JP2007112374A - Vehicular interior material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a vehicular interior material which is excellent in touch feeling when a skin surface is touched or rubbed by a hand, and capable of absorbing disagreeable noise in a vehicle, and preventing the impairment of the appearance of the skin surface. <P>SOLUTION: The vehicular interior material has a structure in which a base material layer 3, an intermediate layer 2 and a surface layer 1 are laminated in this order. Conical projecting parts are formed on the side face of the surface layer (the surface) of the intermediate layer (2), and the skin layer is sliced and removed. Spaces 4 demarcated by the projecting parts do not form any independent closed spaces but communicate with each other. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an interior material for a vehicle that is used as an interior material such as an instrument panel, a door trim, or a ceiling of a vehicle and has excellent tactile sensation and sound absorption characteristics.

  As interior materials for vehicles such as automobiles (for example, instrument panels and door trims), the tactile sensation when touching or rubbing the skin surface with a hand is good, no unpleasant sound is generated, and unpleasant sound inside the vehicle. The thing which is excellent in the performance which absorbs is required.

Conventionally, in order to meet such demands, by using molding methods such as slush molding and low-pressure molding, a composite molded body having a three-layer structure of skin layer-foaming layer-base material is obtained, and surface feel is improved. It was.
However, most of the sound absorption is not specifically considered. On the other hand, an interior part having a two-layer structure of a skin layer and a base material layer with improved tactile sensation by molding the skin layer of the composite molded body with a soft resin or a foamed resin is also known (for example, , See Patent Document 1 and Patent Document 2.)
JP 63-115711 A JP 2002-348435 A

  However, such conventional two-layer interior products have the advantage of increasing productivity by using injection molding methods such as insert molding and two-color molding, but compared with a three-layered multilayer molded body. The tactile sensation is remarkably inferior, and in order to improve the tactile sensation with only the skin layer, it is necessary to increase the thickness of the skin layer.

In addition, in order to compensate for these drawbacks, a method of improving the tactile sensation by providing a through-hole portion or a void portion in the base material layer so that the skin layer is recessed and easily deformed (for example, patent document) (See 3.)
JP-A-6-210779

However, in the structure according to this method, the through hole or the void portion has an independent cell structure, so when the vehicle is left under hot weather such as summer, the air in the through hole or void portion expands, The surface may swell and impair the appearance.
In addition, any two-layer structure cannot be expected so much with respect to sound absorption required as an interior material.

  The present invention has been made in view of such problems of the prior art, and the object of the present invention is to provide a good feel when the skin surface is touched or rubbed with a hand, and an unpleasant sound in the vehicle. An object of the present invention is to provide a vehicle interior material that absorbs water and does not impair the appearance of the skin surface.

  As a result of intensive studies to achieve the above object, the present inventors have found that the above object can be achieved by forming a predetermined communication space at at least one interface in the composite molded body having a three-layer structure. The present invention has been completed.

That is, the vehicle interior material of the present invention is an interior material formed by laminating a base material layer, an intermediate layer and a surface layer in this order,
At least one interface of the interface between the base material layer and the intermediate layer and the interface between the intermediate layer and the surface layer is formed by partial bonding,
A space defined by these joint portions communicates with each other.

  The vehicle interior material according to the present invention preferably has a concave and / or convex shape on at least one of the surface and the back surface of the intermediate layer, the surface of the base material layer, the back surface of the surface layer, and the like. And

  According to the present invention, since a predetermined communication space is formed at least one interface in the composite molded body having a three-layer structure, the touch when the skin surface is touched or rubbed with the hand is good, and the interior of the vehicle It is possible to provide an interior material for a vehicle that absorbs the unpleasant noise of the vehicle and does not impair the appearance of the skin surface.

  Hereinafter, the vehicle interior material of the present invention will be described in detail. In the present specification, “%” represents mass percentage unless otherwise specified.

As described above, the vehicle interior material has excellent tactile sensation and sound absorption, and is formed by laminating a base material layer, an intermediate layer, and a surface layer in this order.
Then, at least one of the interface between the base material layer and the intermediate layer and the interface between the intermediate layer and the surface layer is formed by partial bonding, and the interface is formed by a bonding portion that realizes the partial bonding. A plurality of spaces are partitioned and are connected to each other.

Here, the interface between the base material layer and the intermediate layer is composed of the surface of the base material layer and the back surface of the intermediate layer, and the interface between the intermediate layer and the surface layer is composed of the surface of the intermediate layer and the back surface of the surface layer.
Moreover, the partial joining in these interfaces is implement | achieved by forming a recessed part or a convex part, or typically an uneven | corrugated | grooved part in one or both surfaces which comprise an interface, and joining the said surfaces. Can do.

In addition, when forming uneven portions on both surfaces constituting the interface, the uneven portions or the like may be partially fitted, but when completely fitted to form a space in the interface, It is out of the scope of the present invention.
From the above, typically, the vehicle interior material of the present invention has the above-mentioned at least one of the surface or back surface of the intermediate layer or both the surface and back surface, the surface of the base material layer, and the back surface of the surface layer. Such an uneven part is formed.

The shape of the concavo-convex portion is not particularly limited as long as it realizes partial bonding at the interface as described above and communicates a plurality of spaces defined by the concavo-convex portion.
Specifically, in the case of the convex portion, a spherical shape, a hemispherical shape, a cube or a rectangular parallelepiped shape, a conical shape, and a convex portion whose cross section has a triangular shape, a quadrangular shape, or a trapezoidal shape are exemplified.
On the other hand, in the case of the concave portion, a spherical shape, a hemispherical shape, a cube or a rectangular parallelepiped shape, a cylindrical shape, and a concave portion having a quadrangular or trapezoidal cross section are exemplified.

In addition, the communication of the above-mentioned spaces is not limited as long as any one of the plurality of spaces communicates with at least one other space, and all the spaces need to communicate with each other. Absent.
However, in the vehicle interior material of the present invention, it is preferable that the concave and convex portions or the like make a continuous space appear around it.

In addition, it is not particularly limited as long as the above-described partial joining of the interface and communication of the space can be realized, but the pitch (formation interval) of the concave portion, the convex portion, or the concave and convex portion is preferably 0.5 to 10 mm, preferably Is preferably 2 to 8 mm.
If the pitch is less than 0.5 mm, it depends on the combination of the depth and height of the concavo-convex part, but the amount of movement of the surface when touching the finger is small, making it difficult to improve the target tactile sensation. Although depending on the combination of the depth and height of the part, since the space at the time of finger touching is too open, the amount of movement becomes conversely too large, and there is a possibility that it is difficult to obtain the target tactile feeling improvement effect.

Moreover, it is preferable to set it as 0.5-3 mm as the depth of the said recessed part, and the height of a convex part.
If the depth of the concave portion or the height of the convex portion is less than 0.5 mm, the amount of movement of the surface layer is small when touched by a finger, and it is difficult to obtain the target tactile feeling improvement effect. There is a possibility that it becomes difficult to obtain a target tactile sensation improving effect.

  By adopting the configuration as described above, the mechanism that the vehicle interior material of the present invention exhibits a good tactile sensation is not necessarily clear at this time, but it is a partial joining of a predetermined interface, that is, representatively. Due to the presence of uneven parts, when the interior material surface is touched by hand, the load applied vertically upward and downward with respect to the surface is widely dispersed in the lateral and oblique directions, and the uneven parts themselves are slightly elastically deformed. It is estimated that a soft tactile sensation is realized.

The concave and convex portions may be formed on at least one interface described above. However, if emphasis is placed on the tactile sensation, it is formed on the surface layer side, typically on the surface or back surface of the intermediate layer, particularly on the surface of the intermediate layer. It is preferable to do this.
Moreover, although the sound absorption performance can be improved by forming such uneven portions, it is desirable to form on the surface of the base material if importance is attached to the improvement of the sound absorption performance.

  Furthermore, in the interior material for a vehicle of the present invention, the formed spaces are not individually independent but communicated with each other, so that partial expansion is suppressed even when the vehicle is left under hot weather such as in summer. The appearance surface is hardly damaged.

Next, the material of each layer in the vehicle interior material of the present invention will be described.
First, the base material is not particularly limited, and a suitable material may be selected as an automobile interior part and according to the molding method. For example, recycling of olefin-based resin, AS resin, and the like is possible. Possible thermoplastic resins are good, but it is also possible to use a hardened fiber such as a thermosetting resin or a non-woven fabric.
Further, the form of the resin may be a bulk body or a foam body.

  In molding, if a thermoplastic resin is used, parts are often manufactured by injection molding. However, if a desired concavo-convex shape is given to the mold in advance, the surface of the base material layer will be uneven during molding. It is also possible to form them simultaneously.

Next, as the intermediate layer material, a foam such as a resin foam is desirable, and examples thereof include polyamides such as polyurethane, polyvinyl chloride, and nylon (registered trademark), polyester, and polypropylene. Among them, moldability, cost, and sound absorption are mentioned. A polyurethane excellent in performance and the like is preferable.
Further, for example, a fiber composite obtained by compressing and solidifying fibers such as polyester and nylon (registered trademark) using a homogeneous material or a binder such as a phenol resin can also be used.

By using a resin foam body or fiber composite as described above as the intermediate layer material, the sound absorbing performance can be further improved.
In addition, although the said foam has an uneven | corrugated | grooved part formed in at least one surface of front and back, the uneven | corrugated | grooved part may be formed in both surfaces of the surface and the back surface.

Moreover, examples of the surface layer material include polyamides such as polyurethane, polyvinyl chloride, and nylon (registered trademark), polyesters, and polyolefins, and polyurethane is preferable in consideration of touch feeling and adhesiveness to the intermediate layer.
The manufacturing method is not particularly limited, and conventionally known methods such as powder slush and skin vacuuming can be applied.

  It should be noted that a fiber aggregate such as a fabric is also suitable as the surface layer material, which is further effective in sound absorption performance. However, it is somewhat difficult to form the uneven portion.

Further, in the surface layer and the intermediate layer described above, the skin layer (hard surface) is formed on the surface on which the uneven portion is formed, that is, on the surface when the uneven portion is formed on the surface, and on the back surface when the uneven portion is formed on the back surface. The layer) is preferably absent.
In a normal foam, a skin layer is generally formed, but it can be removed by slicing.
Since there is no skin layer (hard layer), the feeling of hardness due to the presence of the skin layer is removed, so that the tactile sensation is further improved. Moreover, the sound absorption performance can be further improved by removing the skin layer.

In the vehicle interior material of the present invention, the thicknesses of the base material layer, the intermediate layer, and the surface layer can be appropriately changed according to the site to be applied and the required performance. 0.0-10.0 mm, the intermediate layer is 2.0-15.0 mm, and the surface layer is 0.5-1.5 mm.
The thickness of the entire interior material is typically 4.0 to 20.0 mm.

  EXAMPLES Hereinafter, although an Example and a comparative example demonstrate this invention further in detail, this invention is not limited to these Examples.

Example 1
FIG. 1 is a cross-sectional view showing an embodiment of a vehicle interior material of the present invention.
The interior material of this example has a structure in which the base material layer 3, the intermediate layer 2, and the surface layer 1 are laminated in this order, and a conical convex portion is formed on the side surface (surface) of the intermediate layer 2. The skin layer has been sliced away.
Note that the spaces 4 defined by the convex portions do not form independent closed spaces but communicate with each other.

  The material of the surface layer 1 is vinyl chloride and is formed by powder slush. The material of the mid layer 2 is polyethylene foam. The material of the base material layer 3 is a general polypropylene, which is produced by injection molding.

(Example 2)
FIG. 2 is a cross-sectional view showing another embodiment of the vehicle interior material of the present invention. Hereinafter, the same components and members as those described above are denoted by the same reference numerals, and description thereof is omitted.
The interior material of this example was formed by forming conical convex portions on the surface (back surface) of the intermediate layer 2 on the base material layer side, and the skin layer was sliced and removed.

  The material of the surface layer 1 is polyurethane (TPU) and is formed by powder slush. The material of the intermediate layer 2 is polyurethane foam. The material of the base material layer 3 is a general polypropylene, which is produced by injection molding.

(Example 3)
FIG. 3 is a cross-sectional view showing still another embodiment of the vehicle interior material of the present invention.
The interior material of this example is formed by forming conical convex portions on the base layer side surface (back surface) of the intermediate layer 3 and the back surface of the surface layer 1, and the skin layer was sliced and removed.
The material of the surface layer 1 was polyurethane (TPU), and was molded by powder slush. The material of the intermediate layer 2 is polyurethane foam. The material of the base material layer 3 is a general polypropylene, which is produced by injection molding.

(Comparative Example 1)
FIG. 4 is a cross-sectional view showing a conventional general three-layer vehicle interior material.
The material of the surface layer 1 is vinyl chloride and is formed by powder slush. The material of the intermediate layer 2 is polyurethane foam. The material of the base material layer 1 is a general polypropylene.

[Performance evaluation]
(1) Tactile sensation evaluation The tactile sensation evaluation of the interior material of the Example and the comparative example was performed.
The evaluation items were evaluated by a panel with a five-level evaluation of a soft feeling with a high contribution rate as an item for judging whether the feel was good or bad.
In order to exclude the visual influence, the panel was devised so that the sample could not be seen directly, and the panelist touched the sample surface with the belly of the finger to make a judgment.
Judgment was based on Comparative Example 1, with 5 being considerably better than this, 3 being equivalent, and 1 being considerably inferior. The obtained results are shown in Table 1.

(2) Sound absorption performance The interior material of the example and the comparative example was measured for the sound absorption rate according to JIS A1405: 1998 sound-measurement of sound absorption rate and impedance by impedance tube-standing wave ratio method.
The size of the sample is according to the description in 6.1.2 Reference of JIS A1405. For the low frequency side (operating frequency 100 to 800 Hz), a sample with a thickness of 30 mm cut into a circle with a diameter of 92 mm is used. For a frequency of 800 to 5000 Hz or more, a 30 mm thick material cut into a circle with a diameter of 29 mm was used. The sample was set so that the surface layer side was in the incident direction of the sound wave.
The sound absorption coefficient was obtained according to the calculation method of α defined in 3.1 normal incident sound absorption coefficient of JIS A1405: 1998. The measurement environment was 23 ° C. and 60 RH. The measurement was performed three times and the average value of these was adopted. The obtained results are shown in Table 1.

  As is apparent from the results shown in Table 1, Examples 1 to 3 belonging to the scope of the present invention exhibit good tactile sensation.

It is sectional drawing which shows one Example of the vehicle interior material of this invention. It is sectional drawing which shows the other Example of the vehicle interior material of this invention. It is sectional drawing which shows other Example of the vehicle interior material of this invention. It is sectional drawing which shows an example of the conventional interior material for three-layer structure vehicles.

Explanation of symbols

1 surface layer 2 intermediate layer 3 base material layer 4 space

Claims (10)

In the interior material for vehicles formed by laminating the base material layer, the intermediate layer and the surface layer in this order,
At least one interface of the interface between the base material layer and the intermediate layer and the interface between the intermediate layer and the surface layer is formed by partial bonding,
A vehicle interior material characterized in that a space defined by the joint portion communicates therewith.   The vehicle interior material according to claim 1, wherein the base material layer is made of a bulk body or a foam body of a thermoplastic resin or a thermosetting resin.   The vehicle interior material according to claim 1 or 2, wherein the intermediate layer is made of a resin foam body or a fiber composite body.   The vehicular interior material according to any one of claims 1 to 3, further comprising a concave portion and / or a convex portion on at least one of a front surface and a back surface of the intermediate layer.   The concave portion and / or the convex portion are provided on the front surface or the back surface of the intermediate layer, and no skin layer is present on the front surface or the back surface of the intermediate layer having the concave portion and / or the convex portion. 4. Vehicle interior material according to 4.   The interior material for a vehicle according to any one of claims 1 to 5, wherein the surface of the base material layer has a concave portion and / or a convex portion.   The vehicular interior material according to any one of claims 1 to 6, further comprising a concave portion and / or a convex portion on a back surface of the surface layer.   The vehicle interior material according to claim 7, wherein no skin layer is present on the surface of the surface layer.   The interior material for a vehicle according to any one of claims 4 to 8, wherein a pitch of the concave portion and / or the convex portion is 0.5 to 10 mm.   The vehicle interior material according to any one of claims 4 to 9, wherein a depth of the concave portion is 0.5 to 3 mm, and a height of the convex portion is 0.5 to 3 mm.

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