JPH0521064B2 - - Google Patents
Info
- Publication number
- JPH0521064B2 JPH0521064B2 JP61084799A JP8479986A JPH0521064B2 JP H0521064 B2 JPH0521064 B2 JP H0521064B2 JP 61084799 A JP61084799 A JP 61084799A JP 8479986 A JP8479986 A JP 8479986A JP H0521064 B2 JPH0521064 B2 JP H0521064B2
- Authority
- JP
- Japan
- Prior art keywords
- cross
- foam sheet
- layer
- heat
- thickness
- 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
- 239000006260 foam Substances 0.000 claims description 63
- 239000010410 layer Substances 0.000 claims description 47
- 239000000463 material Substances 0.000 claims description 40
- 229920001155 polypropylene Polymers 0.000 claims description 16
- 238000004519 manufacturing process Methods 0.000 claims description 15
- 238000001125 extrusion Methods 0.000 claims description 12
- 238000002844 melting Methods 0.000 claims description 11
- 230000008018 melting Effects 0.000 claims description 11
- 239000000853 adhesive Substances 0.000 claims description 8
- 230000001070 adhesive effect Effects 0.000 claims description 8
- 229920000573 polyethylene Polymers 0.000 claims description 7
- 238000003825 pressing Methods 0.000 claims description 5
- 239000007787 solid Substances 0.000 claims description 5
- 239000012790 adhesive layer Substances 0.000 claims description 2
- 210000003491 skin Anatomy 0.000 description 30
- 238000000034 method Methods 0.000 description 17
- 238000003475 lamination Methods 0.000 description 13
- 238000010030 laminating Methods 0.000 description 9
- 229920001577 copolymer Polymers 0.000 description 7
- 229920000642 polymer Polymers 0.000 description 7
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 7
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 6
- 239000012793 heat-sealing layer Substances 0.000 description 6
- 239000004743 Polypropylene Substances 0.000 description 5
- 238000000137 annealing Methods 0.000 description 5
- 238000002788 crimping Methods 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- 239000000835 fiber Substances 0.000 description 5
- 238000009413 insulation Methods 0.000 description 5
- 238000000465 moulding Methods 0.000 description 5
- -1 polyethylene Polymers 0.000 description 5
- 239000002648 laminated material Substances 0.000 description 4
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 4
- 239000005977 Ethylene Substances 0.000 description 3
- 229920005830 Polyurethane Foam Polymers 0.000 description 3
- 229920001400 block copolymer Polymers 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 238000005187 foaming Methods 0.000 description 3
- 239000011496 polyurethane foam Substances 0.000 description 3
- 239000001294 propane Substances 0.000 description 3
- 230000037303 wrinkles Effects 0.000 description 3
- 239000004711 α-olefin Substances 0.000 description 3
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 2
- 239000004831 Hot glue Substances 0.000 description 2
- 239000002216 antistatic agent Substances 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 210000002615 epidermis Anatomy 0.000 description 2
- HQQADJVZYDDRJT-UHFFFAOYSA-N ethene;prop-1-ene Chemical group C=C.CC=C HQQADJVZYDDRJT-UHFFFAOYSA-N 0.000 description 2
- 239000003063 flame retardant Substances 0.000 description 2
- 210000004209 hair Anatomy 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 229920001903 high density polyethylene Polymers 0.000 description 2
- 239000004700 high-density polyethylene Substances 0.000 description 2
- 238000005304 joining Methods 0.000 description 2
- 239000010985 leather Substances 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 238000003856 thermoforming Methods 0.000 description 2
- VXNZUUAINFGPBY-UHFFFAOYSA-N 1-Butene Chemical compound CCC=C VXNZUUAINFGPBY-UHFFFAOYSA-N 0.000 description 1
- 239000004604 Blowing Agent Substances 0.000 description 1
- 206010016322 Feeling abnormal Diseases 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 235000008331 Pinus X rigitaeda Nutrition 0.000 description 1
- 235000011613 Pinus brutia Nutrition 0.000 description 1
- 241000018646 Pinus brutia Species 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000006096 absorbing agent Substances 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 230000003796 beauty Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- IAQRGUVFOMOMEM-UHFFFAOYSA-N butene Natural products CC=CC IAQRGUVFOMOMEM-UHFFFAOYSA-N 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 239000011162 core material Substances 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 239000003431 cross linking reagent Substances 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 238000010894 electron beam technology Methods 0.000 description 1
- 239000000839 emulsion Substances 0.000 description 1
- 229920005676 ethylene-propylene block copolymer Polymers 0.000 description 1
- 229920005674 ethylene-propylene random copolymer Polymers 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 244000144992 flock Species 0.000 description 1
- 239000004088 foaming agent Substances 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 239000012760 heat stabilizer Substances 0.000 description 1
- 239000012943 hotmelt Substances 0.000 description 1
- 229920000092 linear low density polyethylene Polymers 0.000 description 1
- 239000004707 linear low-density polyethylene Substances 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 229920001179 medium density polyethylene Polymers 0.000 description 1
- 239000004701 medium-density polyethylene Substances 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000006072 paste Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920005606 polypropylene copolymer Polymers 0.000 description 1
- 229920005629 polypropylene homopolymer Polymers 0.000 description 1
- 229920005604 random copolymer Polymers 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 238000009823 thermal lamination Methods 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
Landscapes
- Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
- Laminated Bodies (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
Description
【発明の詳細な説明】
（産業上の利用分野）
この発明は、例えば自動車の天井材、ドア内張
材、トランクルームマツトなどの自動車用内装材
の製造方法に関するものである。DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for manufacturing automobile interior materials such as automobile ceiling materials, door lining materials, and trunk room mats.
（従来の技術）
この種の内装材、例えば自動車の成形天井に
は、品質として、剛性、耐熱性、深絞り成形性、
ハンドリング性および断熱性、さらには内装材と
しての美感、ソフト感等が要求される。そして、
これらの要求品質を満たすため、従来は、基材と
して、レジンフエルト、プラスチツクハニカム、
ダンボール等の比較的硬い材料が使用されるとと
もに、表面材として、ポリウレタン発泡体、ポリ
エチレン発泡体等のパツド材と、ニツト、塩ビレ
ザー等の表皮が使用されるのが一般であつた。こ
の種の成形天井としては、例えば、非発泡のプロ
ピレン系重合体シート／ポリプロピレン発泡体／
非発泡のプロピレン系重合体シートが基材として
使用されるとともに、ポリウレタン発泡体／布、
塩ビレザー等が表面材として使用され、これらを
積層して、５種の積層体とされたものが考案され
ている（実開昭55−148926号公報参照）。(Prior art) This type of interior material, such as the molded ceiling of an automobile, has qualities such as rigidity, heat resistance, deep drawability,
Handling and heat insulation properties are required, as well as aesthetics and a soft feel as an interior material. and,
In order to meet these quality requirements, resin felt, plastic honeycomb,
Generally, a relatively hard material such as cardboard was used, and as a surface material, a pad material such as polyurethane foam or polyethylene foam, and a skin such as knit or PVC leather were used. This type of molded ceiling includes, for example, non-foamed propylene polymer sheet/polypropylene foam/
A non-foamed propylene polymer sheet is used as the base material, as well as polyurethane foam/cloth,
PVC leather or the like is used as the surface material, and five types of laminates have been devised by laminating these materials (see Japanese Utility Model Application Publication No. 148926/1983).
（発明が解決しようとする問題点）
しかしながら、このような成形天井では、構造
が複雑で、製造工程も複雑となり、製造コストの
高騰を招いていた。(Problems to be Solved by the Invention) However, such a molded ceiling has a complicated structure and a complicated manufacturing process, leading to a rise in manufacturing costs.
また、表面材として成形できないポリウレタン
発泡体が使用されているので、加熱成形による深
くてシヤープな造形的美感を得ることができない
という問題もあつた。 Furthermore, since polyurethane foam, which cannot be molded, is used as the surface material, there is a problem in that it is not possible to obtain a deep, sharp aesthetic appearance by heat molding.
（問題点を解決するための手段）
本発明は、まず２枚の架橋発泡シートのそれぞ
れの片面に、非発泡の表皮層をそれぞれ押出ラミ
ネートして、２枚のラミネート品を形成する。押
出ラミネートは、例えば非発泡のプロピレン系重
合体を押出金型を通じてシート状の表皮層を形成
し、この表皮層を架橋発泡シートに添わせ、ロー
ルで圧着し、冷却することにより行なう。(Means for Solving the Problems) In the present invention, first, a non-foamed skin layer is extrusion laminated on one side of each of two crosslinked foam sheets to form two laminate products. Extrusion lamination is carried out, for example, by passing a non-foamed propylene polymer through an extrusion mold to form a sheet-like skin layer, applying this skin layer to a crosslinked foam sheet, pressing it with a roll, and cooling.
架橋発泡シートはプロピレン系重合体とエチレ
ン系重合体とからなる。 The crosslinked foam sheet is made of a propylene polymer and an ethylene polymer.
架橋発泡シートを構成するプロピレン系重合体
としては、例えば、エチレンとプロピレンのラン
ダム共重合体、ブロツク共重合体、あるいはラン
ダム・ブロツク共重合体、エチレン・ブテン・プ
ロピレン共重合体等のα−オレフイン・プロピレ
ン共重合体などがあげられる。この共重合される
α−オレフインは共重合体の融点が130〜170℃の
間になされるのが好ましい。プロピレン系重合体
のメルトフローレート（MFR）は0.1〜50が好ま
しく、より好ましくは0.3〜30とされる。 Examples of the propylene polymer constituting the crosslinked foam sheet include α-olefins such as random copolymers of ethylene and propylene, block copolymers, random block copolymers, and ethylene-butene-propylene copolymers. - Examples include propylene copolymers. The melting point of the copolymerized α-olefin is preferably between 130 and 170°C. The melt flow rate (MFR) of the propylene polymer is preferably 0.1 to 50, more preferably 0.3 to 30.
架橋発泡シートを構成するエチレン系重合体と
しては、低密度ポリエチレン、中密度ポリエチレ
ン、高密度ポリエチレン、線状低密度ポリエチレ
ン、エチレン・酢酸ビニル共重合体、無定型エチ
レン・プロピレン共重合体等があげられ、これら
は、単独あるいは二種以上混合して使用すること
ができる。また、これらのエチレン系重合体の
MFRは0.1〜50が好ましく、より好ましくは0.2〜
30とされる。 Examples of the ethylene polymers constituting the crosslinked foam sheet include low density polyethylene, medium density polyethylene, high density polyethylene, linear low density polyethylene, ethylene/vinyl acetate copolymer, amorphous ethylene/propylene copolymer, etc. These can be used alone or in a mixture of two or more. In addition, these ethylene polymers
MFR is preferably 0.1 to 50, more preferably 0.2 to 50.
It is said to be 30.
架橋発泡シートはポリプロピレン系重合体の量
が増えると、耐熱性があり、腰も強くなるが、反
面割れ易くて、特に低温の衝撃強度が低く、硬す
ぎてクツシヨン性が悪くなる。また、押出機等で
の熱成形が困難になり、架橋剤および発泡剤の分
解が起こつて、良好な成形物、ひいては良好な発
泡体が得られない。逆に、ポリプロピレン系重合
体の量が減つてエチレン系重合体の量が増える
と、耐熱性および機械的強度等の物性が低下す
る。したがつて、架橋発泡シート中のポリプロピ
レン系重合体の量は、10〜80重量％が好ましく、
より好ましくは20〜70重量％とされる。 As the amount of polypropylene polymer increases, crosslinked foam sheets become more heat resistant and stiff, but on the other hand, they tend to break easily, have low impact strength especially at low temperatures, and are too hard, resulting in poor cushioning properties. Furthermore, thermoforming using an extruder or the like becomes difficult, and the crosslinking agent and foaming agent decompose, making it impossible to obtain a good molded product or a good foam. Conversely, when the amount of polypropylene polymer decreases and the amount of ethylene polymer increases, physical properties such as heat resistance and mechanical strength decrease. Therefore, the amount of polypropylene polymer in the crosslinked foam sheet is preferably 10 to 80% by weight,
More preferably, it is 20 to 70% by weight.
架橋発泡シートは高発泡体であつて、発泡倍率
は10〜50倍が好ましく、より好ましくは20〜40倍
とされる。 The crosslinked foam sheet is a highly foamed material, and the expansion ratio is preferably 10 to 50 times, more preferably 20 to 40 times.
また、架橋発泡シートの厚さは、薄くなると曲
げ強度が低下し、逆に厚くなると経済性がなくな
るため、１〜５mmとされるのが好ましい。 Further, the thickness of the cross-linked foam sheet is preferably 1 to 5 mm, since the thinner the sheet, the lower the bending strength, and the thicker the sheet, the less economical.
表皮層は実質的に発泡されていないポリプロピ
レンおよびプロピレンを主体とした他のモノマー
との共重合体シートである。 The skin layer is a substantially unfoamed polypropylene and propylene-based copolymer sheet with other monomers.
表皮層を構成するプロピレン系重合体として
は、例えばエチレン・プロピレンブロツク共重合
体、エチレン・プロピレンランダム共重合体、エ
チレン・ブテン・プロピレン共重合体等のα−オ
レフイン・プロピレン共重合体などがあげられ
る。また、必要に応じて、これらに、さらに顔
料、難燃剤、帯電防止剤、抗酸化剤、増量剤など
無機物や有機物を加えることもできる。なお、表
皮層の肉厚は、薄くなると機械的強度が低下し、
逆に厚くなると重くなるので0.1〜１mmとされる
のが好ましい。非発泡層及び発泡層はそれぞれ対
称であるのが反り難い点でより好ましい。 Examples of propylene-based polymers constituting the skin layer include α-olefin/propylene copolymers such as ethylene/propylene block copolymers, ethylene/propylene random copolymers, and ethylene/butene/propylene copolymers. It will be done. Further, if necessary, inorganic or organic substances such as pigments, flame retardants, antistatic agents, antioxidants, and fillers can be added to these. In addition, as the thickness of the skin layer becomes thinner, the mechanical strength decreases.
On the other hand, the thicker it is, the heavier it becomes, so it is preferably 0.1 to 1 mm. It is more preferable that the non-foamed layer and the foamed layer are symmetrical so that they are less likely to warp.
次にラミネート品の表皮層に植毛加工をする。
植毛加工は、非発泡の表皮層の上にロールコータ
ーなどで接着剤を塗布し、その上に短繊維を静電
変圧加工機等によつて植毛加工し、乾燥炉によつ
て乾燥させる。使用される接着剤は、プロピレン
系重合体と短繊維との親和性が良く、接着、固化
するものが使用され、ホツトメルト形、エマルジ
ヨン形、ペースト形等の接着剤が使用される。 Next, the epidermal layer of the laminate is treated with flocking.
In the flocking process, an adhesive is applied onto the non-foamed skin layer using a roll coater or the like, short fibers are flocked thereon using an electrostatic transformer or the like, and then dried in a drying oven. The adhesive to be used is one that has good affinity with the propylene polymer and short fibers and can be bonded and solidified, such as hot melt, emulsion, or paste adhesives.
植毛加工した後、この植毛加工したラミネート
品と植毛加工していないラミネート品とを、架橋
発泡シート側の表面を互いに相対させ、架橋発泡
シート面をプロパンガス炎などで熔融して圧着
し、熔融、圧着により熱融着層を形成する。 After flocking, the flocked laminate product and the non-flocked laminate product are placed with their cross-linked foam sheet sides facing each other, and the cross-linked foam sheet surfaces are melted and pressed using a propane gas flame. , a heat-sealing layer is formed by pressure bonding.
次に、内装材を構成する各層間の肉厚関係につ
いて説明する。 Next, the relationship between the thicknesses of the layers constituting the interior material will be explained.
架橋発泡シートの固体肉厚Tfと非発泡の表皮
層の肉厚Tsとの比Ts／Tfは１〜50に設定するの
が好ましい。なお、ここに固体肉厚Tfとは、架
橋発泡シートから空気を抜き出したものの厚さを
いう。 The ratio Ts/Tf of the solid thickness Tf of the crosslinked foam sheet to the thickness Ts of the non-foamed skin layer is preferably set to 1-50. Note that the solid wall thickness Tf herein refers to the thickness of the crosslinked foam sheet after removing air.
内装材の成形性を改良するためには、いわゆる
ネツキング、つまり表皮層が成形時に局部的に肉
薄となつて裏側がすけて見えたり、亀裂ができた
りする現象を解消する必要がある。そして、この
ネツキングの解消のためには、積層発泡シートの
加熱収縮をできるだけ少なくする必要がある。 In order to improve the moldability of interior materials, it is necessary to eliminate so-called netting, a phenomenon in which the skin layer becomes locally thin during molding, causing the back side to show through or cracks to form. In order to eliminate this netting, it is necessary to minimize the heat shrinkage of the laminated foam sheet.
固体肉厚Tfと肉厚Tsとの比Ts／Tfが１以上で
あれば、内装材における表皮層の占める割合が支
配的となり、この歪の少ない表皮層が本来加熱収
縮の大きな架橋発泡シートを補強して、内層材の
加熱収縮を最小限に抑えることができる。 If the ratio Ts/Tf between the solid wall thickness Tf and the wall thickness Ts is 1 or more, the proportion of the skin layer in the interior material will be dominant, and this skin layer with less distortion will naturally cause the crosslinked foam sheet to have a large heat shrinkage. It can be reinforced to minimize heat shrinkage of the inner layer material.
一方、Ts／Tfが50よりも大きくなると、表皮
層の割合が内装材のほとんどを占めてしまい、内
装材全体としての断熱性、ソフト感などを得難
い。 On the other hand, when Ts/Tf is greater than 50, the surface layer accounts for most of the interior material, making it difficult to obtain heat insulation properties and a soft feel for the interior material as a whole.
また、Ts／Tfが１よりも小さいと、架橋発泡
シートの歪が内装材全体の加熱収縮を大きくする
ように働くため好ましくない。 Moreover, if Ts/Tf is smaller than 1, it is not preferable because the distortion of the crosslinked foam sheet acts to increase the heat shrinkage of the entire interior material.
したがつて、１≦Ts／Tf≦50とするのが好ま
しい
架橋発泡シートの表面同士を熔融、圧着して形
成される熱融着層の厚みTlは0.1〜0.5mmとし、か
つ架橋発泡シートの肉厚の１〜25％に設定するの
が好ましい。以下説明する。 Therefore, it is preferable that 1≦Ts/Tf≦50. The thickness Tl of the heat-sealing layer formed by melting and pressing the surfaces of the cross-linked foam sheets is 0.1 to 0.5 mm, and It is preferable to set it to 1 to 25% of the wall thickness. This will be explained below.
架橋発泡シート同士の積層は、ガスによる火炎
等により熔融し圧着することによつておこなわれ
るが、架橋発泡シートの表面同士を接合する際
に、接合部分に充分な熱量を与えて0.1mm以上の
低発泡または非発泡層である熱融着層を形成すれ
ば、架橋発泡シートの製造時に固定された歪を除
去できるとともに、融着時の熱が架橋発泡シート
の歪をアニールする効果をも発揮する。これによ
り、成形性が良好なものとなる。 Lamination of cross-linked foam sheets is carried out by melting and crimping with gas flame, etc., but when joining the surfaces of the cross-linked foam sheets, sufficient heat is applied to the joint part to form a layer of 0.1 mm or more. By forming a low-foaming or non-foaming layer, the heat-sealing layer, it is possible to remove the distortion fixed during the production of the cross-linked foam sheet, and the heat during fusing also has the effect of annealing the distortion of the cross-linked foam sheet. do. This results in good moldability.
なお、引取速度を大きくして架橋発泡シート同
士を接合すると、比熱の小さいポリオレフイン系
発泡体では、架橋発泡シートの表面のみが熔融さ
れて、接合が可能である反面、熱融着層を形成し
難く、また、アニールは、熱がある一定以上の時
間作用する必要があるため、アニール効果を期待
することも難しい。したがつて、引取速度はあま
り大きくしないことが好ましい。 Note that when the cross-linked foam sheets are joined together by increasing the take-up speed, only the surface of the cross-linked foam sheets is melted in the case of polyolefin foam having a low specific heat, and joining is possible. Furthermore, since annealing requires heat to act for a certain period of time or more, it is difficult to expect an annealing effect. Therefore, it is preferable not to increase the take-up speed too much.
一方、熱融着層の厚みTlが0.1mmよりも大きく
なると、内装材としての断熱性、ソフト感を得難
い。 On the other hand, if the thickness Tl of the heat-adhesive layer is greater than 0.1 mm, it is difficult to obtain heat insulation properties and a soft feel as an interior material.
したがつて、0.1≦Tl≦0.5mmとするのが好まし
く、架橋発泡シートの発泡倍率、厚みの関係は１
％≦（Tl／架橋発泡シートの肉厚）≦25％とする
のが好適である。 Therefore, it is preferable that 0.1≦Tl≦0.5mm, and the relationship between the expansion ratio and thickness of the crosslinked foam sheet is 1.
It is preferable that %≦(Tl/thickness of cross-linked foam sheet)≦25%.
（作用）
本発明の製造方法は、押出ラミネート法によ
つて、架橋発泡シートの表面にほとんど歪のない
表皮層を形成すること、架橋発泡シートの表面
に表皮層を積層する際の加熱によりアニール効果
を得ること、２枚の架橋発泡シートを重ね合わ
せて積層することにより、架橋発泡シートの加熱
収縮を全体として平均化すること、および架橋
発泡シートの表面を熔融し、圧着することによつ
て、架橋発泡シートの製造時に固定された歪を抑
制し、加熱成形時の加熱収縮率を減少して、安定
確実な成形性を得る。(Function) The manufacturing method of the present invention includes forming a skin layer with almost no distortion on the surface of a cross-linked foam sheet by extrusion lamination, and annealing by heating when laminating the skin layer on the surface of the cross-linked foam sheet. By stacking two cross-linked foam sheets on top of each other, the heat shrinkage of the cross-linked foam sheets is averaged as a whole, and by melting and press-bonding the surface of the cross-linked foam sheets. , suppressing the distortion fixed during the production of the crosslinked foam sheet, reducing the heat shrinkage rate during hot molding, and achieving stable and reliable moldability.
また、熔融、圧着する前のラミネート品の非発
泡の表皮層に接着剤を用いて植毛加工することに
より、損傷がなく、しかも均一な植毛面が得られ
る。 Further, by using an adhesive to flock the non-foamed skin layer of the laminate before melting and pressing, a uniform flocked surface without damage can be obtained.
プロピレン系重合体とエチレン系重合体からな
る２枚の架橋発泡シートが積層されて芯材になる
ことにより、自動車用内装材自体の軽量化を図る
とともに、充分な耐衝撃性、剛性、耐熱性、成形
性、ハンドリング性、耐熱性、防音性等を得る。 By laminating two cross-linked foam sheets made of propylene-based polymer and ethylene-based polymer to form the core material, it is possible to reduce the weight of the automotive interior material itself, while also providing sufficient impact resistance, rigidity, and heat resistance. , moldability, handling properties, heat resistance, soundproofing properties, etc.
架橋発泡シートの一面にプロピレン系重合体か
らなる非発泡の表皮層を積層することにより、内
装材としての充分な美感、ソフト感等を得るため
の深くシヤープな熱成形性を得る。 By laminating a non-foamed skin layer made of a propylene polymer on one side of a cross-linked foam sheet, deep and sharp thermoformability is obtained to obtain a sufficient aesthetic appearance, soft feel, etc. as an interior material.
表皮層に植毛加工することにより、内装材とし
ての美感、ソフト感等を得る。 By flocking the epidermis layer, a beautiful and soft feel can be obtained as an interior material.
また押出ラミネート法により架橋発泡シートと
表皮層とをそれぞれ積層しているが、これは以下
の理由による。 Furthermore, the cross-linked foam sheet and the skin layer are laminated using an extrusion lamination method for the following reasons.
架橋発泡シートと表皮層との熱ラミネートによ
る積層方法としては、押出ラミネート法のほか、
熱ロールラミネート法および三層同時押出ラミネ
ート法などが考えられる。 In addition to the extrusion lamination method, there are other methods of laminating the cross-linked foam sheet and the skin layer by thermal lamination.
Possible methods include hot roll lamination and three-layer coextrusion lamination.
しかしながら、熱ロールラミネート法では、成
形性が悪く、また、成形品の反りやしわ、接着性
にも若干問題がある。また、三層同時押出ラミネ
ート法では、成形品のしわ、接着性については良
好であるが、成形性や成形品の反りに若干問題が
ある。しかも、３層同時押出ラミネート法は装置
が複雑かつ大型になる欠点を有する。 However, the hot roll lamination method has poor moldability, and also has some problems with warping and wrinkling of the molded product and with adhesion. Furthermore, in the three-layer coextrusion lamination method, the molded product has good wrinkles and adhesion, but there are some problems with moldability and warpage of the molded product. Moreover, the three-layer coextrusion lamination method has the disadvantage that the apparatus is complicated and large.
これに対して、押出ラミネート法では、成形性
および成形品の反りやしわ、接着性のすべてにお
いて良好である。 On the other hand, the extrusion lamination method is good in terms of moldability, warpage and wrinkles of the molded product, and adhesion.
（実施例）
図面を参照しながら実施例を説明する。第１図
は製造された内装材の断面を示し、第２図乃至第
４図は製造装置の概念図を示している。(Example) An example will be described with reference to the drawings. FIG. 1 shows a cross section of the manufactured interior material, and FIGS. 2 to 4 show conceptual diagrams of the manufacturing apparatus.
第１図において、１ａ，１ｂは架橋発泡シート
であり、架橋発泡シート１ａ，１ｂは、高密度ポ
リエチレン（密度0.955、MFR6.0）40重量部、エ
チレン・ブテン・ポリプロピレン共重合体（密度
0.90、MFR8.0、融点142℃）40重量部、エチレ
ン・プロピレン・ブロツク共重合体（密度0.90、
MFR5.0、融点165℃）20重量部および発泡剤、
架橋促進剤、熱安定剤からなる独立気泡の電子線
架橋発泡シートで、発泡倍率は30倍であり、厚さ
は2.5mm、固体肉厚Tfは0.083mmである。 In Fig. 1, 1a and 1b are cross-linked foam sheets, and the cross-linked foam sheets 1a and 1b are made of 40 parts by weight of high-density polyethylene (density 0.955, MFR 6.0), ethylene-butene-polypropylene copolymer (density
0.90, MFR8.0, melting point 142℃) 40 parts by weight, ethylene propylene block copolymer (density 0.90,
MFR5.0, melting point 165℃) 20 parts by weight and blowing agent,
This is a closed cell electron beam crosslinked foam sheet made of a crosslinking accelerator and a heat stabilizer.The foaming ratio is 30 times, the thickness is 2.5mm, and the solid wall thickness Tf is 0.083mm.
架橋発泡シート１ａ，１ｂには非発泡の表皮層
２ａ，２ｂを押出ラミネートしてラミネート品３
ａ，３ｂを形成する。 Non-foamed skin layers 2a and 2b are extruded and laminated to the crosslinked foam sheets 1a and 1b to form a laminate product 3.
Form a and 3b.
非発泡の表皮層２ａ，２ｂは、MFR2.0、融点
163℃のポリプロピレンホモポリマーを主成分と
し、更に難燃剤、紫外線吸収剤、帯電防止剤、顔
料を配合したもので、肉厚Tsは0.2mmである。 The non-foamed skin layers 2a and 2b have an MFR of 2.0 and a melting point of
The main component is polypropylene homopolymer at 163°C, with flame retardants, ultraviolet absorbers, antistatic agents, and pigments added, and the wall thickness Ts is 0.2 mm.
短繊維４は、径３デニール、長さ１mmのナイロ
ンである。 The short fibers 4 are nylon with a diameter of 3 denier and a length of 1 mm.
また、ラミネート品３ａ，３ｂの圧着時に形成
された熱融着層５の厚みTlは0.2mmである。 Further, the thickness Tl of the heat-sealing layer 5 formed when the laminate products 3a and 3b are bonded is 0.2 mm.
次に、内装材の製造方法について説明する。 Next, a method for manufacturing the interior material will be explained.
第２図において、表皮層２ａ，２ｂ用混合原料
を直径90mmの単軸押出機に供給し、これを押出金
型１１からダイヘツド部での樹脂温度235℃で押
し出してシート状にする。そして、金型から流出
後直ちに、あらかじめ製造された架橋発泡シート
１ａ，１ｂの片面に添わせながら、金属製鏡面ロ
ール１２とゴム製バツクアツプロール１３により
圧着して非発泡の表皮層２ａ，２ｂを積層する。
なお鏡面ロール１２は50℃に調温し、ロール間の
圧力は線接触として２Kg／cmとした。 In FIG. 2, mixed raw materials for the skin layers 2a and 2b are supplied to a single-screw extruder with a diameter of 90 mm, and extruded from an extrusion mold 11 at a resin temperature of 235° C. at the die head to form a sheet. Immediately after flowing out of the mold, the non-foamed skin layers 2a, 2b are applied to one side of the cross-linked foam sheets 1a, 1b manufactured in advance and are pressed together with a metal mirror roll 12 and a rubber back-up roll 13. Laminate.
The temperature of the mirror roll 12 was controlled at 50° C., and the pressure between the rolls was 2 kg/cm as a line contact.
圧着されたラミネート品３ａ，３ｂは引取ロー
ル１４により引き取り速度6m／minで引き取り、
巻取ロール１５に巻き取る。 The crimped laminate products 3a and 3b are taken up by a take-up roll 14 at a take-up speed of 6 m/min.
It is wound up on a winding roll 15.
次に第３図に示すように、一方のラミネート品
３ａの表皮層２ａの上にロールコーター１６でホ
ツトメルト形接着剤を200g／m2塗布し、その上
に静電変圧加工機１７によつて短繊維４を植毛加
工し、更に乾燥炉１８で、90℃の雰囲気中を通過
させて乾燥させ、引取ロール１９で引き取り、巻
物とし植毛付きラミネート品６を得た。なお非発
泡層の表面は接着性をよくするため、あらかじめ
プライマー処理をした。 Next, as shown in FIG. 3, 200 g/m 2 of hot melt adhesive is applied onto the skin layer 2a of one of the laminate products 3a using a roll coater 16, and then an electrostatic transformer 17 is used to coat the hot melt adhesive onto the skin layer 2a of one of the laminate products 3a. The short fibers 4 were flocked, dried by passing through an atmosphere at 90° C. in a drying oven 18, and taken up by a take-up roll 19 to obtain a flocked laminate 6 as a roll. The surface of the non-foamed layer was previously treated with a primer to improve adhesion.
続いて、第４図に示すように、植毛加工された
植毛付ラミネート品６と植毛加工されていないラ
ミネート品３ｂとを、互いに架橋発泡シート１
ａ，１ｂの表面が相対するように配置する。この
後、プロパンガス炎２０で両架橋発泡シート１
ａ，１ｂの表面を熔融し、直ちに圧着ロール２１
で圧着し、圧着によつて熱融着層５を形成し引取
ロール２３で引き取つた。圧着ロール２１の温度
は18℃とした。 Subsequently, as shown in FIG. 4, the flocked laminate product 6 and the non-flocked laminate product 3b are bonded to each other by a cross-linked foam sheet 1.
The surfaces of a and 1b are arranged so as to face each other. After this, both cross-linked foam sheets 1 are heated with a propane gas flame 20.
The surfaces of a and 1b are melted, and the pressure roll 21 is immediately applied.
The heat-sealing layer 5 was formed by pressure bonding, and was taken off with a take-off roll 23. The temperature of the pressure roll 21 was 18°C.
なお、熔融時の架橋発泡シート１ａ，１ｂの表
面温度は、ヒートラベルを貼着し、積層材を切開
してしらべたもので約165℃であつた。積層材の
引取速度は6m／min、圧着ロール２１間の設定
クリアランスは3.0mm、圧着ロール間の圧力は３
Kg／cmであつた。 The surface temperature of the crosslinked foam sheets 1a and 1b when melted was approximately 165° C. when a heat label was attached and the laminated material was cut open and examined. The take-up speed of the laminated material is 6 m/min, the set clearance between the crimping rolls 21 is 3.0 mm, and the pressure between the crimping rolls is 3.
It was Kg/cm.
そして、この積層材を切断装置２２により長
辺：短辺＝1.3：１の割合で切断して、面積を約
２m2とし、自動車用大型品成形用積層材（内装
材）を得た。なお、このラミネート条件で形成さ
れた上記熱融着層５の厚みTlは約0.2mm、その重
量は650g／m2であり、非常に軽量、美麗なもの
であつた。 This laminated material was then cut by the cutting device 22 at a ratio of long side: short side = 1.3:1 to have an area of approximately 2 m 2 to obtain a laminated material (interior material) for molding large automobile parts. The heat-sealing layer 5 formed under these laminating conditions had a thickness Tl of approximately 0.2 mm and a weight of 650 g/m 2 , making it extremely lightweight and beautiful.
（発明の効果）
以上詳述したように、本発明の自動車用内装材
の製造方法によれば、特に自動車用天井材、ドア
内装材、トランクルームマツト材など大型品で加
熱成形を必要とする場合に、安定した成形性が確
保できる。(Effects of the Invention) As detailed above, according to the method for manufacturing an automobile interior material of the present invention, especially when large products such as automobile ceiling materials, door interior materials, and trunk room pine materials require heat forming. In addition, stable moldability can be ensured.
すなわち、成形性および成形品の反りやし
わ、接着性に優れる押出ラミネート法によつて、
架橋発泡シートの表面にほとんど歪のない表皮層
が形成されること、架橋発泡シートの表面に表
皮層を積層する際の加熱がアニール効果になつて
いること、２枚の架橋発泡シートを重ね合わせ
て積層にすることにより、貼り合わせた積層発泡
シートの加熱収縮が全体として平均化されている
こと、および架橋発泡シート同士を熔融、圧着
したことにより、架橋発泡シートの製造時に固定
された歪が抑制されていること、などにより加熱
成形時の加熱収縮率が非常に小さく、安定確実な
成形性が得られる。 In other words, through the extrusion lamination method, which has excellent moldability and prevents warping and wrinkles of molded products,
A skin layer with almost no distortion is formed on the surface of the cross-linked foam sheet, the heating when laminating the skin layer on the surface of the cross-linked foam sheet has an annealing effect, and two cross-linked foam sheets are stacked together. By laminating them together, the heat shrinkage of the bonded laminated foam sheets is averaged out as a whole, and by melting and pressing the cross-linked foam sheets together, the strain fixed during the manufacture of the cross-linked foam sheets is reduced. Due to this, the heat shrinkage rate during heat molding is extremely small, and stable and reliable moldability can be obtained.
また、熔融、圧着する前のラミネート品の非発
泡の表皮層に接着材を用いて植毛加工するから、
植毛加工ではまだ充分な柔軟性を有しており、接
着剤塗布面の平面性を容易に確保でき、接着剤塗
布の均一性、植毛層の均一性を得ることが出来
る。しかもラミネート品を、それぞれの架橋発泡
シート側の表面に互いに相対させ、その表面を熔
融して圧着するので圧着ロールは冷却したものが
使用でき、植毛層に対しては架橋発泡シート自身
が断熱性としての働きをするので、植毛層の毛倒
れを起こすことがない。 In addition, since the non-foamed skin layer of the laminate is flocked using an adhesive before being melted and crimped,
In the flocking process, it still has sufficient flexibility, and the flatness of the surface to which the adhesive is applied can be easily ensured, and uniformity of the adhesive application and uniformity of the flocked layer can be obtained. Moreover, since the laminate products are placed facing each other on the cross-linked foam sheet side and the surfaces are melted and crimped, a cooled crimping roll can be used, and the cross-linked foam sheet itself has thermal insulation properties for the flocked layer. Because it acts as a hair transplant, it does not cause the hairs in the transplanted layer to fall.
また、本発明製造方法により得られる自動車用
内装材は以下に列挙するような種々の優れた効果
を有する。 Furthermore, the automobile interior material obtained by the manufacturing method of the present invention has various excellent effects as listed below.
基材としての積層発泡シートが、プロピレン系
重合体とエチレン系重合体からなる２枚の架橋発
泡シートを積層して構成されているから、自動車
用内装材自体の軽量化を図るとともに、充分な耐
衝撃性、剛性、耐熱性、深絞り成形性、ハンドリ
ング性、断熱性、防音性等を備えている。 Since the laminated foam sheet as a base material is constructed by laminating two crosslinked foam sheets made of propylene polymer and ethylene polymer, it is possible to reduce the weight of the automobile interior material itself and to provide sufficient It has impact resistance, rigidity, heat resistance, deep drawability, handling properties, heat insulation properties, soundproofing properties, etc.
積層発泡シートの両面に積層するプロピレン系
重合体からなる非発泡の表皮層は、成形性がよ
く、深くシヤープな造形的美感など所望の美感を
熱成形により得て、内装材としての充分な美感、
ソフト感等を得ることができる。 The non-foamed skin layer made of propylene-based polymer that is laminated on both sides of the laminated foam sheet has good moldability, and the desired aesthetic appearance such as a deep, sharp sculptural aesthetic can be obtained by thermoforming, making it aesthetically pleasing enough to be used as an interior material. ,
A soft feeling etc. can be obtained.
少なくとも一方の表皮層に植毛加工するので内
装材としての美感、ソフト感等をさらに際立たせ
る。 At least one of the skin layers is flocked to further enhance the beauty and softness of the product as an interior material.
第１図は本発明製造方法により製造された自動
車用内装材の一例を示す断面図、第２図乃至第４
図は同内装材の製造方法を説明するための概念図
であつて、第２図は押出ラミネート工程を示し、
第３図は植毛加工工程を示し、第４図は熔融、圧
着の工程を示す。
１ａ，１ｂ……架橋発泡シート、２ａ，２ｂ…
…非発泡の表皮層、３ａ，３ｂ……ラミネート
品、４……短繊維、５……熱融着層、６……植毛
付ラミネート品、１１……押出金型、１２……鏡
面ロール、１４……引取ロール、１５……巻取ロ
ール、１６……ロールコーター、１７……静電変
圧加工機、１８……乾燥炉、１９……引取ロー
ル、２０……プロパンガス炎、２１……圧着ロー
ル、２２……切断装置、２３……引取ロール。
FIG. 1 is a sectional view showing an example of an automobile interior material manufactured by the manufacturing method of the present invention, and FIGS.
The figure is a conceptual diagram for explaining the manufacturing method of the interior material, and Figure 2 shows the extrusion lamination process,
FIG. 3 shows the flocking process, and FIG. 4 shows the melting and crimping process. 1a, 1b...Crosslinked foam sheet, 2a, 2b...
...Non-foamed skin layer, 3a, 3b... Laminated product, 4... Short fiber, 5... Heat fusion layer, 6... Laminated product with flocking, 11... Extrusion mold, 12... Mirror roll, 14... Take-up roll, 15... Take-up roll, 16... Roll coater, 17... Electrostatic transformation processing machine, 18... Drying oven, 19... Take-up roll, 20... Propane gas flame, 21... Pressure roll, 22... cutting device, 23... take-up roll.
Claims (1)
なる２枚の架橋発泡シートのそれぞれの片面に、
プロピレン系重合体からなる非発泡の表皮層をそ
れぞれ押出ラミネートして、２枚のラミネート品
を形成し、 接着剤を用いて、少なくとも一方の表皮層に植
毛加工した後、 前記両ラミネート品を、それぞれの架橋発泡シ
ート側の表面を互いに相対させ熔融して圧着する
ことを特徴とする 自動車用内装材の製造方法。 ２ 架橋発泡シートの固体肉厚Tfと非発泡の表
皮層の肉厚Tsとの比Ts／Tfが１〜50であり、 熔融して圧着された熱融着層の厚みTlが0.1〜
0.5mmであり、 かつ該厚みTlが前記架橋発泡シートの肉厚の
１〜25％である 特許請求の範囲第１項記載の自動車用内装材の製
造方法。[Claims] 1. On one side of each of two crosslinked foam sheets made of a propylene polymer and an ethylene polymer,
The non-foamed skin layers made of propylene polymer are extrusion laminated to form two laminates, and at least one of the skin layers is flocked using an adhesive, and then both of the laminates are 1. A method for producing an interior material for an automobile, which comprises: facing each other, melting and pressing the surfaces of the cross-linked foam sheets. 2. The ratio Ts/Tf of the solid wall thickness Tf of the crosslinked foam sheet to the wall thickness Ts of the non-foamed skin layer is 1 to 50, and the thickness Tl of the melted and press-bonded thermal adhesive layer is 0.1 to 50.
The method for producing an interior material for an automobile according to claim 1, wherein the thickness Tl is 1 to 25% of the thickness of the crosslinked foam sheet.
Priority Applications (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP61084799A JPS62240539A (en) | 1986-04-12 | 1986-04-12 | Manufacture of interior material for automobile |
| CA 528230 CA1279806C (en) | 1986-01-28 | 1987-01-27 | Laminated structure for interior finishing materials, and method of production |
| EP19870101076 EP0231013B1 (en) | 1986-01-28 | 1987-01-27 | Laminated structure for interior finishing materials, and method of production |
| DE8787101076T DE3770648D1 (en) | 1986-01-28 | 1987-01-27 | LAMINATE STRUCTURE FOR INTERIOR FINISHING MATERIALS AND METHOD FOR THEIR PRODUCTION. |
| US07/007,866 US4721643A (en) | 1986-01-28 | 1987-01-28 | Laminated structure for interior finishing materials, and method of production thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP61084799A JPS62240539A (en) | 1986-04-12 | 1986-04-12 | Manufacture of interior material for automobile |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS62240539A JPS62240539A (en) | 1987-10-21 |
| JPH0521064B2 true JPH0521064B2 (en) | 1993-03-23 |
Family
ID=13840752
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP61084799A Granted JPS62240539A (en) | 1986-01-28 | 1986-04-12 | Manufacture of interior material for automobile |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS62240539A (en) |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2547150B2 (en) * | 1992-03-17 | 1996-10-23 | ムサシ化成工業株式会社 | Method of joining plastic foam materials to each other |
| KR100882718B1 (en) * | 2007-07-18 | 2009-02-06 | 한일이화주식회사 | Ceiling material for automobile interior |
| KR20090008575A (en) * | 2007-07-18 | 2009-01-22 | 두양산업(주) | Ceiling material for automobile interior |
| JP2012081679A (en) * | 2010-10-14 | 2012-04-26 | Tsp:Kk | Foam heat insulating material and production method thereof |
-
1986
- 1986-04-12 JP JP61084799A patent/JPS62240539A/en active Granted
Also Published As
| Publication number | Publication date |
|---|---|
| JPS62240539A (en) | 1987-10-21 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US4721643A (en) | Laminated structure for interior finishing materials, and method of production thereof | |
| US4211590A (en) | Method of making perforated contoured trim panel | |
| US5164254A (en) | Hoodliner | |
| US4256797A (en) | Contoured resilient vehicle trim panel | |
| US4263247A (en) | Resin-foam laminate | |
| US5049439A (en) | Thermoformable article | |
| US5514458A (en) | Large-size panel of thermoplastic synthetic resin for automotive vehicle interior, and process for the production thereof | |
| US5300360A (en) | Thermoplastic composite adhesive film | |
| US5376203A (en) | Rotary molding apparatus and method | |
| JPH0521064B2 (en) | ||
| JPS62174131A (en) | Manufacture of trim | |
| JP2612731B2 (en) | Manufacturing method of laminated skin material | |
| JPS6049106B2 (en) | Manufacturing method for interior panels for vehicles, etc. | |
| JPH0520608Y2 (en) | ||
| KR101592277B1 (en) | Lightweight composites for car interior part containing thermally expandable microcapsule and method of manufacturing of the same | |
| JP2008207548A (en) | Method for producing thermoplastic resin molded article | |
| JPS62175240A (en) | Trim for automobile and manufacture thereof | |
| JPS62174130A (en) | Manufacture of trim | |
| JPH0340596Y2 (en) | ||
| JP3070960B2 (en) | Laminates and molded articles from them | |
| JP3172281B2 (en) | Manufacturing method of automotive interior materials | |
| JPH0346997Y2 (en) | ||
| JPS62270309A (en) | Manufacture of laminated interior automotive trim member | |
| JPH01275020A (en) | Manufacture of laminated trim | |
| JP3853077B2 (en) | Dispersion method stampable sheet expansion molded body and dispersion method stampable sheet |