JPH0624767B2 - Manufacturing method of automobile interior materials - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for manufacturing automobile interior materials such as automobile ceiling materials, door lining materials, and luggage compartment mats.

(Prior Art) This type of interior material, for example, a molded ceiling of an automobile, has qualities such as rigidity, heat resistance, deep drawing formability, handleability and heat insulating property, and further aesthetics and softness as an interior material. Required. In order to satisfy these required qualities, conventionally, relatively hard materials such as resin felt, plastic honeycomb, and cardboard are used as the base material, and polyurethane foam, polyethylene foam, etc. pads are used as the surface material. It was common to use wood and skins such as knit and PVC leather. As a molded ceiling of this type, for example, a non-foamed propylene-based polymer sheet / polypropylene foam / non-foamed propylene-based polymer sheet is used as a base material, and polyurethane foam / cloth, PVC leather, etc. are used. Used as a surface material,
It is devised that these are laminated to form a laminated body of 5 layers (see Japanese Utility Model Publication No. 55-148926).

(Problems to be Solved by the Invention) However, in such a molded ceiling, the structure is complicated, the manufacturing process is complicated, and the manufacturing cost is increased.

Further, since a polyurethane foam that cannot be molded is used as the surface material, there is a problem in that a deep and sharp molding aesthetic cannot be obtained by heat molding, and a desired aesthetic cannot be obtained.

(Means for Solving the Problems) The interior material of the present invention has a non-foamed skin layer made of a propylene-based polymer laminated on both sides of a laminated foam sheet having a two-layer structure, and one skin The layered foam sheet has a structure in which an uneven pattern such as a squeeze pattern is formed on the surface of the layer, and the laminated foam sheet is formed by laminating two cross-linked foam sheets made of a propylene polymer and an ethylene polymer through a heat-sealing layer. It becomes.

The skin layer is a substantially non-foamed polypropylene and a propylene-based copolymer sheet with other monomers. Examples of the propylene-based polymer forming the skin layer include ethylene / propylene block copolymer,
Examples include α-olefin / propylene copolymers such as ethylene / propylene random copolymers and ethylene / butene / propylene copolymers. Also, if necessary,
Inorganic or organic substances such as pigments, flame retardants, antistatic agents, antioxidants and extenders can be added to these.
The thickness of the skin layers 2 and 3 is preferably 0.1 to 1 mm because the mechanical strength decreases as the thickness decreases and the thickness increases as the thickness increases.

Examples of the propylene-based polymer that constitutes the crosslinked foamed sheet include, for example, a random copolymer of ethylene and propylene, a block copolymer, or a random block copolymer, an ethylene-butene-propylene copolymer, or the like α.
-Examples include olefin / propylene copolymers.
It is preferable that the melting point of the copolymerized α-flefin is between 130 and 170 ° C. In addition, the melt flow rate (MFR) of the propylene-based polymer is 0.
It is preferably 1 to 50, and more preferably 0.3 to 30.

As the ethylene-based polymer constituting the crosslinked foamed sheet,
Examples include low-density polyethylene, medium-density polyethylene, high-density polyethylene, linear low-density polyethylene, ethylene / vinyl acetate copolymer, and amorphous ethylene / propylene copolymer, which may be used alone or in combination of two or more. Can be used. M of these ethylene polymers
FR is preferably 0.1 to 50, more preferably 0.2 to 30.

When the amount of polypropylene-based polymer in the crosslinked foamed sheet increases, it has heat resistance and rigidity, but it is easy to crack,
In particular, the impact strength at low temperatures is low, and it is too hard, resulting in poor cushioning. Further, thermoforming with an extruder or the like becomes difficult, and the cross-linking agent and the foaming agent are decomposed, so that a good molded product and eventually a good foam cannot be obtained. On the contrary, when the amount of the polypropylene-based polymer decreases and the amount of the ethylene-based polymer increases, physical properties such as heat resistance and mechanical strength deteriorate. Therefore, the amount of the polypropylene-based polymer in the crosslinked foamed sheet is preferably 10 to 80% by weight, more preferably 20 to 70% by weight.
Weight%

The cross-linked foam sheet is a high foam, and the expansion ratio is 10-50.
Culture is preferable, and more preferably 20 to 40.

The thickness of the crosslinked foamed sheet is preferably 1 to 5 mm because the thinner it is, the lower the bending strength is, and the thicker it is, the less economical it is.

Next, the thickness relationship between the layers forming the interior material will be described.

(A) The ratio Ts / Tf between the solid wall thickness Tf of the crosslinked foamed sheet and the wall thickness Ts of the non-foamed skin layer is set to 1 to 50. The solid wall thickness Tf refers to the thickness of air obtained by extracting air from a crosslinked foamed sheet.

The reason for setting Ts / Tf will be described below.

In order to improve the moldability of the interior material, it is necessary to eliminate so-called necking, that is, the phenomenon that the skin layer is locally thinned at the time of molding and the back side is visible or cracked. In order to eliminate this necking, it is necessary to reduce the heat shrinkage of the laminated foam sheet as much as possible.

If the ratio Ts / Tf between the solid wall thickness Tf and the wall thickness Ts is 1 or more, the ratio of the skin layer in the interior material is dominant, and the skin layer with less strain is essentially a crosslinked foamed sheet with large heat shrinkage. It can be reinforced to minimize heat shrinkage of the inner layer material.

On the other hand, when Ts / Tf is larger than 50, the ratio of the skin layer occupies most of the interior material, and it becomes difficult to obtain the heat insulating property and soft feeling as the interior material as a whole.

When Ts / Tf is less than 1, the strain of the crosslinked foamed sheet acts to increase the heat shrinkage of the entire interior material, which is not preferable.

Therefore, it is necessary to set 1 ≦ Ts / Tf ≦ 50.

(B) The thickness T1 of the heat-sealing layer is 0.1 to 0.5 mm, and is set to 1 to 25% of the thickness of the crosslinked foamed sheet.

The reason for setting the wall thickness T1 will be described below.

Lamination of crosslinked foamed sheets is performed by melting and crimping with a gas flame, etc., but when joining the surfaces of the crosslinked foamed sheets, a sufficient amount of heat is applied to the joint portion to achieve low foaming of 0.1 mm or more. Alternatively, by forming a heat-sealing layer that is a non-foaming layer, the strain fixed during the production of the crosslinked foamed sheet can be removed, and the heat at the time of fusion also has an effect of annealing the strain of the crosslinked foamed sheet. . Thereby, the moldability becomes good. When the cross-linking foam sheets are joined together by increasing the take-up speed, in the polyolefin foam having a small specific heat, only the surface of the cross-linking foam sheet is melted, and although the joining is possible, a heat-bonding layer is formed. It is difficult, and it is difficult to expect an annealing effect because annealing needs to act for a certain time or longer. Therefore, it is preferable that the take-up speed is not too high.

On the other hand, when the wall thickness T1 is larger than 0.5 mm, it is difficult to obtain the heat insulating property and soft feeling as the interior material.

Therefore, it is necessary to set 0.1 mm ≤ T1 ≤ 0.5 mm. In other words, from the relationship between the expansion ratio and the thickness of the crosslinked foamed sheet, 1% ≤ (T1 / the thickness of the crosslinked foamed sheet) ≤ 25%. There is a need to.

The present invention can be modified in various ways. For example, the concavo-convex pattern may be provided not only on one skin layer but also on the other skin layer, and the concavo-convex pattern may be provided on both upper and lower surfaces.

Next, a second method for manufacturing an automobile interior material according to the present invention will be described.
Description will be made with reference to FIGS.

(1) An extrusion die 8 and a thermocompression-bonding roll 9A having an uneven pattern surface on one surface 6a of a crosslinked foamed seal 6 made of a propylene-based polymer and an ethylene-based polymer manufactured in advance.
Thus, the molten resin sheet 10 of the propylene polymer is extrusion-laminated, and the non-foamed skin layer 3 is laminated to form the first laminated product A. At this time, the concavo-convex pattern 4 such as a diaphragm pattern is formed on the skin layer 3 by the concavo-convex pattern of the thermocompression bonding roll 9A.
To form. In FIG. 2, 11 is a crosslinked foamed sheet 6
Form wrapped with, 12 is a backup roll, 13
Is a guide roll, 14 is a take-up device, and 15 is a laminated product A
It is a form wrapped around.

(2) On the other hand, one side 5a of the crosslinked foamed sheet 5 made of a propylene polymer and an ethylene polymer, which has been manufactured in advance.
The extrusion die 8 and the thermocompression-bonding roll 9 having a flat surface
The molten resin sheet 10 of the propylene-based polymer is extrusion-laminated by B, the non-foamed skin layer 2 is laminated, and the second
The laminated product B is formed.

(3) Subsequently, these laminated products A and B are arranged with their surfaces on the side of the crosslinked foamed sheets 6 and 5 facing each other, and thereafter, by a heating and fusing means 16 such as a flame by gas or a strong infrared heater. , Cross-linked foamed sheet 5,
The surface of 6 is melted and pressure-bonded by pressure-bonding rolls 17 to form a laminated material C. At this time, the heat-sealing layer 7 is simultaneously formed on the pressure-bonded portion.

(4) Then, the laminated material C is cut into a predetermined size by the cutting device 18 to obtain an automobile interior material. In FIG. 3, 1
Reference numeral 9 is a take-up device, and 20 is a carrier truck.

In the manufacturing method of the present invention, the cross-linked foamed sheets 5 and 6 and the skin layers 2 and 3 are laminated by the extrusion laminating method, for the following reason.

As a method of laminating the crosslinked foamed sheets 5 and 6 and the skin layers 2 and 3 by thermal lamination, an extrusion laminating method, a heat roll laminating method (described later), a three-layer coextrusion laminating method (described later) and the like can be considered.

However, the hot roll laminating method has poor moldability, and there are some problems in warpage, wrinkles, and adhesiveness of the molded product. In addition, the three-layer coextrusion laminating method is good in terms of wrinkles and adhesiveness of the molded product, but has some problems in moldability and warpage of the molded product. Moreover, the three-layer coextrusion laminating method has a drawback that the apparatus becomes complicated and large in size.

On the other hand, the extrusion laminating method is good in all of the moldability, the warp and wrinkles of the molded product, and the adhesiveness.

Further, in the manufacturing method of the present invention, in the step (1), the uneven pattern 4 is simultaneously provided at the time of extrusion lamination, but this is for the following reason.

As a method of applying the uneven pattern 4 to the laminated product A, a method of attaching a skin layer having an uneven pattern in advance, a method of applying an uneven pattern by pressing with a roller having an uneven pattern while bonding, and a finished laminate A method of heating the product to near the melting point and pressing it with a roll having an uneven pattern to give the uneven pattern is considered.

However, in the method of (3), when the skin layer with an uneven pattern is formed, the metal roll with an uneven pattern and the backup roll made of hard rubber are used to sandwich the film, so that there is a notch part, and this is the heat forming in the post process. This is one of the causes of molding failure (necking failure).

In addition, in the method of (1), in order to reduce residual strain during heat molding, the heat resistance required for the purpose of interior materials (heat dripping for ceiling materials, heat deformation for door lining materials) It is preferable to set the heat distortion temperature of the crosslinked foamed sheet of the inner layer, which is difficult to be performed, to be slightly lower than that of the skin layer.
However, when such a method for uneven patterning of a laminated material is used, there is a problem that “the uneven pattern disappears” during heat molding unless the skin layer is made to have its melting point or higher at the time of uneven patterning. If the melting point is higher than the melting point, the crosslinked foamed sheet may be damaged, which is not preferable.

On the other hand, in the present invention, since the uneven pattern 4 is simultaneously applied during extrusion lamination, the above problems do not occur, and the skin layer 3 digs into the crosslinked foamed sheet 6 to form an almost uniform wall thickness. .

(Function) The manufacturing method of the present invention forms an almost undistorted skin layer on the surface of the crosslinked foamed sheet by an extrusion laminating method, and an annealing effect is obtained by heating when laminating the skin layer on the surface of the crosslinked foamed sheet. To obtain, to average the heat shrinkage of the laminated foam sheet as a whole by stacking two crosslinked foam sheets on top of each other, and to form a heat fusion layer at the boundary portion of the crosslinked foam sheet to crosslink By suppressing the strain that is lost during the production of the foamed sheet, etc., the heat shrinkage rate during heat molding can be reduced as much as possible,
Obtain stable and reliable moldability.

The laminated foamed sheet as a base material is formed by laminating two crosslinked foamed sheets made of a propylene-based polymer and an ethylene-based polymer to reduce the weight of the automobile interior material itself, and to obtain sufficient impact resistance, It has rigidity, heat resistance, moldability, handling, heat insulation, and soundproofing.

The non-foamed skin layer consisting of propylene-based polymerization resistance laminated on both sides of the laminated foam sheet has good moldability, and the desired aesthetics such as deep and sharp modeling aesthetics can be obtained by thermoforming, resulting in sufficient aesthetics as an interior material. , Get a soft feeling, etc.

The concavo-convex pattern such as a squeeze pattern provided on at least one of the skin layers further enhances the aesthetics and softness of the interior material.

(Example) Next, the Example of this invention is described.

Examples and Comparative Examples 1 and 2 1 in the figure is a laminated foam sheet, and the laminated foam sheet 1 is formed by laminating crosslinked foam sheets 5 and 6. Crosslinked foamed sheets 5 and 6 are made of high density polyethylene (density 0.95
5, MFR6.0) 40 parts by weight, ethylene / butene / polypropylene copolymer (density 0.90, MFR8.0, melting point 142 ° C) 40
A closed-cell electron beam crosslinked foamed sheet consisting of 20 parts by weight of ethylene / propylene / block copolymer (density 0.90, MFR5.0, melting point 165 ° C), with a foaming ratio of 30 times and a thickness. Is 2.5 mm and the solid wall thickness Tf is 0.083 mm.

The non-foamed skin layer 2 is formed on the crosslinked foamed sheets 5 and 6, respectively.
3 is laminated, and the non-foamed skin layers 2 and 3 are MFR.
It has a polypropylene homopolymer with a melting point of 2.0 and a melting point of 163 ° C as its component, and has a wall thickness Ts of 0.2 mm.

Further, the thickness T1 of the heat-sealing layer 7 formed when the laminated products A and B are pressure-bonded is 0.2 mm.

Met. Further, since it is mainly a general-purpose resin, is made of the same type of material, and no adhesive is required, it was extremely inexpensive.

Next, the results of tests conducted to investigate the characteristics of this example will be described.

(A) Sample Sample 1: Extrusion laminated product (Example) Sample 2: Heat roll laminated product (Comparative Example 1) Sample 3: Three-layer coextrusion laminated product (Comparative Example 2) (a) Lamination of Comparative Examples 1 and 2 Structure As shown in FIG. 4, non-foamed skin layers b and c are laminated on both sides of a foamed sheet a, and one of the skin layers c is provided with an uneven pattern d.

Foam sheet a is made of high density polyethylene (density 0.955, M
FR6.0) 40 parts by weight, ethylene / butene / polypropylene copolymer (density 0.90, MFR8.0, melting point 142 ° C) 40 parts by weight, ethylene / propylene / block copolymer (density 0.
90, MFR 5.0, melting point 165 ° C.) 20 parts by weight of closed-cell electron beam crosslinked foamed sheet, which has a foaming ratio of 30 times and a thickness of 5.0 mm.

The non-foamed skin layers b, b are composed of polypropylene homopolymer having MFR 2.0 and a melting point of 163 ° C. and have a wall thickness of 0.2 mm.

(b) Manufacturing method of Comparative Examples 1 and 2 Comparative Example 1: Hot roll laminating method The foamed sheet a and the skin layers b and c prepared in advance are pressure-laminated with a thermocompression roll. An uneven pattern d is previously attached to one of the skin layers c before being attached.

The temperature of the thermo-compression roll is 150 ℃, the take-up speed is 5.5m / min
Met.

Comparative Example 2: Three-Layer Simultaneous Extrusion Laminating Method The skin layers b and c are extrusion laminated on both sides of the foamed sheet a at the same time. An uneven pattern d is simultaneously applied to one of the skin layers c during extrusion lamination.

The resin temperature of the extrusion laminate is 240 ° C., and the take-up method will be described below.

(1) In FIG. 2, the mixed raw material for the skin layer 3 was supplied to a single-screw extruder having a diameter of 90 mm, and this was fed from the extrusion die 8 to a resin temperature 24
Extrude at 0 ℃ into a sheet. Immediately after this, one side 6a of the cross-linked foamed sheet 6 manufactured in advance
Thermocompression-bonding roll 9 having a textured surface
A non-foamed skin layer 3 is laminated by pressing with A and a rubber backup roll 12 to form a laminated product A. At this time, an uneven pattern 4 such as a diaphragm pattern is formed on the skin layer 3 by the uneven pattern of the thermocompression bonding roll 9A.

At this time, the extrusion laminating speed was 8 m / min, and the take-up speed of the laminated product A by the take-up device 14 was 8 m / mi.
It was n.

(2) On the other hand, in FIG. 2, the mixed raw material for the skin layer 2 has a diameter of 9
It is supplied to a 0 mm single-screw extruder and extruded from the extrusion die 8 at a resin temperature of 240 ° C. to form a sheet. Immediately after this, one side 5a of the cross-linked foamed sheet 5 manufactured in advance
Of the non-foamed skin layer 2 by pressure bonding with a thermocompression bonding roll 9B having a flat surface and a backup roll 12
Are laminated to form a laminated product B. Note that the extrusion laminating speed and the take-up speed of the laminated product B are both the above.
The conditions were the same as in step (1).

(3) Subsequently, in FIG. 3, two laminated products A and B having non-foamed skin layers 2 and 3 on one surface are arranged such that the surfaces of the crosslinked foamed sheets 5 and 6 face each other. Thereafter, the surfaces of both cross-linked foamed sheets 5 and 6 were melted by a propane gas flame 16, immediately pressed by pressure rolls 17 and 17, and at the same time a heat-sealing layer 7 was formed and cooled to form a laminated material C. The surface temperature of the crosslinked foamed sheets 5 and 6 at the time of melting was about 160 ° C., and the take-up speed of the laminated material C was 6 m / min.

(4) Long side: short side = 1.
It was cut at a ratio of 4: 1 to have an area of about 2.2 m ² to obtain a laminated material (interior material) for molding a large-sized automobile. The thickness T1 of the heat-sealing layer 7 formed under the laminating conditions was about 0.2 mm, and the thickness of the laminated material C was due to the secondary foaming of the crosslinked foamed sheets 5 and 6.
It was 5.5 mm, its weight was 502 g / m ² , and its very light weight was 6 m / min.

(B) Characteristic test (a) Moldability test Samples 1 to ² having an area of 2.2 m ² by a hot press molding machine
When 3 was heat-molded to obtain a molded ceiling, the condition of the sample during heating and the defective rate after molding were examined. The heating conditions at this time were that the surface temperature of the sample was 140 to 145 ° C. in the heat label display, and the heating time was 40 seconds. The test results are shown in Table 1.

(B) Heat shrinkage rate test Write a reference line of predetermined dimensions on samples 1 to 3 at room temperature. These samples are put in a gear type aging tester set to a predetermined temperature, heated for a certain period of time, and then allowed to cool, and the dimensions of the above-mentioned reference line are measured again. Then, from this measurement result, the heat shrinkage ratio of the sample was calculated by the following equation. The test results are shown in Table 2.

The cross sections of the uneven portions of Samples 1 to 3 after the heat molding were observed. The observation results are shown below.

Samples 1 and 3: wall thickness Ts of skin layers 3 and c as shown in FIG.
Was approximately 200μ and was almost uniform.

Sample 2: As shown in FIG. 6, the thickness of the flat portion of the skin layer c
Ts was about 250μ, and the wall thickness Tsmin of the recess was 135μ.

As shown in Table 1, in Sample 1, there was no waviness during heat molding, and therefore the contact of the material with the mold during pressing was almost uniform, and there was no necking failure after molding. A good concavo-convex pattern was formed with no disappearance of grain. Further, as shown in Table 2, the heat shrinkage rate under the temperature conditions close to the heating conditions for molding was uniform in both MD and TD and only slightly shrank. Further, the skin layer 3 having the uneven pattern has a substantially uniform wall thickness Ts and does not serve as a starting point of necking, which is one of the reasons why the necking failure does not occur.

On the other hand, as shown in Table 1, Sample 2 has many waviness during heat molding, and the necking failure after molding is 70%.
% Was extremely high. That is, due to the corrugation phenomenon, the upper side of the corrugated peak of the material and the lower side of the corrugation of the material come into quick contact with the mold during pressing, and solidification of this part occurs quickly, while the non-contact part is stretched, which causes the necking failure. It is estimated that it will become. In addition, the rate of disappearing grain was extremely high at 90%, and it almost disappeared. Further, as shown in Table 2, the heat shrinkage rate under the temperature conditions close to the heating conditions for molding is MD shrinkage, TD slightly expansion, and MD
And the heat shrinkage of TD was not uniform. Further, when there is a large difference in the thickness of the uneven patterning during film formation, and when there is a notch, this is the starting point for the necking.

Further, as shown in Table 1, the sample 3 had a corrugation phenomenon, though not so much as the sample 2 at the time of heat molding, and the necking defect after molding was as high as 30%. It is presumed that this is due to the same reason as in Sample 2 above. In addition, the rate of grain disappearance was 40%, which was quite high. Further, as shown in Table 2, the heat shrinkage rate was in the middle of the two.

As described above, Sample 1 was found to be superior to Samples 2 and 3 in both moldability and heat shrinkage. In particular, the heat shrinkage rate of sample 1 is very small because of the following reasons.

The crosslinked foamed sheets 5 and 6 generally have a large heat shrinkage, but the thickness Ts of the non-foamed skin layers 2 and 3 is equal to or larger than the solid wall thickness Tf of the crosslinked foamed sheets 5 and 6, and the skin layer 2, 3 is dominant, and the skin layers 2 and 3 having almost no distortion are formed by the extrusion laminating method.

When the skin layers 2 and 3 are laminated on the surfaces of the crosslinked foamed sheets 5 and 6, heating has an annealing effect.

Since the laminated foam sheet 1 is formed by stacking the cross-linked foam sheets 5 and 6, the heat shrinkage ratio thereof is averaged,
The maximum value of the heat shrinkage is smaller than that of a single-plate crosslinked foamed sheet.

A thermal fusion bonding layer 7 having a thickness of 0.1 mm or more is formed at the boundary between the crosslinked foamed sheets 5 and 6.

(Effects of the Invention) As described in detail above, according to the method for producing an automobile interior material of the present invention, particularly when a large-sized article such as an automobile ceiling material, a door interior material, and a luggage compartment mat requires heat molding, Stable moldability can be secured.

That is, by the extrusion laminating method which is excellent in moldability, warpage and wrinkles of a molded article, and adhesiveness, a skin layer having almost no distortion is formed on the surface of the crosslinked foamed sheet, and a skin layer is laminated on the surface of the crosslinked foamed sheet. The heating at the time of annealing has an annealing effect, the heat shrinkage of the laminated foam seals that have been laminated is averaged as a whole by stacking and stacking two crosslinked foam sheets, and The heat shrinkage rate during heat molding is extremely small due to the fact that a heat fusion layer is formed at the boundary part of the sheet to suppress the strain fixed during the production of the crosslinked foamed sheet, and there is also a necking failure or graining. It does not disappear, and stable and reliable moldability is obtained.

Further, the automobile interior material obtained by the above production method has various excellent effects as listed below.

Since the laminated foamed sheet as the base material is constituted by laminating two crosslinked foamed sheets made of a propylene-based polymer and an ethylene-based polymer, it is possible to reduce the weight of the automobile interior material itself and to sufficiently reduce the weight. It has impact resistance, rigidity, heat resistance, deep drawability, handling, heat insulation and soundproofing.

The non-foamed skin layer made of propylene-based polymer laminated on both sides of the laminated foam sheet has good moldability, and the desired aesthetics such as deep and sharp aesthetics can be obtained by thermoforming, and sufficient aesthetics as an interior material. A soft feeling can be obtained.

The concavo-convex pattern such as a squeeze pattern provided on at least one of the skin layers further enhances the aesthetics and softness of the interior material.

[Brief description of drawings]

FIG. 1 is a sectional view showing the structure of an automobile interior material which is an embodiment of the present invention, and FIGS. 2 and 3 are schematic process drawings for explaining a method of manufacturing the interior material. Fig. 2 is an extrusion laminating process diagram, Fig. 3 is a final laminating process diagram, Fig. 4 is a cross-sectional view showing the structure of a comparative sample used for the characteristic test of the interior material, and Figs. 5 and 6 are unevenness in the test. The cross section of the patterned portion is shown. FIG. 5 shows samples 1 and 3 and FIG. 6 shows sample 2. 1 ... Laminated foam sheet, 2, 3 ... Non-foamed skin layer, 4
...... Asperity pattern, 5,6 ...... Crosslinked foamed sheet, 7 ...... Heat fusion layer, A, B ...... Laminated product.

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification number Reference number within the agency FI technical display location // B29K 23:00 105: 04 B29L 31:58 4F (72) Inventor Hideo Nishimura Toyota City, Aichi Prefecture Toyota Town 1 Toyota Motor Co., Ltd. (72) Inventor Satoru Omura 1 Toyota Town, Toyota City, Aichi Prefecture Toyota Motor Co., Ltd.

Claims (2)

[Claims] 1. A non-foamed skin layer made of a propylene-based polymer is extrusion-laminated on one surface of each of two cross-linked foamed sheets made of a propylene-based polymer and an ethylene-based polymer to form two laminates. A product is formed, and at the time of this extrusion lamination, a concavo-convex pattern is simultaneously formed on at least one of the skin layers, and at the same time, the surfaces of the two laminated products are opposed to each other and the surfaces are melted and pressure-bonded, A method for manufacturing an automobile interior material, characterized in that a heat-sealing layer is formed in this portion. 2. A ratio Ts / Tf between the solid wall thickness Tf of the crosslinked foamed sheet and the wall thickness Ts of the non-foamed skin layer is set to 1 to 50, and the wall thickness T1 of the heat fusion layer is set to 0.1 to. 0.5mm and the wall thickness T1
The method for producing an interior material for an automobile according to claim 1, wherein is 1 to 25% of the thickness of the crosslinked foamed sheet.