiveness, cost, and processability. Inevitably, needle punching is performed. If it does so, since a fiber will stand still in the thickness direction, it will result in increasing the perpendicular permeability | transmittance of incident sound still more. For these reasons, it was a limitation of the prior art that an effective improvement in sound absorption characteristics could not be expected even when trying to obtain a laminated skin material having excellent sound absorption characteristics using a non-woven fabric whose flatness was not adjusted.

On the other hand, a sheet in which glass fibers are laminated on urethane foam or a laminated sheet in which glass fibers are mixed or laminated on polypropylene resin are widely used as a base material for automobile interior materials and automobile interior materials. These automobile ceiling materials are characterized by excellent moldability and heat resistance. However, the conventional automobile ceiling materials as described above have a problem in environmental compatibility (that is, recyclability, particularly thermal recyclability) because glass fiber is used as a constituent material. Furthermore, since these composite materials use glass fibers, they are inferior in environmental compatibility also in terms of an increase in CO ₂ amount due to a reduction in weight and an increase in fuel efficiency.

  In order to solve such problems, a lightweight and heat-resistant modified polyphenylene ether resin (hereinafter referred to as “modified PPE resin”) foamed laminate in which a modified PPE resin non-foamed layer is laminated on both sides of a foamed layer. A foamed laminated sheet for automobile ceiling materials using a sheet has been proposed (Patent Document 4). The foamed laminated sheet for automobile ceiling materials using this modified PPE resin is not only excellent in heat resistance and light weight, but also made of glass-free material, so it is highly recyclable and environmentally friendly. As proposed.

  Furthermore, flame retardant regulations are imposed on automobile interior materials in order to ensure the safety of persons left behind in the event of a fire. However, when a heat-resistant resin foam laminate sheet such as the above-mentioned modified PPE resin foam laminate sheet is used as a ceiling material, it is glass-free, and thus various means for obtaining flame retardancy that meets the regulations. However, a more environmentally friendly, cheap and effective solution has not yet been found.

  Then, although the method of adding a flame retardant to a lamination sheet was examined, manufacture is complicated and causes a raise of material cost and manufacturing cost. In Patent Document 5, a method using natural fibers is disclosed, but in order to obtain the current flame retardancy, it is necessary to use a flame retardant thermoplastic resin coating. In addition to the contrary results, it leads to an increase in material costs and manufacturing costs.

  In the recent strong demand for environmental compatibility, the appearance of a glass-free and good flame retardancy is expected.

  In addition, an automobile interior material molded using a modified PPE-based foam laminated sheet frequently uses a polyolefin-based hot melt adhesive as an inexpensive and moderately heat-resistant adhesive when laminating a skin material. . Polyolefin-based hot melt adhesives are those in which the base resin polyolefin resin maintains adhesion to various skin materials. On the other hand, in automobile interior base materials, amide-based or ester-based additives are used as adhesives. By blending with, the adhesion to the skin material at a relatively high temperature is maintained. However, the polyolefin-based hot melt adhesive has not been able to obtain adhesion with a skin material that can withstand a high temperature of about 100 ° C.

  Furthermore, recently, the quietness in the car has been highlighted as the engine noise of the car decreases and the soundproofing effect in the car improves. However, when a heat-resistant resin foam laminate sheet such as the modified PPE resin foam laminate sheet is mounted on an automobile as an automobile interior material, when the interior of the vehicle is rapidly cooled with a cooler or the like, or when traveling on an uneven road surface, There was a problem that abnormal noise was generated when traveling on a sharp curve. In order to solve this problem, urethane foam sheets are pre-laminated on ceiling interior materials or craft tape is applied during molding of automotive interior materials. Is complicated, and causes an increase in material cost and manufacturing cost. Therefore, the emergence of alternative methods is expected.

As described above, the present situation is that no material that can satisfy all of these required qualities has been found, and the appearance of a new material is expected.
JP 55-11947 A JP-A-6-122349 JP-A-14-215169 Japanese Utility Model Publication No. 4-11162 Japanese Examined Patent Publication No. 4-81505

  The object of the present invention is excellent in glass-free lightweight, recyclability and heat resistance by a foamed laminated sheet based on a modified PPE resin, improved in flame resistance or sound absorption characteristics, and excellent in high temperature adhesion stability. An automobile interior material base material and an automobile interior material formed by molding the automobile interior material base material are provided.

  As a result of diligent research to solve the above problems, the present inventor has obtained a mixed resin of a polyphenylene ether resin (hereinafter referred to as “PPE resin”) and a polystyrene resin (hereinafter referred to as “PS resin”). On both sides of the foamed layer obtained by extrusion foaming using a modified polyphenylene ether resin (hereinafter referred to as “modified PPE resin”) as a base resin and a specific hydrocarbon foaming agent as a foaming agent, Use a laminated foam sheet in which a non-foamed layer containing a rubber component is contained in a heat-resistant resin having a glass transition temperature lower than that of the foamed layer base resin, and as a skin layer, on the back of a single-layer skin material or a breathable skin material By laminating a laminated skin material that achieves both practical characteristics and sound absorption characteristics by laminating multilayer fiber bodies with adjusted fiber structures, it is glass-free, lightweight, recyclable, and Excellent heat resistance, found that it is possible fire retardant or sound-absorbing properties to obtain a more improved automobile interior material for a base material and an automobile interior material, thereby completing the present invention.

That is, the present invention
A laminated foam sheet made by laminating a non-foamed layer on both sides of a modified polyphenylene ether-based resin foam layer, and a skin material is laminated on the indoor non-foamed layer via an adhesive layer, and abnormal noise is generated on the outdoor non-foamed layer. A base material for automobile interior materials, in which a prevention layer is laminated,
The modified polyphenylene ether resin foam layer is a modified polyphenylene ether resin, which is a mixed resin of 25 to 70 parts by weight of a polyphenylene ether resin and 75 to 30 parts by weight of a polystyrene resin, and the modified polyphenylene resin. It is a foam sheet obtained by extrusion foaming using 2 to 5 parts by weight of a hydrocarbon-based foaming agent with respect to 100 parts by weight, and having a thickness of 1 to 5 mm and a foaming ratio of 3 to 20 times.
The non-foamed layer is a non-foamed layer having a thickness of 50 to 300 μm containing 0.3 to 15 parts by weight of a rubber component with respect to 100 parts by weight of a heat-resistant resin having a glass transition temperature Tg lower than that of the base resin of the foamed sheet. ,
The skin material is a single-layer skin material having a basis weight of 100 to 300 g / m ² including synthetic fibers and regenerated fibers, or at least one surface of a breathable skin material, and fibers containing synthetic fibers and regenerated fibers are layered in layers. It is a laminated skin material having a basis weight of 100 to 300 g / m ² , in which multilayer fiber bodies obtained by forming in an arranged state are laminated,
And abnormal noise prevention layer is a polyester non-woven fabric of polyolefin film having a basis weight 10 to 100 g / m ² or a basis weight 10 to 60 g / m ^2, automotive interior materials for substrate (claim 1),
The ratio of the fibers arranged in multiple layers in the plane direction (plane rate) of the multilayer fiber body in the laminated skin material is 50% or more, and the fibers arranged crossing the fibers in the length direction of the skin material The ratio (cross rate) is 50 to 200%,
And the base material for automotive interior materials (Claim 2) according to claim 1, which is a multilayer nonwoven fabric comprising 80 to 20% by weight of polyester fiber and 20 to 80% by weight of natural fiber or recycled fiber.
The base material for automobile interior materials according to claim 1, wherein the single-layer skin material is a single-layer nonwoven fabric containing 85 to 98% by weight of polyester fibers and 15 to 2% by weight of rayon fibers (claim 3),
The automobile interior according to any one of claims 1 to 3, wherein the adhesive layer for laminating the laminated skin material is a polystyrene resin, a styrene-butadiene copolymer resin, or a carboxy-modified styrene-butadiene copolymer resin. Base material for materials (claim 4),
The base material for automobile interior materials according to any one of claims 1 to 4, wherein the hydrocarbon-based blowing agent is isobutane (claim 5),
The base material for automobile interior materials according to any one of claims 1 to 5, wherein the heat-resistant resin constituting the non-foamed layer is a heat-resistant polystyrene resin and / or a modified polyphenylene ether resin (Claim 6).
The base material for automobile interior materials according to any one of claims 1 to 6, wherein the rubber component content in the indoor non-foamed layer is less than the rubber component content in the outdoor non-foamed layer (claim). 7),
The base for an automobile interior material according to any one of claims 1 to 7, wherein a rubber component content in the indoor non-foamed layer is 0.3 to 3 parts by weight with respect to 100 parts by weight of the heat resistant resin. Material (claim 8),
The base material for automobile interior materials according to any one of claims 1 to 8, wherein the polyester-based nonwoven fabric as the noise prevention layer is laminated by an anchor effect to the non-foamed layer resin (claim 9), And it is related with the motor vehicle interior material (claim 10) formed by shape | molding the base material for motor vehicle interior materials of any one of Claims 1-9.

  The base material for automotive interior materials of the present invention is a single-layer skin material or indoors through a thermoplastic resin having compatibility with a foamed laminated sheet based on a modified polyphenylene ether resin having heat resistance. This is an all-plastic material made by laminating laminated skin materials that retain appropriate sound absorption characteristics (especially on the high frequency side) to ensure quietness, and is excellent in lightness, recyclability, and heat resistance. (Especially on the high frequency side) is improved, and various properties required for automobile interior materials are satisfied.

  The base material for automobile interior materials and the automobile interior material having excellent sound absorption characteristics according to the present invention will be described with reference to the drawings.

  FIG. 1 shows a configuration of a base material for automobile interior material according to an embodiment of the present invention, and a foamed layer using a modified PPE resin, which is a mixed resin of a PPE resin and a PS resin, as a base resin. 10, non-foamed layers (indoor side non-foamed layer 12 and outdoor non-foamed layer 14) made of a thermoplastic resin are laminated, and a thermoplastic resin adhesive layer 22 is interposed on the surface of the indoor side non-foamed layer 12. Thus, the single-layer skin material 27 is laminated, and the noise prevention layer 18 is laminated on the surface of the outdoor non-foamed layer 14.

  FIG. 2 shows a configuration of a base material for automobile interior material according to an embodiment of the present invention, and a foamed layer using a modified PPE resin, which is a mixed resin of a PPE resin and a PS resin, as a base resin. 10, non-foamed layers (indoor side non-foamed layer 12 and outdoor non-foamed layer 14) made of a thermoplastic resin are laminated, and a thermoplastic resin adhesive layer 22 is interposed on the surface of the indoor side non-foamed layer 12. Thus, a laminated skin material 26 composed of the breathable skin material 20 and the multilayer fiber body 24 is laminated, and the noise preventing layer 18 is laminated on the surface of the outdoor non-foamed layer 14.

  FIG. 3 shows the configuration of an automotive interior material base material and an automotive interior material according to an embodiment of the present invention, and a modified PPE resin, which is a mixed resin of a PPE resin and a PS resin, is used as a base resin. A non-foamed layer (indoor non-foamed layer 12 and outdoor non-foamed layer 14) made of a thermoplastic resin is laminated on both surfaces of the foamed layer 10 and a thermoplastic resin adhesive is formed on the surface of the indoor non-foamed layer 12. A laminated skin material 26 composed of a breathable skin material 20 and a multilayer fiber body 24 is laminated via the layer 22, and an abnormal sound preventing layer 18 is laminated on the surface of the outdoor non-foamed layer 14 via the adhesive layer 16. It becomes.

  Examples of the PPE resin in the modified PPE resin used as the base resin for the foamed layer 10 in the present invention include poly (2,6-dimethylphenylene-1,4-ether) and poly (2-methyl-). 6-ethylphenylene-4-ether), poly (2,6-diethylphenylene-1,4-ether), poly (2,6-diethylphenylene-1,4-ether), poly (2-methyl-6- 6) n-propylphenylene-1,4-ether), poly (2-methyl-6-n-butylphenylene-1,4-ether), poly (2-methyl-6-chlorophenylene-1,4-ether), And poly (2-methyl-6-bromophenylene-1,4-ether), poly (2-ethyl-6-chlorophenylene-1,4-ether), and the like. These may be used alone or in combination of two or more. Used together look.

  The PS resin in the modified PPE resin used as the base resin for the foam layer 10 in the present invention is styrene or a derivative thereof such as α-methylstyrene, 2,4-dimethylstyrene, monochlorostyrene, dichlorostyrene, It is a resin mainly composed of p-methylstyrene, ethylstyrene or the like. Therefore, the PS-based resin is not limited to a homopolymer composed only of styrene or a styrene derivative, but may be a copolymer obtained by copolymerizing with another monomer.

  Specific examples of the styrene monomer that is polymerized on the PPE resin, preferably graft polymerized, include styrene, α-methylstyrene, 2,4-dimethylstyrene, monochlorostyrene, dichlorostyrene, p- Examples include methyl styrene and ethyl styrene. These may be used alone or in combination of two or more. Of these, styrene is preferred from the viewpoint of versatility and cost.

  The mixing ratio of the PPE resin and the PS resin of the modified PPE resin that is the base resin used for the foamed layer 10 in the present invention (the total of the PPE resin and the PS resin is 100 parts by weight) is PPE. 25 to 70 parts by weight of resin and 75 to 30 parts by weight of PS resin are preferable, 35 to 60 parts by weight of PPE resin and 65 to 40 parts by weight of PS resin are more preferable, 38 to 58 parts by weight of PPE resin and PS 62 to 42 parts by weight of a resin is more preferable. When the amount of PPE resin in the modified PPE resin is less than 25 parts by weight, heat resistance tends to be inferior. When the amount of PPE resin is more than 70 parts by weight, the viscosity at the time of heating flow increases and foam molding is difficult. Tend to be.

  The foaming agent used when obtaining the foamed layer 10 of the present invention is preferably a hydrocarbon-based foaming agent, for example, ethane, propane, butane, isobutane, pentane, methyl chloride, dichloromethane, chlorofluoromethane, dichloroethane, dichloromethane. Difluoroethane and the like. Among these, it is preferable that KB value which shows the solubility of foaming agents, such as ethane, propane, butane, and pentane, is 20-50. In particular, isobutane and a mixture of isobutane and normal butane with a high ratio of isobutane have a low foaming agent's moderate solubility and low dissipation of the foaming agent. Is preferable because of its small size.

  Moreover, what was made into the said range by mixing suitably 2 or more types of things with a high and low KB value than this range can also be used. It is preferable that the usage-amount of the hydrocarbon type foaming agent at the time of obtaining the foaming layer 10 of this invention is 2-5 weight part with respect to 100 weight part of modified PPE-type resin. If the amount of the hydrocarbon-based foaming agent used is less than 2 parts by weight, the secondary foaming ratio at the time of molding may be too low, which tends to affect obtaining good moldability. When exceeding, extrusion foaming tends to become unstable, or the surface of the foamed sheet tends to be rough.

  As thickness of the modified PPE resin foam layer 10 (primary foam layer) in this invention, 1-5 mm is preferable and 1.5-3.5 mm is more preferable. If the thickness of the primary foamed layer is less than 1 mm, the strength and heat insulating properties are inferior and may not be suitable as a foamed laminated sheet for automobile interior materials. On the other hand, if it exceeds 5 mm, foaming (secondary foaming) occurs when heat is applied during molding heating, but it is difficult to transmit to the central portion in the thickness direction of the foamed layer 10, so that sufficient heating cannot be performed and moldability deteriorates. There is a case. In addition, if the heating time is extended to perform sufficient heating, bubbles on the surface of the foam layer are generated, and it may be difficult to obtain an acceptable product.

  The expansion ratio of the modified PPE resin foam layer 10 (primary foam layer) in the present invention is preferably 3 to 20 times, and more preferably 5 to 15 times. When the expansion ratio of the primary foam layer is less than 3 times, the flexibility is inferior, and there is a tendency that damage due to bending or the like tends to occur, and the effect of reducing the weight is small. When the expansion ratio of the primary foam layer exceeds 20 times, the strength tends to decrease or the moldability tends to decrease because it is difficult to heat to the center.

  The closed cell ratio of the modified PPE resin foam layer 10 (primary foam layer) in the present invention is preferably 70% or more, and more preferably 80% or more. When the closed cell ratio is less than 70%, the heat insulation and rigidity are inferior, and it is difficult to obtain the desired secondary foaming ratio by molding heating, and the moldability tends to be inferior.

  The cell diameter of the modified PPE resin foam layer 10 (primary foam layer) in the present invention is preferably 0.05 to 0.9 mm, more preferably 0.1 to 0.7 mm. If the cell diameter is less than 0.05 mm, sufficient strength tends to be difficult to obtain, and if it exceeds 0.9 mm, the heat insulation tends to be poor.

The amount of residual volatile components in the foamed layer 10 (primary foamed layer) in the present invention is preferably 1 to 5% by weight, more preferably 2 to 4% by weight based on the total weight of the foamed layer. If the residual volatile component amount is less than 1% by weight, the secondary foaming ratio may be too low, which may affect the obtaining of good moldability. On the other hand, if the residual volatile component amount exceeds 5% by weight, there is a tendency for air accumulation to occur between the non-foamed layer and dimensional stability over time.
The amount of residual volatile components may be measured by gas chromatography, but usually the temperature of the foamed layer test piece is not less than the temperature at which the modified PPE resin begins to soften and not more than the decomposition temperature of the modified PPE resin. By heating in the range, the volatile components are sufficiently volatilized and can be measured by the weight difference before and after heating.

  The base resin of the foamed layer 10 used in the present invention includes, as necessary, a bubble regulator, impact resistance improver, lubricant, antioxidant, antistatic agent, pigment, stabilizer, odor reducing agent, etc. May be added.

  Non-foamed layers 12 and 14 of thermoplastic resin are laminated on both surfaces of the foamed layer 10 in the base material for automobile interior materials according to the present invention. Among these non-foamed layers 12 and 14, the indoor non-foamed layer 12 functions to suppress the heat shrinkage of the laminated skin material 26 laminated on one surface thereof, and the foamed layer 10 on the other surface is formed during molding. The stretched and flattened cell has a function of suppressing heat shrinkage caused by changing the shape in a direction in which the flattening rate is canceled during heating. The outdoor non-foamed layer 14 has a function of suppressing the heat shrinkage of the foamed layer 10.

  Here, the heat shrinkage of the foam layer 10 is greatly influenced by the cell shape, the change in the cell internal pressure due to curing, the closed cell ratio, the heating temperature, and the like, and it is very difficult to control the shrinkage. However, since the deformation of the molded body at a high temperature greatly depends on the heat shrinkage of the foamed layer 10, the heat shrinkage of the foamed layer 10 is suppressed by the non-foamed layers 12 and 14 laminated on both surfaces of the foamed layer 10. Is important.

  On the other hand, in the non-foamed layer of the present invention, the non-foamed layer 12 or 14 is cracked when punched when a secondary foamed laminated sheet is molded as an automobile interior material or when the laminated sheet or molded product is transported. From the viewpoint of preventing the above, a rubber component is contained. The content of the rubber component in the non-foamed layer is preferably 0.3 to 15 parts by weight, more preferably 0.4 to 13 parts by weight, and 0.6 to 11 parts by weight with respect to 100 parts by weight of the heat resistant resin. Further preferred.

  As the rubber component in the present invention, rubbers such as natural rubber and synthetic rubber, and those obtained by graft polymerization of a monomer having an olefin double bond such as styrene and methyl methacrylate around rubber particles are suitably used. Is done. Specific examples of rubber include, for example, styrene-butadiene rubber, hydrogenated styrene-butadiene rubber, butadiene rubber, isoprene rubber, ethylene-propylene copolymer, ethylene-propylene-diene copolymer, acrylonitrile-butadiene copolymer, Examples include chloroprene rubber, butyl rubber, acrylic rubber, and ethylene-acrylic rubber. These may be used alone or in combination of two or more. Among these, styrene-butadiene rubber and hydrogenated styrene-butadiene rubber are preferable from the viewpoint of high compatibility with PS resin, heat-resistant PS resin, and modified PPE resin and versatility.

  In the present invention, in order to control the heat shrinkage rate of the foamed layer 10, the non-foamed layer is more effective as the rigidity increases, and the rigidity of the non-foamed layers 12 and 14 depends on the amount of rubber component contained in the non-foamed layer. There is a tendency that it becomes larger as there is less.

  However, if the amount of the rubber component contained in the non-foamed layer is reduced, the impact resistance is deteriorated. Therefore, it is important to adjust the amount of the rubber component in the non-foamed layer.

  The rubber content of the heat-resistant resin constituting the non-foamed layer in the present invention is different between the indoor non-surface layer 12 and the outdoor non-surface layer 14, and the rubber content of the indoor non-surface layer 12 is determined. Is preferably less than the rubber content of the outdoor non-surface layer 14.

  That is, since the outdoor non-foamed layer 14 is not laminated with a cushioning material such as a skin material, if the impact resistance is deteriorated by reducing the amount of the rubber component, there arises a problem such as generation of cracks during trimming. For this reason, an appropriate amount of rubber component is required for the outdoor non-foamed layer 14.

  In contrast, in the indoor non-foamed layer 12, a laminated skin material 26 is laminated via a thermoplastic resin adhesive layer 22, and the laminated skin material 26 serves as a cushioning material. Even if it is not included, there is no problem such as generation of cracks during trimming. Here, the phrase “substantially free of rubber component” means that the rubber component is contained within a range that satisfies the above effects, for example, 0.3 to 3 parts by weight, preferably 0.3% by weight or more. It is less than 1.5% by weight, more preferably 0.3% by weight or more and less than 0.8% by weight.

  On the other hand, it is considered that the deformation of the molded body at a high temperature also occurs due to relaxation of residual strain existing in the non-foamed layers 12 and 14. In order to reduce the residual strain of the non-foamed layers 12 and 14, it is considered effective to increase the molding temperature and to reduce the heat resistance of the non-foamed layers 12 and 14, but when the molding temperature is increased, There is a possibility that bubble breakage may occur in the foamed layer 10, surface roughening or peeling of the non-foamed layer may occur. Further, if the heat resistance of the non-foamed layers 12 and 14 is lowered, it may be difficult to control the shrinkage of the foamed layer.

  On the other hand, in the present invention, by setting the glass transition temperature of the non-foamed layers 12 and 14 to a temperature lower than the glass transition temperature of the foamed layer 10, a laminated sheet having further excellent moldability and heat resistance can be obtained. Can be obtained.

  Here, the lower the glass transition temperature of the non-foamed layers 12 and 14 with respect to the foamed layer 10 depends on the heat-resistant temperature required for the obtained automobile interior material base material and the base material. The temperature is appropriately set depending on the molding temperature and molding method.

  Examples of the thermoplastic resin used for the non-foamed layers 12 and 14 in the present invention include PS resins, heat-resistant PS resins, modified PPE resins, and the like. These may be used alone or in combination of two or more. From the viewpoint of adhesion to the base resin of the foam layer 10, a modified PPE resin and a heat-resistant PS resin are preferably used.

  In the present invention, the indoor non-foamed layer 12 and the outdoor non-foamed layer 14 may be thermoplastic resins made of the same base resin, or may be thermoplastic resins made of different base resins. For example, the indoor non-foamed layer 12 and the outdoor non-foamed layer 14 are both required to be a PPE resin, or the indoor non-foamed layer 12 is a heat-resistant PS resin and the outdoor non-foamed layer 14 is a PPE resin. It is appropriately selected depending on the performance and cost.

  Of the resins constituting the non-foamed layer, for example, a modified PPE resin is used as the indoor non-foamed layer 12, a heat-resistant PS resin is used as the outdoor non-foamed layer 14, and a modified PPE resin is used as the foamed layer 10. In this case, the glass transition temperature of the indoor non-foamed layer 12 and the outdoor non-foamed layer 14 is preferably 5 ° C. to 50 ° C. of the glass transition temperature of the foamed layer 10.

  When a modified PPE resin is used as the indoor non-foamed layer 12 in the present invention, as in the case of the foamed layer 10 described above, a monomer mainly composed of a styrene compound or a polymer thereof with respect to the PPE resin. For example, a mixed resin of a PPE resin and a PS resin, a PPE-styrene copolymer obtained by polymerizing a styrene monomer on a PPE resin, Examples thereof include a mixture of a coalescence and a PS resin or a PPE resin, a mixture of the copolymer, a PPE resin, and a PS resin. Among these, a mixed resin of a PPE resin and a PS resin is preferable from the viewpoint of easy production.

  Specific examples and preferred examples of these PPE resins, PS resins or styrene monomers, specific examples of monomers that can be polymerized with PS resins and styrene monomers, the reasons for using them, This is the same as described for the foamed layer 10. However, as a preferable specific example of the PS resin, a styrene-butadiene copolymer represented by high impact polystyrene (HIPS) is preferable because the impact resistance improving effect of the non-foamed layers 12 and 14 is large.

  When a heat resistant PS resin is used as the outdoor non-foamed layer 14 in the present invention, the heat resistant PS resin used is a copolymer of styrene or a derivative thereof and another monomer, and has a heat resistant property. Examples of the monomer having an improving effect and copolymerizable with styrene or a derivative thereof include, for example, an unsaturated carboxylic acid such as maleic acid, fumaric acid, acrylic acid, methacrylic acid, itaconic acid or a derivative thereof and an acid thereof. Examples thereof include nitrile compounds such as anhydrides, acrylonitrile, methacrylonitrile, and derivatives thereof. These may be used alone or in combination of two or more.

  In addition, when polymerizing styrene or a styrene derivative, a polymer obtained by adding synthetic rubber or rubber latex, an unsaturated carboxylic acid such as maleic acid, fumaric acid, acrylic acid, methacrylic acid, itaconic acid or the like Derivatives and acid anhydrides thereof, and copolymers with nitrile compounds such as acrylonitrile and methacrylonitrile may also be used. Among these, styrene-maleic anhydride copolymer, styrene-acrylic acid copolymer, styrene-methacrylic acid copolymer and acrylonitrile-butadiene-styrene copolymer are effective in improving heat resistance and versatility. From the viewpoint of cost.

  The heat-resistant PS resin may be used alone or in combination of two or more. The heat-resistant PS resin may be used by blending with other thermoplastic resins. Examples of the thermoplastic resin to be blended include polystyrene, HIPS, polycarbonate, polyester, polyamide, and copolymers thereof. . Among these, HIPS is preferable from the viewpoints of versatility, uniform dispersion, the effect of improving the impact resistance of the non-foamed layer, and cost. A known HIPS can be used, and the content of the rubber component is usually 1 to 15% by weight.

  50-300 micrometers is preferable and, as for the thickness of the non-foaming layers 12 and 14 in this invention, 75-200 micrometers is more preferable. When the thickness of the non-foamed layer is less than 50 μm, the strength, rigidity, heat resistance and the like tend to decrease, and when it is thicker than 300 μm, the moldability of the foamed laminated sheet tends to be inferior.

  In the heat-resistant resin constituting the non-foamed layer in the present invention, a filler, a lubricant, an antioxidant, an antistatic agent, a pigment, a stabilizer, an odor reducing agent, etc. are used alone or in combination of two or more as necessary. May be added.

  As shown in FIGS. 1 to 3, the automobile interior material according to the present invention is not provided with the adhesive layer 16 (FIGS. 1 and 2) or on the surface of the outdoor non-foamed layer 14. (FIG. 3) An abnormal noise prevention layer 18 is provided. When the base resin is a polyolefin resin and is a film, the noise prevention layer 18 has an effect of preventing noise and may be hereinafter referred to as an noise prevention film. In other words, this anti-noise film prevents abnormal noise that occurs when mounted on an automobile, when the interior is rapidly cooled by a cooler, etc., or when traveling on uneven roads or while traveling on a sharp curve. It is effective to do.

  As the base resin of the noise preventing film in the present invention, a polyolefin resin or a polyacetal resin, which is a crystalline resin excellent in slidability, is preferable. More preferably, polyolefin resin is preferable from the viewpoint of cost, versatility, and ease of film processing.

  Examples of the polyolefin resin used as the base resin of the noise preventing film in the present invention include, for example, homopolymers such as low-density polyethylene, high-density polyethylene, and linear polyethylene, ethylene-propylene copolymer, and ethylene-acetic acid. Vinyl copolymers, copolymers of ethylene and monomers that can be copolymerized with olefins such as methacrylate, acrylate, butene, polyethylene resins composed of mixtures of these, propylene homopolymers, propylene-vinyl acetate A polypropylene resin comprising a copolymer, a copolymer of propylene and a monomer copolymerizable with an olefin such as methacrylate, acrylate, or butene, or a mixture thereof is preferable. Among these, low-density polyethylene, high-density polyethylene, linear polyethylene, homopolypropylene, or ethylene-propylene copolymer is more preferable from the viewpoint of good slidability and low material cost.

  In addition, coloring the anti-noise film with a colorant such as a pigment such as carbon black makes it possible to increase the light resistance, which is preferable for cars having a sunroof.

  Examples of the method of laminating the noise preventing film on the non-foamed layer 14 include a method of laminating without the adhesive layer 16 (FIGS. 1 and 2) and a method of laminating via the adhesive layer 16 (FIG. 3). It is done.

  In order to laminate the anti-noise film on the non-foamed layer 14 without the adhesive layer 16, it is preferable to use an anti-noise film made of a laminated film as shown below. That is, a film having a base resin made of a polystyrene resin that can be effectively thermally bonded to the non-foamed layer 14 made of a heat-resistant PS resin using a laminated film made of a polyolefin resin film-polystyrene resin film. It is preferable to dispose a film using a polyolefin-based resin having excellent slidability as a base resin on the indoor side and thermally bond this laminated film to the non-foamed layer 14 made of a heat-resistant PS-based resin. .

  When laminating via the adhesive layer 16, the non-foamed layer 14 and the anti-noise film are adhered to each other by at least chemical bonds such as intermolecular force, hydrogen bond, and covalent bond. What has a function is used.

  Specific examples of the adhesive layer 16 include, for example, thermoplastic adhesives such as vinyl acetate, cellulose, acrylic, polyamide, and polyvinyl acetate, urethane, melamine, phenol, epoxy, acrylic, and the like. Thermosetting adhesives, rubber adhesives such as chloroprene rubber, nitrile rubber, and silicone rubber, natural products such as starch, protein, and natural rubber, and hot melt adhesives. Specific examples of hot melt adhesives include polyolefin, modified polyolefin, polyurethane, ethylene-vinyl acetate copolymer resin, polyamide, polyester, thermoplastic rubber, styrene-butadiene copolymer, styrene. -The thing which uses resin, such as an isoprene copolymer system, as a component is mention | raise | lifted.

  As thickness of the film which uses polyolefin resin as base resin, 10-100 micrometers is preferable and 20-50 micrometers is more preferable. If the thickness of the film having a polyolefin resin as a base resin is less than 10 μm, the noise prevention effect may not be obtained. On the other hand, if it is thicker than 100 μm, heat distortion may occur in the interior material due to distortion during molding of a film layer using a polyolefin-based resin as a base resin, and the cost may be increased wastefully.

  As thickness of the film which uses a polystyrene-type resin as base resin, 10-100 micrometers is preferable and 20-50 micrometers is more preferable. If the thickness of the film having a polystyrene resin as a base resin is thinner than 10 μm, stable adhesion to the outdoor non-foamed layer 14 may not be obtained. On the other hand, if it is thicker than 100 μm, stable adhesion to the non-foamed layer 14 can be obtained if a large amount of heat is applied, but it causes a significant decrease in productivity or a film having a polystyrene resin as a base resin. There is a concern that heat distortion may occur in the interior material due to distortion during molding of the layer.

  In the present invention, the noise prevention layer 18 can also be provided as a nonwoven fabric layer. The non-woven fabric layer for preventing abnormal noise prevents abnormal noise generated when the vehicle is mounted on an automobile, when the inside of the vehicle is rapidly cooled by a cooler, etc., or when traveling on an uneven road surface or traveling on a sharp curve. It will be effective.

  On the other hand, since the automobile interior material of the present invention is attached to an automobile via a nonwoven fabric for preventing abnormal noise, particularly at the interface between the non-foamed layer and the nonwoven fabric for preventing abnormal noise, Even when used for a long period of time or in a harsh environment, stable adhesiveness that does not drop off is required.

  The nonwoven fabric layer for preventing abnormal noise according to the present invention can be of any kind as long as it is a cloth-like product obtained by joining raw fibers with an adhesive, a molten fiber or a mechanical method. The type of raw fiber is not particularly limited, and any of synthetic fiber, semi-synthetic fiber, or natural fiber can be used. Specifically, for example, synthetic fibers such as polyester, polypropylene, polyamide (nylon), polyacrylonitrile, and natural fibers such as wool, cotton, and cellulose can be used. Among these, polyester fiber is preferable from the viewpoint of recyclability and the like, and polyethylene terephthalate fiber having particularly high heat resistance is preferable. These fibers can be used alone or in combination of two or more. The type of the nonwoven fabric includes a bonded binder-bonded fabric, a needle punched fabric, a spunbonded fabric, a spray fiber fabric, a water punched fabric, and a stitchbonded fabric, and any nonwoven fabric can be used depending on the manufacturing method. Among these, a spunbond cloth and a water punch cloth made of long fiber filaments are preferable. The filament is crimpable, has high strength, has a soft texture, and is convenient for absorbing sound.

Anti-rattle nonwoven layer of the present invention, in consideration of quality and cost, preferably has a basis weight of 10 to 60 g / m ^2, to have a basis weight of 20 to 40 g / m ² More preferred. When the basis weight of the nonwoven fabric layer for preventing abnormal noise is less than 10 g / m ² , the surface of the outdoor non-foamed layer 14 is partially exposed at the place where the nonwoven fabric layer is provided, and an effective noise preventing effect or the like cannot be obtained. Sometimes. On the other hand, if the basis weight exceeds 60 g / m ² , heat resistance deformation may occur in the interior material due to molding distortion of the nonwoven fabric layer, or the cost may increase wastefully.

  As a method of laminating the nonwoven fabric layer 18 for preventing abnormal noise in the present invention on the outdoor non-foamed layer 14, a method of laminating without the adhesive layer 16 (FIGS. 1 and 2), bonding in the same manner as the anti-noise film. A method of laminating through the agent layer 16 (FIG. 3) is exemplified.

  When the nonwoven fabric layer 18 for preventing abnormal noise is laminated on the outdoor non-foamed layer 14 without the adhesive layer 16 interposed therebetween, the base resin of the outdoor non-foamed layer 14 is heated and melted as described above. The base resin of the outdoor non-foamed layer 14 is pressed between the foamed layer 10 and the nonwoven fabric layer 18 so that the base resin of the outdoor non-foamed layer 14 appropriately permeates the nonwoven fabric layer 18 for preventing abnormal noise. It is a preferred embodiment that good adhesion is obtained by the anchor effect caused by this. The abnormal sound-preventing nonwoven fabric layer that has been pressure-bonded in this manner can be attached to an automobile, and can provide a stable adhesion that does not fall off even when used for a long period of time or in a harsh environment.

  When laminating via the adhesive layer 16, the adhesive layer used is composed of at least the outdoor non-foamed layer 14 and the anti-noise film by chemical bonds such as intermolecular force, hydrogen bond, and covalent bond. What has the function to adhere | attach is used.

  Specific examples of the adhesive layer 16 include thermoplastic adhesives such as vinyl acetate, cellulose, acrylic, polyamide, and polyvinyl acetate, and heat such as urethane, melamine, phenol, epoxy, and acrylic. Examples thereof include curable adhesives, rubber adhesives such as chloroprene rubber, nitrile rubber, and silicone rubber, natural products such as starch, protein, and natural rubber, and hot melt adhesives. Specific examples of hot melt adhesives include, for example, polyolefin-based, modified polyolefin-based, polyurethane-based, ethylene-vinyl acetate copolymer resin-based, polyamide-based, polyester-based, thermoplastic rubber-based, styrene-butadiene copolymer systems. (Hereinafter referred to as “SB type”), and those containing a resin such as a styrene-isoprene copolymer system.

  As shown in FIGS. 2 and 3, the base material for automobile interior material according to the present invention includes, for example, a thermoplastic resin adhesive layer 22 on the surface of the indoor non-foamed layer 12, and a breathable skin material 20 and multilayer fibers. A laminated skin material 26 composed of the body 24 or a single-layer skin material 27 is laminated as shown in FIG.

  In the present invention, by laminating the laminated skin material 26, it is possible to obtain an interior base material and an interior material excellent in sound absorption characteristics in a high frequency range (for example, 4000 Hz or more).

  In the present invention, by laminating the single-layer skin material 27, good flame retardancy can be obtained while suppressing the production cost without using a flame retardant thermoplastic resin coating.

  As the thermoplastic resin adhesive layer 22 in the present invention, a thermoplastic resin that is compatible with the constituent resin of the indoor non-foamed layer 12 is used. Specific examples include a PS resin, a heat-resistant PS resin, and a modified PPE resin. Examples thereof include resins, SB resins, and acid-modified SB resins. Among these, PS resin, SB resin, and carboxy-modified SB resin are particularly preferable from the viewpoint of processability, versatility, and cost.

  The PS resin as the adhesive resin is a resin mainly composed of styrene or a derivative thereof, for example, α-methylstyrene, 2,4-dimethylstyrene, monochlorostyrene, dichlorostyrene, p-methylstyrene, ethylstyrene, and the like. is there. Accordingly, the PS-based resin is not limited to a homopolymer made of only styrene or a styrene derivative, but may be a copolymer made by copolymerizing with another monomer.

  The SB resin as an adhesive resin is a copolymer of styrene or its derivative and butadiene monomer. In addition to the composition based on the ratio of monomers, the molecular structure based on the double structure of butadiene (1,2 addition) It has a structure, 1,4-addition structure (cis and trans), and a bridge structure), and its rubber-like properties are deceived from the 1,4-addition structure. If the cross-linking structure is too much, the rubber-like elongation characteristics are lost, and if the cross-linking structure is too small, characteristics such as solvent resistance are not exhibited. Therefore, final resin physical properties are designed by adjusting the amount of the cross-linking structure and designing the molecular weight.

  The carboxy-modified SB resin as an adhesive resin is a copolymer of a styrene and butadiene monomer and an unsaturated carboxylic acid monomer, and the unsaturated carboxylic acid monomer used is a single base. Either acid or dibasic acid can be used, and examples thereof include maleic acid, fumaric acid, acrylic acid, methacrylic acid, crotonic acid, and itaconic acid.

  When an SB resin or a carboxy-modified SB resin is used as the adhesive layer 22, it has compatibility with the constituent resin of the indoor non-foamed layer 12, and the laminated skin material 26 does not peel even at high temperatures. Those having heat resistance are preferred, and specifically those having a styrene component content in the resin of 60% by weight or more are preferred.

  As a method for adhering the thermoplastic resin adhesive layer 16 and the laminated skin material 26 or the single-layer skin material 27, (a) an adhesive resin diluted solution (latex) is applied to the surface of the indoor non-foamed layer 12, and the wet state A method in which the laminated skin material 26 or the single-layer skin material 27 is dried in a state of being laminated on the coated surface, and temporarily bonded, and then bonded by heating and pressing. (B) the laminated skin material 26 or the single-layer skin material 27 A method in which an adhesive resin diluted solution is applied in advance, dried in a state in which the indoor non-foamed layer 12 is laminated on an undried application surface, temporarily bonded, and then bonded by heat pressing; A method in which the adhesive resin diluted solution is applied in advance to the material 26 or the single-layer skin material 27 and dried, and is arranged so that the coated surface and the indoor non-foamed layer 12 are in contact with each other, and bonded by heat pressing; Resin diluted solution indoors A method of applying and drying on the surface of the foamed layer 12, placing the coated surface in contact with the laminated skin material 26 or the single-layer skin material 27, and bonding them by heat pressing; e) constituent resin of the adhesive resin adhesive layer A method in which the diluted solution is applied to the surface of the indoor non-foamed layer 12 and the laminated skin material 26 or the single-layer skin material 27, dried, placed so that the coated surfaces are in contact with each other, and bonded by heat pressing; An adhesive resin diluted solution is applied in advance to the laminated skin material 26 or the single-layer skin material 27, dried, and the foamed layer 10 and the laminated skin 26 or so that the molten indoor indoor non-foamed layer 12 is in contact with the dried application surface. For example, a method of laminating and bonding by sandwiching and pressing with a single-layer skin material 27 can be given.

  A dilute solution of the adhesive resin that uses an organic solvent can also be used. However, it is possible to make the adhesive layer unevenly distributed in the vicinity of the surface of the skin material, and to reduce the work environment load, water is used as the solvent. Particularly preferred are latexes of the resin emulsion type used as

  As the latex, any latex known to those skilled in the art for carpet backing, coated paper, and nonwoven fiber treatment can be used. The solid content concentration in the latex stock solution is usually 40% by weight or more, but it can be used after optionally diluting with water in accordance with the coating amount and coating method. However, if the concentration of the solid content of the latex water diluted solution is too low, drying in the process becomes insufficient and may cause poor adhesion, so 20% by weight or more is preferable.

  Examples of the latex application method include various roll coaters, spraying, foam spraying, and the like, which are selected depending on the application amount and the shape of the application surface.

  For latex, as necessary additives, stabilizers, anti-aging agents, vulcanization accelerators, dispersants, fillers, thickeners, colorants, antifoaming agents, gelling agents, antifreeze agents , Softeners, thickening resins and the like.

  PS resin latex, SB resin latex and carboxy-modified SB resin latex can be used alone, but in order to satisfy various required properties as interior materials, several types of latex are mixed and used. It is preferable to do.

The amount of the constituent resin applied to the thermoplastic resin adhesive layer 22 is arbitrarily selected depending on the type of thermoplastic resin to be used and the required adhesive strength with the laminated skin material 26 or the single-layer skin material 27. 0.5 to ²⁰ g per 1 m ² is preferable, and 3.0 to 10 g is more preferable. When the constituent resin coating amount of the thermoplastic resin adhesive layer 22 is less than 0.5 g, there is a possibility that the effect of improving the adhesiveness may not be expressed. When the constituent resin coating amount of the thermoplastic resin adhesive layer 22 is more than 20 g, There is a possibility that the thermoplastic resin adhesive layer 22 oozes out from the laminated skin material 26 or the single-layer skin material 27 during molding and contaminates the mold.

  The multilayer fiber body 24 constituting the laminated skin material 26 in the present invention is formed in a state in which fibers are arranged in a multilayered manner. The multi-layer fiber body 24 is obtained by supplying fibers from one direction of a plane, unpacking and matting the layers into layers, blowing hot air, performing needle punching, etc. Say. Therefore, it is obtained by the same method as the production of the web, which is a pre-process for producing a general nonwoven fabric. However, the above-described manufacturing method for obtaining the multilayer fiber body 24 is an example thereof, and is not particularly limited as long as the fiber is formed in a layered state in a multilayer manner.

  In addition, in the present invention, a multi-layer fiber body having a large degree of fiber crossing (high cross ratio) is different from supplying fibers from one general plane direction, and fibers from both the plane flow direction and the width direction. Is obtained by unpacking and matting the layers in layers and then integrating them by spraying hot air or performing needle punching. For the multilayer fiber body 24 having a high cross rate, these manufacturing methods are merely examples, and the method is not particularly limited as long as the fibers are formed in a multilayered state.

  The raw material of the multilayer fiber body 24 obtained by forming the fibers of the present invention in layers is not particularly limited, and any of synthetic fibers, semi-synthetic fibers, natural fibers or regenerated fibers can be used. it can.

  The synthetic fiber referred to in the present invention is used in a concept including synthetic fiber and semi-synthetic fiber. Specific examples of synthetic fibers include polyester fibers, polypropylene fibers, polyamide (nylon) fibers, polyacrylonitrile fibers, polyvinyl chloride fibers, polyvinylidene chloride fibers, and the like. Also, heat-fusible fibers having a function as a binder can be mixed and used.

  Specific examples of the semi-synthetic fiber in the present invention include, for example, cellulosic fibers and protein fibers, and one or a mixture of two or more of these fibers can be used.

Specific examples of the regenerated fiber in the present invention include, for example, rayon fibers, special rayon fibers, cupra, and the like, and one or a mixture of two or more of these fibers can be used.
Among the raw material fibers constituting the nonwoven fabric described above, from the viewpoint of strength, heat resistance, light resistance and flammability, it is preferable to use polyester fibers as synthetic fibers, and polyethylene terephthalate fibers with particularly high heat resistance are the most. preferable. Further, rayon fibers are most preferable from the viewpoint of economy as recycled fibers blended with the synthetic fibers.

  In view of cost and processability, the raw fiber in the present invention is preferably a polyester fiber, and more preferably a polyethylene terephthalate fiber from the viewpoint of good shape maintainability during heat molding.

  Furthermore, when exposed to harsh thermoforming presses (for example, skin-integrated thermoforming), mixing regenerated fibers such as rayon or natural fibers improves the shape maintainability during thermoforming, preferable. Further, in view of cost and processability, it is preferable to mix 20% to 80%, and more preferably 40% to 70%, of regenerated fibers such as rayon or natural fibers.

  In the multilayer fiber body 24 in the present invention, it is preferable to use a heat-fusible fiber as a binder. Specific examples of heat-fusible fibers include, for example, fibers such as polyethylene, polypropylene, low melting point (for example, about 60 ° C. to 180 ° C.) polyester (hereinafter, sometimes simply referred to as “low melting point polyester”), polyamide, and the like. In addition, a core-sheath fiber having a low melting point polyolefin or polyester fiber as a sheath component and a high melting point polyester fiber as a core component is preferable. When polyethylene terephthalate is used as a synthetic fiber, a low melting point (same polymer) For example, it is particularly preferable to use polyester fibers (including core-sheath fibers) in view of recyclability. The mixing amount of the heat-fusible fiber in the entire fiber body is preferably 5 to 30%. If the mixing amount of the heat-fusible fiber in the whole fiber body is more than 30%, the increase in the binding force between the fibers and the generation of the fiber mass may cause a decrease in sound absorption performance due to the suppression of the vibration of the fiber part. The thickness variation of the fibrous body may occur. Further, if the mixing amount is less than 5%, the effect of mixing the heat-fusible fiber may not be recognized.

  As thickness of the fiber which comprises the multilayer fiber body 24 in this invention, 1 denier (1.1 decitex)-10 denier (11.1 decitex) are preferable, and 2 denier (2.2 decitex)-7 denier (7 .7 dtex) is more preferred. If the thickness of the fiber is less than 1 denier, the shape maintaining property of the fiber orientation tends to deteriorate, and the sag of the entire fiber body tends to increase. On the other hand, if it is larger than 10 denier, the fiber gap in the fiber body becomes large, the vertical transmission of the incident sound wave is increased, and the sound absorption performance is lowered, and there are cases where the fiber is scattered, wrinkled, and the like.

The basis weight of fibers composing the multilayer fiber body 24 in the present invention is preferably from 50 to 300 g / m ^2, cost, practicality, a light weight, 100 to 200 g / m ² is particularly preferred.

  In order to manufacture the multilayer fiber body 24 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 can be employ | adopted.

  That is, for example, as described above, fibers are supplied from one direction in a plane, and mated by a card method while being unwound, layered in layers, sprayed with hot air, needle punched, etc. Can be obtained.

  Further, for the multilayer fiber body 24 having a high cross rate in the present invention, for example, as described above, the fiber is supplied from both the plane flow direction and the width direction, unlike the case where the fiber is supplied from one general plane direction. Can be obtained in an integrated manner by laminating many layers of mats by a card method while unwinding and layering them, blowing hot air, or performing needle punching.

  In the production of a normal nonwoven fabric, the fibers constituting the multilayer fiber body 24 are entangled with each other by needle punching or the like with respect to the multilayer fiber body 24 obtained as described above. Practical characteristics such as rigidity, workability, and dimensional stability are imparted by intertwining the fibers constituting the multilayer fiber body 24.

  However, in a normal nonwoven fabric manufacturing method, most of the fibers that have been substantially planarly arranged by the needle punching process are rearranged in a direction parallel to the thickness. As a result, the vertical transmittance increases with respect to the incident sound, and the rate at which the incident sound is simply reflected is also increased, resulting in a significant decrease in sound absorption performance.

  Therefore, in the needle punching process, the multilayer fiber body 24 formed in a state in which the fibers obtained by matting by the card method are arranged in multiple layers in a layered manner has a smaller number of needle punches than usual. Then, by adjusting the depth in the direction of decreasing the depth and leaving many fibers arranged in a plane, the multilayer fiber body 24 having a large amount of fibers arranged in a plane, that is, a high plane rate can be obtained.

  In the present invention, the arrangement of the fibers may change depending on the method of laminating the multilayer fiber body 24 and the breathable skin material 20, but after the multilayer fiber body 24 and the breathable skin material 20 are laminated, Finally, the amount of fibers (plane ratio) arranged in the plane direction of the fibers in the multilayer fiber body 24 is preferably 50% or more, more preferably 60% or more, and 66% or more. More preferably it is. By setting the plane rate of the fibers in the multilayer fiber body 50 to 50% or more, the structure is such that there are more fibers arranged in the plane direction than fibers arranged in a random direction, and the fiber lamination is performed with respect to incident sound. The structure works efficiently and exhibits good sound absorption.

  Furthermore, in the fiber supply when the multilayer fiber body 24 is manufactured, the multilayer fiber body 24 in which the degree of crossing (cross rate) in the supply in the flow direction and the supply in the direction perpendicular thereto is increased is the entanglement between the fibers. Since the property is improved, it is effective for the expression of sound absorption and exhibits a great effect.

  The cross rate of the multilayer fiber body 24 in the present invention is preferably 50 to 200%, and the confounding property between the fibers is improved, so that it is effective for the development of sound absorbing performance and exhibits a great effect. 150% is more preferable.

  The multilayer fiber body 24 of the present invention is intended to improve the sound absorbing performance exclusively by adjusting the flatness ratio to a high level or by adjusting the cross ratio to a large extent. Although the performance is high, the surface property and the design property tend to be insufficient, and the function as a skin material may not be achieved.

  For this reason, in the present invention, the multilayer fiber body 24 is provided with a function as a skin material by being laminated and integrated with a breathable skin material 20 having a normal surface property and an excellent design property. It is also possible to provide the sound absorption performance which is the purpose of the above.

  Although it has been described above that the arrangement of the fibers may change depending on the method of laminating the multilayer fiber body 24 and the breathable skin material 20, the flatness may be affected. This means the following: To do. That is, as will be described later, when the multilayer fiber body 24 and the breathable skin material 20 are laminated with an adhesive, the arrangement of the fibers of the multilayer fiber body 24, that is, the plane rate does not change, but the multilayer fiber body 24 does not change. And the breathable skin material 20 are laminated by needle punching, the fiber arrangement of the multilayer fiber body 24 changes. However, the plane rate of the multilayer fiber body 24 in the present invention refers to the final plane rate of the multilayer fiber body 24 after the multilayer fiber body 24 and the breathable skin material 20 are laminated.

    Next, the breathable skin material 20 and the single-layer skin material 27 may be the same as or similar to the multilayer fiber body 24. Since it will be used exposed to the indoor side or surface side as a material, as well as the interior material such as wear resistance, as well as the use of a material having better decorativeness and design than the multilayer fiber body It is necessary to consider the general practical characteristics of That is, what is used as a conventional skin material for automobile interior materials can be used. Specific examples thereof include, for example, cloth, knit, non-woven fabric, a knit / non-woven fabric structure, a knit / urethane / non-woven fabric structure, and a non-woven fabric as a skin material for automobile interior materials. Any of the above can be used.

  The nonwoven fabric layer functioning as the main constituent element of the breathable skin material 20 and the single-layer skin material 27 is a cloth-like material or sheet-like material obtained by joining or intertwining raw material fibers with an adhesive, a molten fiber, or a mechanical method. Any type can be used.

  In the present invention, the raw material fibers constituting the nonwoven fabric as the breathable skin material 20 and the single-layer skin material 27 are not particularly limited, and the types of raw material fibers are not particularly limited, and synthetic fibers (including heat-fusible fibers), semi-synthetic Any of fiber, natural fiber and regenerated fiber can be used, but a fiber obtained by mixing synthetic fiber and regenerated fiber (sometimes referred to simply as “mixed spinning” in the present invention) is used. preferable.

  Specific examples of synthetic fibers (including heat-fusible fibers), semi-synthetic fibers, natural fibers, and recycled fibers are the same as those used in the multilayer fiber body 24.

  The type of the nonwoven fabric includes a bonded binder-bonded fabric, a needle punched fabric, a spunbonded fabric, a spray fiber fabric, a water punched fabric, and a stitchbonded fabric, and any nonwoven fabric can be used depending on the manufacturing method. Among these, the needle punch cloth and the water punch cloth are preferable from the viewpoint that the filament is crimpable, has high strength, and has a soft texture.

  In the present invention, as a preferred embodiment of the nonwoven fabric used as the single-layer skin material 27, polyester fibers and recycled fibers are mixed, and the mixing ratio of the recycled fibers in that case is 2 to 15% by weight of the total weight of the skin material. It is preferable to mix the regenerated fibers in proportions. If the amount of recycled fiber is less than 2% by weight, it tends to be difficult to ensure the flame retardancy of the skin material. If the amount exceeds 15% by weight, the flame retardancy is excellent, but the light resistance tends to deteriorate. There is.

  As a knit used as an element constituting the breathable skin material 20 and the single-layer skin material 27, any knit used for automobile interior materials such as tricot, double raschel, and velvet can be used.

  The knit is made by knitting a loop continuously using a single thread, and has a structure in which the loops are gathered, so it is rich in elasticity and flexible, Wrinkles and creases are not easily formed, and since it is porous, it has excellent heat retention, and has a low specific gravity and a light finish for volume. The knit is finished in various textures depending on how it is knitted, and in particular, the tricot is a loop that is continuously connected in the thickness direction of the fabric. It is particularly preferably used for automobile interiors because of its excellent fit.

  Synthetic fibers, semi-synthetic fibers, natural fibers, regenerated fibers, and the like similar to the above-described nonwoven fabric are used as the raw fibers constituting the knit.

Basis weight breathable skin material 20 of the present invention is preferably from 50 to 300 g / m ^2, cost, practicality, a light weight, 50 to 150 g / m ² is particularly preferred.

In consideration of quality and cost, the nonwoven fabric used as the single-layer skin material 27 in the present invention preferably has a basis weight of 100 to 300 g / m ² , and is 100 to 200 g / m from the viewpoint of practicality and lightness. It is preferable to have a basis weight of ² . If the basis weight of the single-layer skin material 27 is less than 100 g / m ² , it may be impossible to obtain a sufficient feel as an interior material. On the other hand, if it exceeds 300 g / m ² , the molding distortion of the skin material may affect the thermal deformation.

  In order to bond the raw material fibers of the nonwoven fabric used as the breathable skin material 20 and the single-layer skin material 27 to each other, and to ensure the wear resistance of the skin material, a binder resin is used as an adhesive on the front or back surface of the skin material. In general, a method of impregnation by coating or coating is generally performed. In this case, in general, in order to ensure flame retardancy, a method of using a flame retardant mixed with the binder resin or using a halogen-containing binder resin is employed. However, in such a method, if an attempt is made to impregnate a binder resin containing a flame retardant or a halogen-containing binder resin from the design surface (surface) of the skin material, it is very difficult to color the skin material due to the influence of the flame retardant or resin. It becomes. Therefore, in the case of impregnating a binder resin containing a flame retardant or a halogen-containing binder resin, it must be impregnated from the design opposite surface (back surface) of the skin material. Moreover, in order to ensure the abrasion resistance of the skin, the amount of the binder resin containing the flame retardant or the halogen-containing binder resin must be increased.

  In contrast to this fact, in the present invention, flame retardancy is achieved by using a foamed laminated sheet using a modified polyphenylene ether-based resin as a base resin, and using a nonwoven fabric obtained by mixing recycled fibers in a synthetic fiber as a skin material. improves. For this reason, it is possible to use a flame retardant-free binder resin or a halogen-free binder resin without using a binder resin containing a flame retardant, or a halogen-containing binder resin, as a binder resin for bonding the raw material fibers of the nonwoven fabric. It becomes possible.

  These binder resins have excellent toning properties due to their good transparency, can be impregnated from the design surface (surface) of the nonwoven fabric, and can ensure the abrasion resistance of the nonwoven fabric as a skin material only by impregnation with a small amount of binder resin. It becomes like this. In the present invention, such a structure can ensure good flame retardancy, and can use a good skin material that is lightweight and has excellent design and environmental compatibility.

  Here, the design surface (surface) of the skin material means the interior side surface of the automobile when the foamed laminated sheet for automobile interior material of the present invention is used as the automobile interior material. Therefore, the design opposite surface (back surface) of the skin material means the outdoor side surface of the automobile.

  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 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 as one kind or a mixture of two or more kinds.

  In the present invention, when a nonwoven fabric is used as the breathable skin material 20, it can be manufactured in the same manufacturing process as the multilayer fiber body 24. By adjusting the number of punchings and the needle stroke in the needle punching process, it is possible to increase the interlacing of the fibers and increase the rigidity of the fiber body, thereby imparting designability and wear resistance. Furthermore, designability and abrasion resistance can be imparted.

  As a method of laminating the breathable skin material 20 and the multilayer fiber body 24 in the present invention, a method of laminating using an adhesive, a method of lightly needling, a heat fusible fiber mixed and laminating by heat fusion Methods etc. can generally be used. Further, two or more of these laminating methods can be used in combination for lamination.

  The adhesive used when laminating the breathable skin material 20 and the multilayer fiber body 24 preferably has breathability in order to exhibit sound absorption. As a method of bonding via an air-permeable adhesive layer, a multilayer fiber is used via a non-woven hot-melt adhesive having a network structure such as low-melting polyethylene, low-melting polyester, and polyamide. Temporarily fix the body 24 and the breathable skin material and blow hot air to melt and integrate the breathable hot melt adhesive described above, or interpose a urethane, epoxy, or silicone adhesive layer A method, or a latex such as acrylonitrile-butadiene latex, styrene-butadiene latex, vinyl acetate latex, or acrylate latex is applied to the surface of the breathable skin material or the surface to be bonded of the multilayer fiber body 24, and the multilayer fiber body 24 is ventilated. After bonding and bonding pressure-sensitive skin material, it can be integrated by drying. It is below.

  In addition, the adhesive layer obtained by applying latex to the adherend surface of the breathable skin material 20 and / or the multilayer fiber body 24 and drying has good breathability.

  Further, the breathable skin material 20 and the multilayer fiber body 24 may be bonded together by adjusting the amount of the above-mentioned binder fiber that may be included in the material of the multilayer fiber body 24.

  The method for bonding the air-permeable skin material 20 and the multilayer fiber body 24 may be used alone or in combination of a plurality of methods.

The laminated skin material 26 of the present invention, in consideration of quality and cost, preferably has a basis weight of 100 to 300 g / m ^2, the basis weight of 125~300g / m ² in terms of sheer by molding stretching It is preferable to have. If the basis weight of the laminated skin material 27 is less than 100 g / m ² , it may not be possible to obtain a sufficient feel as an interior material. On the other hand, if it exceeds 300 g / m ² , the molding distortion of the skin material may affect the thermal deformation.

  In the laminated skin material 26 of the present invention, the density of the breathable skin material 20 and the multilayer fiber body 24 also greatly affects the sound absorption. That is, the density of the breathable skin material 20 is preferably 1 or more times higher than the density of the multilayer fiber body 24. Furthermore, by providing a difference in the density of the breathable skin material 20 and the multilayer fiber body 24, the sound absorption is further improved. The effect can be increased. Specifically, the density of the breathable skin material 20 is more preferably 1.5 times or more the density of the multilayer fiber body 24. By providing the density difference as described above, the breathable skin material 20 is provided with a function as a breathable skin material and exhibits high sound absorbing performance as the entire laminated skin material 26.

Furthermore, the multilayer fiber body 24 preferably has a low density, and is preferably 0.1 g / cm ³ or less.

  Next, the manufacturing method of the automotive interior material of the present invention will be described.

  The foamed layer 10 (primary foamed layer) used in the present invention is prepared by melting and kneading a modified PPE resin to which various additives are added at 150 ° C. to 400 ° C. with an extruder, and then 150 to 400 ° C., After 2-5 parts by weight of a hydrocarbon-based foaming agent is injected into 100 parts by weight of the resin under a high temperature and high pressure of 3-50 MPa, the foaming temperature is adjusted to an optimum foaming temperature (150-300 ° C.) and a circular die is used. After extrusion into a low-pressure zone (usually in the atmosphere), contact with a mandrel, etc., for example, forming it into a sheet while taking it up at a speed of 0.5 to 40 m / min. can do.

  As a method of laminating the indoor non-foamed layer 12 or the outdoor non-foamed layer 14 on the foamed layer 10, a heat laminating method in which a film is thermally fused to the surface of the foamed layer 10 using a heat roll, There is an extrusion laminating method in which a resin melted by a T die is directly extruded and a film is formed on the surface of the foamed layer 10.

  However, as a method of laminating the outdoor non-foamed layer 14 and the noise-preventing layer 18 on the foamed layer 10, foam molding is performed in advance, and the foamed layer 10 is supplied from the extruder on the upper surface or the lower surface A method of laminating the base resin of the outdoor non-foamed layer 14 in a molten state in a form sandwiched between the foamed layer 10 and the noise preventing layer 18 and pressing with a cooling roller or the like is preferable. The reason for this is that, particularly when a nonwoven fabric for preventing abnormal noise is used as the abnormal noise preventing layer 18, the base resin of the outdoor non-foamed layer 14 soaks into the nonwoven fabric layer appropriately, and good adhesion is obtained by the anchor effect. When attached to an automobile, stable adhesion that does not drop off is obtained even when used for a long time or in harsh environments, foam layer 10, outdoor non-foam layer 14, abnormal noise in one step Since the prevention layer 18 is laminated at the same time, the complexity of work is eliminated, and the increase in manufacturing cost can be suppressed because the adhesive layer is not substantially used. . In particular, it is desirable that the method of laminating the foamed layer 10 by extrusion molding of the foamed layer 10, the extrusion of the outdoor non-foamed layer 14, and the abnormal sound prevention layer 18 in-line can be simplified.

  As a method of adhering the laminated skin material 20 to the foamed laminated sheet, an adhesive resin diluted solution (latex) by the thermoplastic resin adhesive layer 22 is applied to the surface of the non-foamed layer 12, and the laminated skin material is applied to the undried application surface. For example, a method of adhering by heating and pressing after drying and temporarily adhering in a state where the layers 26 are laminated can be given.

  As a method of forming a molded secondary foamed laminated molded body, which is an automotive interior material, from the obtained base material for automotive interior materials, the foamed laminated sheet is clamped and guided in the center of a heating furnace having heaters at the top and bottom, and molded. After being subjected to secondary foaming by heating to a temperature suitable for the temperature (for example, 120 to 200 ° C.), it is molded using a temperature-controlled mold.

  Specific examples of the molding method include, for example, plug molding, free drawing molding, plug and ridge molding, ridge molding, matched molding, straight molding, drape molding, reverse draw molding, air slip molding, plug assist molding, Examples include plug assist reverse draw molding.

  When the above-mentioned (primary) foamed sheet is heated and secondarily foamed, the primary foamed sheet [foaming ratio: 3 to 20 times, preferably 5 to 15 times, thickness: 1 to 5 mm, preferably 1. 5 to 3.5 mm], the secondary foaming is normally performed 1.2 to 4 times, and the secondary foaming is preferably performed 1.5 to 3 times. [As a result, the sheet after the secondary foaming] The magnification is 3.6 to 80 times, preferably 7.5 to 45 times, more preferably 10 to 40 times, and the thickness is 1.2 to 20.0 mm, preferably 2.25 to 10.5 mm. More preferably, it is 3.0 to 7.0 mm].

  As mentioned above, although various embodiments of the substrate for automobile interior materials according to the present invention have been described, the present invention is not limited to the above-described embodiments. For example, a base material for automobile interior materials can be used as a base material for interior materials such as trains as an application, and should be interpreted broadly. In addition, the present invention can be implemented in a mode in which various improvements, changes, and modifications are made based on the knowledge of those skilled in the art without departing from the spirit of the present invention.

  Hereinafter, the present invention will be described in more detail based on examples, but the present invention is not limited thereby.

  Table 1 shows resins used in Examples and Comparative Examples.

In addition, each code | symbol regarding the raw material shown in Table 1 is as follows.
PPE: Polyphenylene ether resin PS: Polystyrene resin SMAA copolymer: Methacrylic acid modified polystyrene resin HIPS: High impact polystyrene resin PS latex: PS resin latex AS latex: Styrene-butadiene copolymer resin carboxy modified SB: Carboxy modified Styrene-butadiene copolymer resin noise prevention layer: PET water needle nonwoven fabric noise prevention film: Linear low density polyethylene resin-polystyrene resin laminate film noise prevention layer: PET spunbond nonwoven fabric with powder hot melt Evaluation methods performed in Examples and Comparative Examples are shown below.

(Thickness of foam layer and molded body)
The thickness of 20 places was measured in the width direction of the obtained primary foamed sheet (modified PPE resin foam layer) and the molded product, and the average value of the measured values was calculated.

(Foaming ratio)
The density df of the primary foamed sheet (modified PPE resin foam layer) was measured according to JIS K 7222, the density dp of the modified PPE resin was measured according to JIS K 7112, and was calculated from the following formula.
Foaming ratio = dp / df

(Closed cell rate)
The closed cell ratio of the obtained primary foamed sheet (modified PPE resin foamed layer) was measured using a multi-pynometer (manufactured by Beckman) according to ASTM D-2859.

(Cell diameter)
The cross section of the obtained primary foamed sheet (modified PPE resin foamed layer) was printed with an optical microscope contrast, 20 cell diameters were measured using a stainless gauge, and the average value of the measured values was calculated.

(Weight)
From five places in the extrusion direction of the obtained primary foamed sheet (modified PPE resin foamed layer), test pieces having a size of 100 mm × 100 mm were cut out, and after measuring their weight, an average value was calculated, m Converted to ² units. About the coating amount of latex, after cutting out the test piece of the magnitude | size of 100 mm x 100 mm from the longitudinal direction for the skin material and the noise prevention layer before and behind application | coating and measuring the weight difference, the average value was computed.

(Impact resistance test)
After plug formation, the interior trim material trimmed with a trimming mold was visually observed for cracks.

(Real car heat resistance test)
A car interior material (width 930 mm × length 1424 mm) 30 as shown in FIG. 4 is mounted on the car ceiling (cut body) and becomes equivalent to a real car through a sun visor, a room mirror, a room lamp, a garnish, and a pillar. It was fixed as follows. In the figure, 34 is an assist grip mounting hole, 36 is a sun visor mounting hole, 38 is a sun visor fastening mounting hole, 32 is a room mirror mounting hole, and 40 is a room light mounting hole.
Next, the automobile interior material was assembled on the automobile ceiling, engraved in the center in the width direction of the front terminal of the automobile interior material, and the height (h ₀ ) from the marked point to the reference point was measured.
Then, after putting the car ceiling with the car interior material attached to the temperature-controlled room set at 85 ± 2 ° C, hold it for 24 hours, take it out from the temperature-controlled room and return it to room temperature, and then the front terminal part of the car interior material The height (h) from the point engraved in the center in the width direction to the reference point was measured. The heat deformation was determined from the difference (h ₀ −h ₁ ) between the initial height h ₀ and the height h ₁ after heat resistance. In addition, the general part of the automobile interior material was visually checked for the presence or absence of deformation, and the presence or absence of the falling off of the base material, the noise-preventing layer and the skin layer was also visually checked.

  As criteria for the determination, the following criteria were used in consideration of practicality as an automobile interior material.

(Running test)
Car interior materials were mounted on automobiles, and the use of ordinary automobiles was investigated for the occurrence of abnormal noise for one month and the occurrence of falling off of the interior materials and the occurrence of floating of the base material, anti-noise layer and skin material.

(Skin material normal temperature peeling test)
A test piece of 150 mm × 25 mm is taken from the interior material, and the laminated skin material is peeled off in an appropriate amount in parallel with the short side, and the peeled skin material and interior substrate are tension tester (Shimadzu Corporation) Manufactured by Autograph DSS-2000) and peeled off at a tensile speed of 200 mm / min to determine the peel strength.
The following criteria were used as criteria for judgment in consideration of practicality as an interior material.
○ ・ ・ 4.9N / 25mm or more,
× ·· Less than 4.9 N / 25 mm.

(Skin heat-resistant creep peel test)
A test piece of 150 mm × 25 mm is taken from the interior material, an appropriate amount of the laminated skin material is peeled off in parallel with the short side, and the end of the peeled portion is marked.
With the interior material fixed, a 100 g weight was caught on the peeled skin material, left in a 100 ° C. constant temperature bath for 24 hours, and the peel length from the marking portion was measured.
The following criteria were used as criteria for judgment in consideration of practicality as an interior material.
○ ・ ・ Less than 10mm,
× ·· 10 mm or more.

(Normal incidence sound absorption coefficient)
It measured using the normal incidence sound absorption measuring device prescribed | regulated to ASTM-E-1050.

(Combustion test)
In accordance with the automobile safety standards applied to automobile interior materials and the combustion standards for automobile interior materials (FMVSS302), a sample piece with a width of 100 mm and a length of 350 mm cut from the automobile interior material is burned at n = 10. A test was conducted. Among the obtained burning rates, the maximum value was taken as the burning rate.

  Table 1 shows a list of materials used in the examples, and Table 2 shows a list of configurations of the multilayer skin materials manufactured in the examples.

Example 1
Iso with respect to 100 parts of a mixed resin in which 57.1 parts by weight of PPE resin (A) and 42.9 parts by weight of PS resin (B) are mixed so that the PPE resin component is 40% by weight and the PS resin component is 60% by weight. -3.4 parts by weight of a blowing agent based on butane (iso-butane / n-butane = 85/15) and 0.32 parts by weight of talc are kneaded with an extruder, extruded with a circular die, and passed through a take-up roll. The primary foamed sheet (modified PPE system) having a primary thickness of 2.0 mm, a primary foaming ratio of 12.9 times, a closed cell ratio of 88%, a cell diameter of 0.17 mm and a basis weight of 150 g / m ² Resin foam layer) was obtained.
Next, a mixed resin in which 50.0 parts by weight of the methacrylic acid-modified polystyrene resin (C) and 50.0 parts by weight of the HIPS resin (D) are mixed while the primary foamed sheet is fed out from a roll has a resin temperature of 245 ° C. Then, the mixture was melted and kneaded with an extruder so as to be extruded into a film using a T-die, and a heat-resistant PS resin non-foamed layer having a thickness of 150 μm was formed on one surface of the primary foamed sheet. Simultaneously with the lamination of the non-foamed layer, the heat-resistant PS resin in which the noise-preventing film is laminated is formed by simultaneously forming the heat-resistant PS-based resin non-foaming layer and rolling out the noise-preventing film (J) on the surface and pressing with a roll by thermal bonding A sheet on which a non-foamed layer was formed was obtained.
While the primary foamed sheet on which the heat-resistant PS resin non-foamed layer is formed is drawn out from the roll, the PPE resin component (A) is 28.6 parts by weight and the PS resin (B) is 66.4 so as to be 20% by weight. A mixed resin obtained by mixing parts by weight and 5.0 parts by weight of HIPS resin (D) is melted and kneaded with an extruder so that the resin temperature is 265 ° C., and extruded into a film using a T-die, and heat resistant PS system A modified PPE resin non-foamed layer having a thickness of 120 μm was laminated on the opposite surface of the sheet on which the resin non-foamed layer was formed, to obtain a laminated foamed sheet as a base material for automobile interior.
On the other hand, fineness 2 denier (2.2 decitex), polyethylene terephthalate (Toyobo Co., Ltd., type 707) fiber 93 parts by weight, and fineness 4 denier (4.4 decitex) Cut-length 51mm low-melting-point polyethylene terephthalate (Toyobo Co., Ltd., type EE7) Fiber mixed with 7 parts by weight of fiber is supplied in an equal amount from two directions perpendicular to the flow direction by a card system. Then, needle punching is performed with the number of punches and the stroke adjusted, and the weight is adjusted to 100 g / m ² and the density is 0.083 g / cm ³ , and hot air at a temperature of 200 ° C. is blown for 5 minutes to return to room temperature. As a result, a multilayer fiber body (L) was obtained.
The multilayer fiber body (L), 90 parts by weight of polyethylene terephthalate (type 707, manufactured by Toyobo Co., Ltd.) having a fineness of 2 denier (2.2 decitex) and a cut length of 51 mm and a fineness of 7 denier (7. 8 decitex) Rayon fiber with a cut length of 51 mm (made by Daiwabo Rayon Co., Ltd., type CD 7.8 decitex × 51 mm) 10 parts by weight breathable skin material with a basis weight of 130 g / m ² and a density of 0.129 g / cm ³ (M The laminated skin material (N) in which the fiber arrangement of the multilayer fiber body (L) part is adjusted to a plane rate of 70% and a cross rate of 100% by adjusting the number of punches and the stroke of needling and integrating the layers. Obtained.
The surface of the obtained laminated foamed sheet on which the modified PPE resin non-foamed layer is formed is sprayed with carboxy-modified SB resin latex (H) (latex diluted with water so that the solid concentration is 40 wt%) by spraying 1 After applying 20 g per square meter (surface-adhesive carboxy-modified SB resin concentration 9.8 g / m ² ), the above-mentioned laminated skin material is pasted on the coated surface and pressure-bonded with a roll, and then 30 minutes in a 100 ° C. constant temperature bath It was dried to obtain a foamed laminated sheet on which the laminated skin material was temporarily fixed.
Clamp the four sides of the automobile interior base material on which the laminated skin material is laminated and place it in a heating furnace so that the surface temperature of the skin material is 160 ° C. and the surface temperature of the back surface of the base material (outdoor non-foamed layer) is 135 ° C. After heating and plug molding with a mold having a clearance of 5.0 mm, the temperature of which was adjusted to 60 ° C., trimming and punching were performed to obtain an automotive interior material having a good appearance without cracks.

When an actual vehicle heat resistance test was performed on the obtained automobile interior material, the amount of heat deformation was −0.5 mm at the front end portion of the automobile interior material, and no heat deformation was observed visually with respect to the general portion of the interior material. Further, the falling off of the interior material and the floating of the base material, the noise prevention layer and the skin material layer did not occur. On the other hand, when a running test was performed, no abnormal noise was generated, and the interior material was not dropped and the base material, the abnormal noise prevention film, and the laminated skin material were not lifted.
Further, a sample was cut out from the general part of the obtained automobile interior material, and a skin material room temperature peel test, a skin material heat-resistant creep peel test, a flammability test, and a normal incidence sound absorption coefficient test were performed. The test results are shown in Table 3.

(Example 2)
A primary foam sheet was obtained in the same manner as in Example 1.
Next, while feeding out the primary foamed sheet from the roll, 7.0 parts by weight of PPE resin (A), 34.0 parts by weight of SMAA copolymer (C), HIPS resin (PPE resin component 5% by weight) D) A mixed resin obtained by mixing 57.0 parts by weight and 2.0 parts by weight of black pigment (E) was melted and kneaded with an extruder so that the resin temperature was 265 ° C., and formed into a film using a T-die. Extruded to form a heat-resistant PS resin non-foamed layer having a thickness of 150 μm on one surface of the primary foamed sheet. Simultaneously with the lamination of the non-foamed layer, the noise-preventing layer (I) is laminated on the surface of the heat-resistant PS-based resin non-foamed layer by the anchor effect of the non-foamed layer resin, and the noise-resistant layer is laminated. A sheet on which a non-foamed layer was formed was obtained.
PPE resin (A) 14.0 parts by weight, PS resin (B) 81.1 parts by weight on the opposite side of the sheet on which the heat-resistant PS resin non-foamed layer is formed, A mixed resin in which 4.9 parts by weight of HIPS resin (D) is mixed is melted and kneaded with an extruder so that the resin temperature is 265 ° C., extruded into a film using a T-die, and heat-resistant PS resin is not foamed A modified PPE-based resin non-foamed layer having a thickness of 120 μm was formed on the opposite surface of the sheet on which the layer was formed to obtain a laminated foamed sheet.
On the other hand, 93 parts by weight of polyethylene terephthalate (type 707) having a fineness of 2 denier and a cut length of 51 mm, and low melting point polyethylene terephthalate (Toyobo Co., Ltd., type 707) having a fineness of 4 denier. Type EE7) Made by mixing 7 parts by weight of fiber. Equal amount of fiber from two directions perpendicular to the flow direction is supplied by a card method and sprayed in a mat shape. After that, the number of punches and strokes are adjusted. Punching was performed, the basis weight was adjusted to 130 g / m ^{2, the} density was adjusted to 0.129 g / cm ³ , hot air at a temperature of 200 ° C. was blown for 5 minutes, and the temperature was returned to room temperature to obtain a multilayer fiber body (O).
90 parts by weight of polyethylene terephthalate (Toyobo Co., Ltd., type 707) having a fineness of 2 denier and a cut length of 51 mm, rayon fiber having a fineness of 7 denier and a cut length of 51 mm (Daiwabow rayon Co., Ltd., type CD7.8 decitex × 51 mm) A breathable skin material (P) having a basis weight of 130 g / m ² and a density of 0.129 g / cm ³ consisting of 10 parts by weight is laminated by adjusting the number of punches and the stroke of needling. By integrating, the laminated skin material (Q) in which the fiber arrangement of the multilayer fiber body (O) portion was adjusted to a plane rate of 70% and a cross rate of 100% was obtained.
A roll coater was used on the surface of the obtained laminated foamed sheet on which the modified PPE resin non-foamed layer was formed, and the resulting mixture was mixed so that the PS resin latex (F) was 20% by weight and the carboxy modified SB resin latex (H) was 80% by weight. 16.6 g of the mixed solution resin latex is applied per square meter (surface-adhesive PS resin concentration is 8.1 g / m ² ), the above-mentioned laminated skin material fed from the other side is laminated with a roll, and subjected to a drying heat treatment, and then the laminated skin material A base material for automobile interior integrated with was obtained.
Clamp the four sides of the automobile interior base material on which the laminated skin material is laminated and place it in a heating furnace so that the surface temperature of the skin material is 160 ° C. and the surface temperature of the back surface of the base material (outdoor non-foamed layer) is 135 ° C. After heating and plug molding with a mold having a clearance of 8.0 mm, the temperature of which was adjusted to 60 ° C., trimming and punching were performed to obtain an automotive interior material having a good appearance without cracks.

When the vehicle interior material obtained was subjected to an actual vehicle heat resistance test, the amount of heat deformation was +1.0 mm at the front terminal portion of the vehicle interior material, and heat resistance deformation of the general portion of the interior material was not visually observed. Further, the falling off of the interior material and the floating of the base material, the noise prevention layer and the skin material layer did not occur. On the other hand, when a running test was performed, no abnormal noise was generated, and the interior material was not dropped, and the base material, the abnormal noise prevention layer, and the laminated skin material were not lifted.
Further, a sample was cut out from the general part of the obtained automobile interior material, and a skin material room temperature peel test, a skin material heat-resistant creep peel test, a flammability test, and a normal incidence sound absorption coefficient test were performed. The test results are shown in Table 3.

(Example 3)
A primary foam sheet was obtained in the same manner as in Example 1.
Next, while this foamed sheet is fed out from a roll, a mixed resin in which 14.3 parts by weight of PPE resin (A) and 85.7 parts by weight of HIPS resin (D) are mixed so that the PPE resin component becomes 10% by weight. The resin was melted and kneaded with an extruder so that the resin temperature was 265 ° C., and extruded into a film using a T-die to form a modified PPE resin non-foamed layer having a thickness of 120 μm on one side of the foamed sheet. Simultaneously with this non-foaming layer lamination, the modified PPE-based resin non-foaming layer is formed, and the anti-noise layer with powder hot melt (K) with a basis weight of 15 g / m @ 2 is brought into contact with the non-foaming layer surface with a roll by unwinding thermal bonding. By pressing, a sheet on which a modified PPE-based resin non-foamed layer on which an abnormal sound prevention layer was laminated was obtained.
21.4 parts by weight of PPE resin (A), 73.6 parts by weight of PS resin (B), HIPS so that the PPE resin component is 15% by weight on the opposite surface of the sheet on which the heat-resistant PS resin non-foamed layer is formed. The mixed resin mixed with 5.0 parts by weight of the resin (D) is melted and kneaded with an extruder so that the resin temperature becomes 265 ° C., and extruded into a film using a T-die to form a heat-resistant PS resin non-foamed layer. A modified PPE resin non-foamed layer having a thickness of 120 μm was formed on the opposite surface of the formed sheet to obtain a laminated foamed sheet.
On the other hand, 35 parts by weight of a polyethylene terephthalate having a fineness of 2 denier and a cut length of 51 mm (manufactured by Toyobo Co., Ltd., type 707), and a low melting point polyethylene terephthalate having a fineness of 4 denier cut length of 51 mm (Toyobo ( Co., Ltd., type EE7) 15 parts by weight of fibers, fineness 3 denier (3.3 decitex), cut length 51 mm of rayon fiber (Daiwabo Rayon Co., Ltd., type CD 3.3 decitex × 51 mm) 50 parts by weight were mixed. Fibers are fed in equal amounts from two directions perpendicular to the flow direction by a card method and dispersed in a mat shape, and then needle punching is performed with the number of punches and stroke adjusted, and the basis weight is 100 g / m ² and the density is 0 It was adjusted to .083g / cm ^3, blowing hot air of temperature of 200 ° C. 5 min, multilayer fiber by returning to room temperature To give the body (R).
90 parts by weight of the above multilayer fiber (R), polyethylene terephthalate (Toyobo Co., Ltd., type 707) having a fineness of 2 denier and a cut length of 51 mm, and a rayon fiber having a fineness of 7 denier and a cut length of 51 mm (Daiwabow rayon ( Co., Ltd., type CD7.8 decitex × 51 mm) 100 g / m ² basis weight and 0.083 g / cm ³ of breathable skin material (S) with a weight per unit of 100 g / m ² , adjusted by adjusting the number of punches and stroke of needling By integrating, a laminated skin material (T) in which the fiber arrangement of the multilayer fiber body (R) portion was adjusted to a plane rate of 70% and a cross rate of 100% was obtained.
A roll coater was used on the surface of the obtained laminated foamed sheet on which the modified PPE resin non-foamed layer was formed, and mixed so that the AS resin latex (F) was 20% by weight and the carboxy modified SB resin latex (H) was 80% by weight. 16.6 g of the mixed solution resin latex is applied per square meter (surface-adhesive PS resin concentration is 8.1 g / m ² ), and the above-mentioned laminated skin material drawn out from the other is laminated with a roll, and subjected to a drying heat treatment to obtain a laminated skin material. A base material for automobile interior integrated with was obtained.

When the vehicle interior material obtained was subjected to an actual vehicle heat resistance test, the amount of heat deformation was +0.7 mm at the front end portion of the vehicle interior material, and heat resistance deformation of the general portion of the interior material was not visually observed. Further, the falling off of the interior material and the floating of the base material, the noise prevention layer and the skin material layer did not occur. On the other hand, when a running test was performed, no abnormal noise was generated, and the interior material was not dropped, and the base material, the abnormal noise prevention layer, and the laminated skin material were not lifted.
Further, a sample was cut out from the general part of the obtained automobile interior material, and a skin material room temperature peel test, a skin material heat-resistant creep peel test, a flammability test, and a normal incidence sound absorption coefficient test were performed. The test results are shown in Table 3.

Example 4
A laminated foam sheet was obtained in the same manner as in Example 3.
On the other hand, a web with a surface weight of 145 g / m ² blended with 90% by weight of polyester fiber 2 denier x 51mm and 10% by weight of rayon fiber 2 denier x 51mm was used, and 300 needle punching treatments were applied from the top and bottom surfaces of the web. / Cm ² to obtain a needle punched nonwoven fabric mat. Acrylic binder resin 10 g / m ² is attached to the back surface of the needle punched nonwoven fabric mat (opposite surface of the design surface and laminated surface with the primary foamed laminated sheet) by coating, subjected to a drying heat treatment, and contains rayon fibers Thus, a non-woven polyester non-woven skin (U) having a surface weight of 155 g / m ² was obtained.
The surface of the obtained laminated foamed sheet on which the modified PPE resin non-foamed layer is formed is sprayed with carboxy-modified SB resin latex (H) (latex diluted with water so that the solid concentration is 40 wt%) by spraying 1 After applying 20 g per square meter (surface-adhered SB resin concentration: 9.8 g / m ² ), the above-mentioned polyester non-woven skin material is pasted on the coated surface, pressure-bonded with a roll, and then 30 minutes in a 100 ° C. constant temperature bath It was dried to obtain a foamed laminated sheet on which the skin material was temporarily fixed.
The four sides of the automobile interior base material on which the skin material was laminated were clamped and placed in a heating furnace, and heated for 60 seconds so that the surface of the skin material reached 140 ° C. After that, the modified PPE resin non-foamed layer is placed in the mold so that the non-foamed layer is on the indoor side, plug molding is performed with a mold clearance of 5.0 mm, trimming and punching are performed, and the car interior has a good appearance without cracks. The material was obtained.

When the vehicle interior material obtained was subjected to an actual vehicle heat resistance test, the amount of heat deformation was +1.0 mm at the front terminal portion of the vehicle interior material, and heat resistance deformation of the general portion of the interior material was not visually observed. Further, the falling off of the interior material and the floating of the base material, the noise prevention layer and the skin material layer did not occur. On the other hand, when a running test was performed, no abnormal noise was generated, and the interior material was not dropped, and the base material, the abnormal noise prevention layer, and the skin material were not lifted.
Further, a sample was cut out from the general part of the obtained automobile interior material, and a skin material room temperature peel test, a skin material heat-resistant creep peel test, and a flammability test were conducted. The test results are shown in Table 3.

FIG. 1 is an enlarged schematic cross-sectional explanatory view showing a main part of an embodiment of an automobile interior material according to the present invention. FIG. 2 is an enlarged schematic cross-sectional explanatory view showing a main part of one embodiment of the automobile interior material according to the present invention. FIG. 3 is an enlarged schematic cross-sectional explanatory view showing a main part of one embodiment of the automobile interior material according to the present invention. FIG. 4 is an explanatory plan view of an automobile interior material according to the present invention.

Explanation of symbols

10: Foamed layer 12: Indoor non-foamed layer 14: Outdoor non-foamed layer 16: Adhesive film layer 18: Anti-noise layer 20: Breathable skin material 22: Adhesive layer 24: Multilayer fiber body 26: Laminated skin Material 27: Single-layer skin material 30: Automotive interior material 32: Rear mirror mounting hole 34: Ashitoto grip mounting hole 36: Sun visor mounting hole 38: Sun visor mounting hole 40: Indoor light mounting hole a: Front terminal b: Rear terminal

Claims (10)

A laminated foam sheet made by laminating a non-foamed layer on both sides of a modified polyphenylene ether-based resin foam layer, and a skin material is laminated on the indoor non-foamed layer via an adhesive layer, and abnormal noise is generated on the outdoor non-foamed layer. A base material for automobile interior materials, in which a prevention layer is laminated,
The modified polyphenylene ether resin foam layer is a modified polyphenylene ether resin, which is a mixed resin of 25 to 70 parts by weight of a polyphenylene ether resin and 75 to 30 parts by weight of a polystyrene resin, and the modified polyphenylene resin. It is a foam sheet obtained by extrusion foaming using 2 to 5 parts by weight of a hydrocarbon-based foaming agent with respect to 100 parts by weight, and having a thickness of 1 to 5 mm and a foaming ratio of 3 to 20 times.
The non-foamed layer is a non-foamed layer having a thickness of 50 to 300 μm containing 0.3 to 15 parts by weight of a rubber component with respect to 100 parts by weight of a heat-resistant resin having a glass transition temperature Tg lower than that of the base resin of the foamed sheet. ,
The skin material is a single-layer skin material having a basis weight of 100 to 300 g / m ² containing synthetic fibers and regenerated fibers, or fibers containing synthetic fibers and regenerated fibers arranged in multiple layers on one side of a breathable skin material. A laminated skin material having a basis weight of 100 to 300 g / m ² , in which a multilayer fiber body obtained by forming in a formed state is laminated,
And abnormal noise prevention layer, a polyester nonwoven fabric having a basis weight of 10 to 100 g / m ² of polyolefin films or basis weight 10 to 60 g / m ^2,
Base material for automotive interior materials. The ratio of the fibers arranged in multiple layers in the plane direction (plane rate) of the multilayer fiber body in the laminated skin material is 50% or more, and the fibers arranged crossing the fibers in the length direction of the skin material The ratio (cross rate) is 50 to 200%,
And the base material for motor vehicle interior materials of Claim 1 which is a multilayer nonwoven fabric containing 80-20 weight% of polyester-type fibers, and 20-80 weight% of natural fibers or a recycled fiber.   The base material for automobile interior materials according to claim 1, wherein the single-layer skin material is a single-layer nonwoven fabric containing 85 to 98% by weight of polyester fiber and 15 to 2% by weight of rayon fiber.   The base material for automotive interior materials according to any one of claims 1 to 3, wherein the hydrocarbon-based blowing agent is isobutane.   The base material for automobile interior materials according to any one of claims 1 to 4, wherein the heat-resistant resin constituting the non-foamed layer is a heat-resistant polystyrene-based resin and / or a modified polyphenylene ether-based resin.   The base material for automotive interior materials according to any one of claims 1 to 5, wherein the rubber component content in the indoor non-foamed layer is less than the rubber component content in the outdoor non-foamed layer.   The base for an automobile interior material according to any one of claims 1 to 6, wherein a rubber component content in the indoor non-foamed layer is 0.3 to 3 parts by weight with respect to 100 parts by weight of the heat resistant resin. Wood.   The automobile interior according to any one of claims 1 to 7, wherein the adhesive layer for laminating the laminated skin material is a polystyrene resin, a styrene-butadiene copolymer resin, or a carboxy-modified styrene-butadiene copolymer resin. Base material for materials.   The base material for automotive interior materials according to any one of claims 1 to 8, wherein a polyester-based non-woven fabric as an anti-noise layer is laminated by an anchor effect to a non-foamed layer resin.   An automobile interior material obtained by molding the automobile interior material base material according to any one of claims 1 to 9.

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