JPH0564587B2 - - Google Patents
Info
- Publication number
- JPH0564587B2 JPH0564587B2 JP61270684A JP27068486A JPH0564587B2 JP H0564587 B2 JPH0564587 B2 JP H0564587B2 JP 61270684 A JP61270684 A JP 61270684A JP 27068486 A JP27068486 A JP 27068486A JP H0564587 B2 JPH0564587 B2 JP H0564587B2
- Authority
- JP
- Japan
- Prior art keywords
- nonwoven fabric
- skin material
- skin
- layer
- core material
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 239000000463 material Substances 0.000 claims description 35
- 239000004745 nonwoven fabric Substances 0.000 claims description 26
- 239000010410 layer Substances 0.000 claims description 24
- 238000000465 moulding Methods 0.000 claims description 21
- 229920005989 resin Polymers 0.000 claims description 10
- 239000011347 resin Substances 0.000 claims description 10
- 239000012790 adhesive layer Substances 0.000 claims description 7
- 239000000835 fiber Substances 0.000 claims description 5
- 239000011230 binding agent Substances 0.000 claims description 3
- 239000011162 core material Substances 0.000 description 24
- 238000000034 method Methods 0.000 description 9
- 239000000853 adhesive Substances 0.000 description 7
- 230000001070 adhesive effect Effects 0.000 description 7
- 230000037303 wrinkles Effects 0.000 description 7
- 238000007796 conventional method Methods 0.000 description 3
- 239000012948 isocyanate Substances 0.000 description 3
- 150000002513 isocyanates Chemical class 0.000 description 3
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000002788 crimping Methods 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 239000004772 Sontara Substances 0.000 description 1
- 229920006311 Urethane elastomer Polymers 0.000 description 1
- 238000003490 calendering Methods 0.000 description 1
- 238000009960 carding Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 238000004049 embossing Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 235000013312 flour Nutrition 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 238000002074 melt spinning Methods 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 238000007666 vacuum forming Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Landscapes
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
- Laminated Bodies (AREA)
Description
産業上の利用分野
本発明はプレス成形用表皮材、更に詳しくは、
たとえば自動車内装部品の表皮材として有用で、
内面側に特殊な不織布層を設けたことにより、該
内装部品芯材のプレス成形時に一体となつて同時
に成形でき、特に内装部品の立体的な複雑形状の
場合にも、芯材と表皮材間のエアー溜りや表面の
シワ発生がない、優れた表装外観の内装部品を作
成するのに適したプレス成形用表皮材に関する。
従来技術と解決すべき問題点
自動車などの内装部品（たとえばドアトリム、
シートバツク、リヤーパーセル、タイヤハウスな
ど）は、そのプラスチツク化のため一般に射出成
形で用いられるか、あるいはその所定形状の芯材
を形成した後、その表面に手貼り、ウエルダー貼
り等で表皮材が設けられている。しかしながら、
射出成形品や手貼りやウエルダー貼りでは、立体
的な複雑形状の場合や、また色、絞等の多品種へ
の対応を十分に果たすことができず、製品外観、
触感性において十分満足できるものではなかつ
た。最近、芯材と表皮材を別々に成形した後、真
空成形で貼合せるといつた手法が採用されつつあ
るが、この方法だと、外観や触感性は改善される
が、芯材と表皮材の別成形となり、これに伴つて
それぞれの成形型が必要であるなど、製品コスト
の高騰は避け得ない。
そこで、芯材と表皮材を同時にプレス成形する
ことにより、工程の削減を図る方法が一部試みら
れているが、表皮材と芯材間にエアーが溜つた
り、シワが発生したりして、製品外観が損われ、
かつ芯材と表皮材の接着性にも問題が起る。
本発明者らは、かかる同時プレス成形における
問題点を解決するため鋭意研究を進めた結果、通
常の樹脂シートからなる表皮層の内面側（芯材に
面する側）に特殊なノーバインダー不織布の層を
接着しておけば、該層の不織布がプレス成形時
に、ほぐれながら延伸し、かつ絞り込まれていく
ほか、後述する作用効果によつて、上述のエアー
溜りやシワ発生がなくなることを見出し、本発明
を完成させるに至つた。
発明の構成と効果
すなわち、本発明は、樹脂シート表皮層、接着
層および不織布層を積層した表皮材において、不
織布層が
厚み0.2〜0.7mm
嵩密度0.10〜0.20ｇ／cm3
縦、横、ななめ方向の伸びがいずれも30％以
上
を有し、繊維のからみ合いで強度を保持している
ノーバインダーの不織布層であることを特徴とす
るプレス成形用表皮材を提供するものである。
本発明における表皮層には、通常の熱可塑性樹
脂（たとえば軟質PVC、PVC／ABS、ABS、
NBR、ウレタンゴム、フイラー入りPP、PPG、
PP、LDPE等）を原料とする樹脂シートが採用
されてよい。特に、加飾性、耐久性、外観および
触感性に優れる、軟質PVC（可塑剤量50〜90％）
のシートが好ましい。また常法により着色、絞
付、発泡したシートも使用することができる。
本発明における接着層に用いる接着剤として
は、表皮層の樹脂シートや不織布層に対して優れ
た接着力を有するポリエステル／イソシアネート
系、ウレタン／イソシアネート系が採用されてよ
い。また、接着層の軟化温度は樹脂シートの軟化
点より高くなるように設定されていることが好ま
しい。低く設定されていると、芯材からの熱で軟
化した表皮層に凹凸が生じたり、あるいはプレス
成形後に樹脂シートと不織布層の剥離が起る傾向
にある。なお、かかる接着剤は不織布に対して点
接着しており、これによつてプレス成形時の不織
布の延伸を妨げることがない。
本発明で用いるノーバインダー不織布とは、溶
融紡糸から得られた長繊維のウエブあるいは短繊
維をカーデイングして得られるウエブを、バイン
ダーを用いずそのままウオータージエツト等でニ
ードリングを行つた、糸のからみ合いで強度を保
持している不織布を指称し、その層が下記要件
（〜）を満足するように設定される。
厚み0.2〜0.7mm、好ましくは0.3〜0.6mm：0.2
mm未満であると、エアー抜きが難かしく、また
0.7mmを越えると、シが発生する。
嵩密度［m2当りの重さ（目付）と厚みから求
める］0.10〜0.20ｇ／cm3、好ましくは0.10〜
0.15ｇ／cm3：0.10ｇ／cm3未満であると、繊維が
からみ合い強度がおちるため剥離やシワが生
じ、また0.20ｇ／cm3を越えると、圧着時に芯材
と接着しない。
縦、横、ななめ方向の伸びがいずれも30％以
上、好ましくは30〜150％：この伸びが少なく
とも30％以上なければ、絞り込み時にシワや破
れが発生する。
また、かかる不織布の材質にあつて、その軟化
温度が後記芯材の軟化点より高いものが好まし
く、これによつて、プレス成形時に芯材中へめり
込み、不織布と芯材が強固に融着し合う。逆に低
いものを使用すると、絞り込まれるときに糸が溶
断したり、あるいは部分的にしか芯材と溶着せ
ず、エアー溜り、表皮材と芯材の接着不良が起る
（冷却後にはがれる）。
なお、当該不織布に代えて、上記ニードリング
前のウエブを用いても、これはからみ合いが少な
く強度がないので、プレス成形後芯材と表皮材の
層間剥離が起る。またバインダーやエンボス等に
より部分的に融着させた不織布では、糸の自由度
が小さくなり、成形時に破れが生じる。
以下、本発明に係るプレス成形用表皮材並びに
その製造および用途について、添付図面に基づき
詳しく説明する。
第１図において、本発明表皮材１は、表皮層
２、接着層３およびノーバインダー不織布層４で
構成され、通常、厚み0.20〜2.00mmの樹脂シート
に接着剤を30〜60ｇ／m2にて塗工し、常法により
乾燥した後、所定厚みのノーバインダー不織布を
ドライラミネートすることにより製造される。
本発明表皮材の用途については、特に自動車内
装部品の表皮材として有用であり、これを該内装
部品芯材のプレス成形加工時に供し、同時成形す
ることにより、たとえば第２図の部分斜視図で示
される自動車ドアトリムが作成される。プレス成
形加工は、常法に従つて行うことができる。たと
えば、第３図の工程（）〜（）で概要される
ように、先ず芯材１０を水平状態に保持しながら
加熱手段１１で軟化点以上に維持し（）、この
芯材１０をプレス型１２内へ挿入し、この上に上
述の積層した表皮材１を設置せしめ（）、スタ
ンピングで成形、圧着、打ち抜きを行い（）、
次いで脱型して製品１３とする。第２図のドアト
リムにおいて、表皮材１と芯材１０はノーバイン
ダー不織布層４を介して強固に結合しており、特
に凸状部Ａやわん曲コーナー部Ｂを含め全体にわ
たり、エアー溜りやシワ発生がなく、均一でなめ
らかな表装外観を呈することが認められる。ま
た、表皮材１の一部にナイフカツトを入れ、これ
をはがした場合、不織布４は材料破壊を起こし、
一部４ａは芯材面に、残り４ｂは表皮材面に残存
しているのが認められる。
このように特殊なノーバインダー不織布を用い
ることにより、外観性状に優れたプレス成形加工
内装部品を作成することができるが、他の手段
（穴あけ、ウレオンフオームラミネート、メリヤ
ス）を用いた場合の比較を下記表１に例示する
（評価は３段法：○，△，×による）。
Industrial Application Field The present invention relates to a skin material for press molding, more specifically,
For example, it is useful as a skin material for automobile interior parts.
By providing a special non-woven fabric layer on the inner surface side, the core material of the interior component can be molded together at the same time during press molding, and even when the interior component has a three-dimensional complex shape, there is no gap between the core material and the skin material. This invention relates to a skin material for press molding that is free from air pockets and wrinkles on the surface and is suitable for creating interior parts with an excellent exterior appearance. Conventional technology and problems to be solved Interior parts of automobiles (e.g. door trim,
Seat bags, rear parcels, tire houses, etc.) are generally made of plastic by injection molding, or after forming a core material in a predetermined shape, a skin material is attached to the surface by hand, welding, etc. It is being however,
Injection molded products, hand pasting, and welding cannot adequately accommodate complex three-dimensional shapes or a wide variety of colors, drawings, etc., resulting in problems with product appearance,
The tactility was not fully satisfactory. Recently, a method has been adopted in which the core material and the skin material are molded separately and then bonded together using vacuum forming.This method improves the appearance and tactility, but the core material and the skin material Separate molding is required, which requires separate molds, which inevitably increases product costs. Therefore, some attempts have been made to reduce the number of processes by press-molding the core and skin materials at the same time, but this has resulted in air being trapped between the skin and core materials and wrinkles occurring. , product appearance is damaged,
Moreover, problems arise in the adhesion between the core material and the skin material. As a result of intensive research in order to solve the problems in simultaneous press molding, the present inventors have developed a special binder-free nonwoven fabric on the inner surface side (the side facing the core material) of the skin layer made of a normal resin sheet. We have discovered that if the layers are adhered, the nonwoven fabric of the layer will be loosened, stretched, and narrowed during press molding, and the above-mentioned air pockets and wrinkles will be eliminated due to the effects described below. The present invention has now been completed. Structure and Effects of the Invention That is, the present invention provides a skin material in which a resin sheet skin layer, an adhesive layer, and a nonwoven fabric layer are laminated, in which the nonwoven fabric layer has a thickness of 0.2 to 0.7 mm, a bulk density of 0.10 to 0.20 g/cm, 3 length, width, and diagonal. The present invention provides a skin material for press molding, characterized in that it is a binder-free nonwoven fabric layer that has elongation in all directions of 30% or more and maintains strength through intertwining of fibers. The skin layer in the present invention is made of ordinary thermoplastic resins (for example, soft PVC, PVC/ABS, ABS,
NBR, urethane rubber, PP with filler, PPG,
A resin sheet made from PP, LDPE, etc.) may be used. In particular, soft PVC (50 to 90% plasticizer content) with excellent decoration, durability, appearance and feel.
The sheet is preferred. It is also possible to use sheets that have been colored, tied, or foamed using conventional methods. As the adhesive used for the adhesive layer in the present invention, a polyester/isocyanate-based adhesive or a urethane/isocyanate-based adhesive that has excellent adhesive strength to the resin sheet of the skin layer or the nonwoven fabric layer may be employed. Moreover, it is preferable that the softening temperature of the adhesive layer is set higher than the softening point of the resin sheet. If it is set low, the skin layer softened by the heat from the core material tends to become uneven, or the resin sheet and nonwoven fabric layer tend to peel off after press molding. Note that the adhesive is point-adhered to the nonwoven fabric, so that it does not impede the stretching of the nonwoven fabric during press molding. The binder-free nonwoven fabric used in the present invention is a yarn made by needling a long fiber web obtained by melt spinning or a web obtained by carding short fibers without using a binder using a water jet or the like. Refers to a nonwoven fabric that maintains its strength through intertwining, and its layers are set so as to satisfy the following requirements (~). Thickness 0.2-0.7mm, preferably 0.3-0.6mm: 0.2
If it is less than mm, it will be difficult to bleed air, and
If it exceeds 0.7mm, scratches will occur. Bulk density [calculated from weight per m 2 (fabric weight) and thickness] 0.10 to 0.20 g/cm 3 , preferably 0.10 to
0.15 g/cm 3 : If it is less than 0.10 g/cm 3 , the fibers become entangled and the strength decreases, resulting in peeling or wrinkles. If it exceeds 0.20 g/cm 3 , it will not adhere to the core material during crimping. Elongation in the vertical, horizontal and diagonal directions is all 30% or more, preferably 30 to 150%: If this elongation is not at least 30% or more, wrinkles and tears will occur during squeezing. In addition, it is preferable that the material of the nonwoven fabric has a softening temperature higher than that of the core material described later, so that it sinks into the core material during press molding and firmly fuses the nonwoven fabric and the core material. Fit. On the other hand, if a lower material is used, the thread may melt or break when it is squeezed, or it may only partially weld to the core material, resulting in air pockets and poor adhesion between the skin material and the core material (they will peel off after cooling). Note that even if the above-mentioned web before needling is used instead of the nonwoven fabric, since this has little entanglement and lacks strength, delamination between the core material and the skin material occurs after press molding. In addition, in a nonwoven fabric that is partially fused with a binder, embossing, etc., the degree of freedom of the yarn is reduced, and tearing occurs during molding. EMBODIMENT OF THE INVENTION Hereinafter, the skin material for press molding according to the present invention, and its manufacture and use will be explained in detail based on the accompanying drawings. In FIG. 1, the skin material 1 of the present invention is composed of a skin layer 2, an adhesive layer 3, and a binder-free nonwoven fabric layer 4. Usually, a resin sheet with a thickness of 0.20 to 2.00 mm is coated with an adhesive at a rate of 30 to 60 g/ m2. After coating and drying by a conventional method, a binder-free nonwoven fabric of a predetermined thickness is dry laminated. Regarding the use of the skin material of the present invention, it is particularly useful as a skin material for automobile interior parts, and by providing it during press molding of the core material of the interior parts and molding at the same time, for example, as shown in the partial perspective view of FIG. The automobile door trim shown is created. Press molding can be performed according to a conventional method. For example, as outlined in steps () to () in FIG. 3, first, the core material 10 is held in a horizontal state and maintained above its softening point by the heating means 11 (), and this core material 10 is pressed into a press mold. 12, and place the laminated skin material 1 described above thereon (), and perform molding, crimping, and punching by stamping (),
The product 13 is then demolded. In the door trim shown in Fig. 2, the skin material 1 and the core material 10 are firmly connected via the binder-free nonwoven fabric layer 4, and the entire surface, including the convex portion A and the curved corner portion B, is free from air pockets and wrinkles. It was observed that there was no occurrence of cracking, and that the surface appearance was uniform and smooth. Moreover, if a knife cut is made in a part of the skin material 1 and this is peeled off, the material of the nonwoven fabric 4 will be destroyed.
It is recognized that a portion 4a remains on the core material surface and the remaining portion 4b remains on the skin material surface. By using this special binder-free nonwoven fabric, it is possible to create press-molded interior parts with excellent appearance properties, but compared to the use of other methods (drilling, ureon foam lamination, stockinette). Examples are shown in Table 1 below (evaluation is based on a three-stage method: ◯, △, ×).
【表】
ンチング加工で小穴をあけた場合
次に実施例を挙げて本発明をより具体的に説明
する。
実施例 １
表皮材の製造
厚み0.35mmのカレンダーPVCシートにウレタ
ン／イソシアネート系接着剤を30ｇ／m2（乾燥）
で塗工し、80℃で２分間乾燥した後、目付30ｇ／
cm2のポリエステル不織布［デユポン（株）製ソン
タラ、厚み0.25mm、嵩密度0.120ｇ／cm3、伸び率
（縦40％、横130％、バイヤス100％）、軟化温度
250℃］をドライラミネートして表皮材を得る。
プレス成形加工
第３図に示す手法に準じ、芯材（木粉入りPP
ボード）を180℃に加熱し、これを所定のプレス
型内の設置し、その上に上記表皮材を広げて置
き、スタンピングで成形、圧着、打ち抜きを行
い、次いで脱型してドアトリム製品を得る。表皮
材は芯材とフイツトして強固に結合しており、わ
ん曲部を含め表装全体にわたつて、エアー溜り
（浮き）やシワ発生がなく、良好な外観を呈して
いた。[Table] When a small hole is made by trenching Next, the present invention will be explained in more detail with reference to Examples. Example 1 Production of skin material 30 g/m 2 of urethane/isocyanate adhesive was applied to a calendered PVC sheet with a thickness of 0.35 mm (dry).
After coating and drying at 80℃ for 2 minutes,
cm 2 polyester nonwoven fabric [Sontara manufactured by Dupont Co., Ltd., thickness 0.25 mm, bulk density 0.120 g/cm 3 , elongation rate (length 40%, width 130%, bias 100%), softening temperature
250℃] to obtain the skin material. Press molding process According to the method shown in Figure 3, the core material (PP with wood flour)
Board) is heated to 180℃, placed in a specified press mold, the above skin material is spread on top of it, molded by stamping, crimped, and punched, and then demolded to obtain a door trim product. . The skin material was tightly bonded to the core material, and the entire surface material, including the curved portions, had a good appearance with no air pockets (lifting) or wrinkles.
第１図は本発明表皮材の一例を示す断面図、第
２図は自動車内装部品の一例を示す部分斜視図、
および第３図はプレス成形加工の概要を示す工程
図であつて、
１……表皮材、２……表皮層、３……接着層、
４……不織布層。
FIG. 1 is a sectional view showing an example of the skin material of the present invention, FIG. 2 is a partial perspective view showing an example of an automobile interior part,
FIG. 3 is a process diagram showing an overview of press molding process, in which 1...Skin material, 2...Skin layer, 3...Adhesive layer,
4...Nonwoven fabric layer.
Claims (1)
積層した表皮材において、不織布層が 厚み0.2〜0.7mm 嵩密度0.10〜0.20ｇ／cm3 縦、横、ななめ方向の伸びがいずれも30％以
上 を有し、繊維のからみ合いで強度を保持している
ノーバインダーの不織布層であることを特徴とす
るプレス成形用表皮材。 ２ 表皮層の樹脂シートが軟質PVCシートであ
る前記第１項記載の表皮材。 ３ 接着層の軟化温度が、樹脂シートの軟化点よ
り高くなつている前記第１項記載の表皮材。[Scope of Claims] 1. In a skin material in which a resin sheet skin layer, an adhesive layer, and a nonwoven fabric layer are laminated, the nonwoven fabric layer has a thickness of 0.2 to 0.7 mm, a bulk density of 0.10 to 0.20 g/cm , and 3 elongation in the vertical, horizontal, and diagonal directions. A skin material for press molding, characterized in that it is a binder-free nonwoven fabric layer that has a binder content of 30% or more and maintains strength through intertwining of fibers. 2. The skin material according to item 1 above, wherein the resin sheet of the skin layer is a soft PVC sheet. 3. The skin material according to item 1 above, wherein the softening temperature of the adhesive layer is higher than the softening point of the resin sheet.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP61270684A JPS63125333A (en) | 1986-11-13 | 1986-11-13 | Skin material for press molding |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP61270684A JPS63125333A (en) | 1986-11-13 | 1986-11-13 | Skin material for press molding |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS63125333A JPS63125333A (en) | 1988-05-28 |
| JPH0564587B2 true JPH0564587B2 (en) | 1993-09-14 |
Family
ID=17489507
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP61270684A Granted JPS63125333A (en) | 1986-11-13 | 1986-11-13 | Skin material for press molding |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS63125333A (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH07108881A (en) * | 1993-10-14 | 1995-04-25 | Daikyo Inc | Automobile trimming material |
| JP4548877B2 (en) * | 1999-10-13 | 2010-09-22 | 旭化成せんい株式会社 | Non-woven microwave tray |
-
1986
- 1986-11-13 JP JP61270684A patent/JPS63125333A/en active Granted
Also Published As
| Publication number | Publication date |
|---|---|
| JPS63125333A (en) | 1988-05-28 |
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