JP2002036405A - Thermoformable core material and automobile ceiling material - Google Patents
Thermoformable core material and automobile ceiling materialInfo
- Publication number
- JP2002036405A JP2002036405A JP2000230887A JP2000230887A JP2002036405A JP 2002036405 A JP2002036405 A JP 2002036405A JP 2000230887 A JP2000230887 A JP 2000230887A JP 2000230887 A JP2000230887 A JP 2000230887A JP 2002036405 A JP2002036405 A JP 2002036405A
- Authority
- JP
- Japan
- Prior art keywords
- heat
- mat
- resistant
- core material
- resin
- 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.)
- Granted
Links
Landscapes
- Laminated Bodies (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、熱成形に適した熱
成形性芯材及び該熱成形性芯材を使用した自動車用天井
材に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thermoformable core material suitable for thermoforming and an automotive ceiling material using the thermoformable core material.
【０００２】[0002]
【従来の技術】従来、自動車などの車両の内装材、特に
自動車の熱成形天井の基材には、無機繊維からなる熱成
形性芯材が好適に使用されている。熱成形性芯材として
は、軽量で、剛性、耐熱性、熱成形性、非通気性等の性
能が優れていることが要求される。このような熱成形性
芯材としては、例えば、特開平７−６０８８３号公報
に、無機繊維及び熱可塑性樹脂繊維からなるマット状基
材の少なくとも一面に耐熱剛性樹脂層を積層し、剛性、
耐熱性等に優れるとともに、非通気性にも優れた熱成形
性芯材が示されている。2. Description of the Related Art Conventionally, thermoforming core materials made of inorganic fibers have been suitably used as interior materials for vehicles such as automobiles, particularly as base materials for thermoforming ceilings of automobiles. The thermoformable core material is required to be lightweight and have excellent properties such as rigidity, heat resistance, thermoformability, and air permeability. As such a thermoformable core material, for example, Japanese Patent Application Laid-Open No. 7-60883 discloses a heat-resistant rigid resin layer laminated on at least one surface of a mat-shaped base material composed of inorganic fibers and thermoplastic resin fibers.
A thermoformable core material which is excellent in heat resistance and the like and is also excellent in air permeability is disclosed.
【０００３】しかしながら、上記熱成形性芯材は、その
一面に不織布などの表面材が積層され、自動車用天井材
とされるが、マット状基材の耐熱剛性樹脂層を形成した
側に表面材を積層すると、自動車用天井材の吸音性が不
足するといった問題があった。また、マット状基材の耐
熱剛性樹脂層を形成していない側に表面材を積層しよう
とすると、マット状基材と表面材との間に接着剤又は熱
活性樹脂が必要となるが、熱成形性芯材の製造途中或い
は熱成形性芯材を熱成形する工程において加熱圧縮した
際、接着剤又は熱活性樹脂がマット状基材に含浸してし
まうため、熱成形性芯材と表面材との接着強度が不足
し、接着不良、剥離等が生じ易く、深いプレス成形が困
難であり、また、得られる自動車天井材が使用中の高温
に対応できなくなるといった問題があった。[0003] However, the thermoformable core material has a surface material such as nonwoven fabric laminated on one surface thereof and is used as a ceiling material for automobiles. However, there is a problem that the sound absorbing properties of the ceiling material for automobiles are insufficient when laminated. Also, if a surface material is to be laminated on the side of the mat-shaped substrate on which the heat-resistant and rigid resin layer is not formed, an adhesive or a thermo-active resin is required between the mat-shaped substrate and the surface material. The adhesive or thermoactive resin impregnates the mat-shaped base material during the production and compression of the moldable core material or during the step of thermoforming the thermoformable core material. However, there is a problem that the adhesive strength with the resin is insufficient, adhesion failure, peeling, and the like are likely to occur, deep press molding is difficult, and the obtained automobile ceiling material cannot cope with high temperatures during use.
【０００４】[0004]
【発明が解決しようとする課題】本発明の目的は、軽量
で、剛性、耐熱性、熱賦形性、非通気性等に優れるとと
もに、吸音性にも優れ、自動車用天井材として好適に使
用することのできる熱成形性芯材と、該熱成形性芯材を
使用した自動車用天井材を提供することにある。SUMMARY OF THE INVENTION An object of the present invention is to provide a lightweight ceiling material which is excellent in rigidity, heat resistance, heat shaping properties, non-breathability, etc., and has excellent sound absorption properties. It is an object of the present invention to provide a thermoformable core material that can be used and an automotive ceiling material using the thermoformable core material.
【０００５】[0005]
【課題を解決するための手段】本発明の熱成形性芯材
は、耐熱性繊維が熱可塑性樹脂で相互に結着されてなる
マット状基材の一面（以下、「表面」と記す）に、前記
熱可塑性樹脂より溶融温度の高い耐熱剛性樹脂からなる
耐熱剛性樹脂層と、熱活性樹脂からなる熱活性樹脂層と
がこの順に積層され、かつ、該耐熱剛性樹脂層及び熱活
性樹脂層に開口面積が５〜１００ｍｍ2の貫通孔が分散
して形成されており、他面（以下、「裏面」と記す）
に、前記熱可塑性樹脂より溶融温度の高い耐熱剛性樹脂
からなる耐熱剛性樹脂層と、熱活性樹脂からなる熱活性
樹脂層とがこの順に積層されてなることを特徴とする。Means for Solving the Problems The thermoformable core material of the present invention is formed on one surface (hereinafter referred to as "surface") of a mat-like substrate in which heat-resistant fibers are mutually bonded by a thermoplastic resin. A heat-resistant rigid resin layer made of a heat-resistant rigid resin having a higher melting temperature than the thermoplastic resin, and a heat-active resin layer made of a heat-active resin are laminated in this order, and the heat-resistant rigid resin layer and the heat-active resin layer Through-holes having an opening area of 5 to 100 mm 2 are dispersedly formed, and the other surface (hereinafter, referred to as “back surface”)
Further, a heat-resistant stiff resin layer made of a heat-resistant stiff resin having a higher melting temperature than the thermoplastic resin and a heat-active resin layer made of a heat-active resin are laminated in this order.
【０００６】本発明で使用されるマット状基材は、耐熱
性繊維が熱可塑性樹脂で相互に結着されてなり、全体に
わたって空隙を有しているものであれば特には限定され
ず、また、耐熱性繊維に熱可塑性樹脂繊維が混抄されて
いるものが好ましい。具体的には、例えば、耐熱性繊維
からなるマット又は耐熱性繊維と熱可塑性樹脂繊維との
混抄繊維からなるマットに熱可塑性樹脂を含浸させたも
の、耐熱性繊維と熱可塑性樹脂繊維との混抄繊維からな
るマットの熱可塑性樹脂繊維の一部又は全部を溶融させ
て耐熱性繊維を相互に結着させたもの、耐熱性繊維から
なるマット又は耐熱性繊維と熱可塑性樹脂繊維との混抄
繊維からなるマットに熱可塑性樹脂粉末を分散させ熱可
塑性樹脂粉末の一部又は全部を溶融させて耐熱性繊維を
相互に結着させたもの等が挙げられる。尚、マット状基
材の空隙率は、小さくなると、得られる熱成形性芯材の
吸音性及び軽量性が低下し、大きくなると、得られる熱
成形性芯材の機械的強度が低下するので、適宜調整する
のが好ましい。[0006] The mat-like substrate used in the present invention is not particularly limited as long as the heat-resistant fibers are bonded to each other with a thermoplastic resin and have voids throughout. Preferably, a heat-resistant fiber mixed with a thermoplastic resin fiber is used. Specifically, for example, a mat made of a heat-resistant fiber or a mat made of a mixed fiber of a heat-resistant fiber and a thermoplastic resin fiber impregnated with a thermoplastic resin, a mixture of a heat-resistant fiber and a thermoplastic resin fiber A material made by melting some or all of the thermoplastic resin fibers of a mat made of fibers and binding heat-resistant fibers to each other, from a mat made of heat-resistant fibers or a mixed fiber of heat-resistant fibers and thermoplastic resin fibers The thermoplastic resin powder is dispersed in a mat, and a part or all of the thermoplastic resin powder is melted to bond heat resistant fibers to each other. In addition, the porosity of the mat-shaped base material is reduced, the sound absorption and lightness of the obtained thermoformable core material are reduced, and when the porosity is increased, the mechanical strength of the obtained thermoformable core material is reduced. It is preferable to adjust appropriately.
【０００７】上記耐熱性繊維としては、例えば、無機繊
維、植物繊維等が挙げられ、得られる熱成形性芯材に要
求される物性に応じて適宜選択するのが好ましく、混抄
して使用してもよい。例えば、得られる熱成形性芯材の
曲げ強度、厚さ回復性等の機械的強度が重視される場合
には無機繊維を使用するのが好ましく、得られる熱成形
性芯材のサーマルリサイクル性が重視される場合には植
物繊維を使用するのが好ましい。The heat-resistant fibers include, for example, inorganic fibers and vegetable fibers. It is preferable to appropriately select the heat-resistant fibers according to the physical properties required of the obtained thermoformable core material. Is also good. For example, when mechanical strength such as bending strength and thickness recovery of the obtained thermoformable core material is important, it is preferable to use inorganic fibers, and the thermal recyclability of the obtained thermoformable core material is high. When importance is attached, it is preferable to use vegetable fibers.
【０００８】上記無機繊維としては、例えば、ガラス繊
維、炭素繊維、ロックウール、セラミック繊維等が挙げ
られ、これらは単独で使用しても２種以上併用してもよ
い。無機繊維の長さは、短すぎても長すぎても、得られ
る熱成形性芯材の熱成形性が低下するので、５〜２５０
ｍｍが好ましく、５０〜１５０ｍｍのものが７０重量％
以上含有されているのがより好ましい。また、無機繊維
の太さは、細くなると、得られる熱成形性芯材の曲げ強
度、厚み回復性などの機械的強度が低下し、太くなる
と、得られる熱成形性芯材の軽量性が低下するので、そ
の直径が５〜２０μｍであるのが好ましく、より好まし
くは７〜１３μｍである。Examples of the inorganic fibers include glass fibers, carbon fibers, rock wool, and ceramic fibers. These may be used alone or in combination of two or more. If the length of the inorganic fiber is too short or too long, the thermoformability of the obtained thermoformable core material is reduced.
mm is preferred, and 50 to 150 mm is 70% by weight.
More preferably, it is contained. Also, as the thickness of the inorganic fiber becomes thinner, the mechanical strength such as bending strength and thickness recovery of the obtained thermoformable core material decreases, and as the thickness increases, the lightness of the obtained thermoformable core material decreases. Therefore, the diameter is preferably 5 to 20 μm, more preferably 7 to 13 μm.
【０００９】上記植物繊維としては、例えば、ジュート
繊維、ケナフ繊維等が挙げられ、これらは単独で使用し
ても２種以上併用してもよい。植物繊維の長さは、短す
ぎても長すぎても、得られる熱成形性芯材の曲げ強度、
厚み回復性などの機械的強度が低下するので、３〜２０
０ｍｍが好ましく、より好ましくは５〜１５０ｍｍであ
る。また、植物繊維の太さは、その直径が２００μｍ以
下のものが一般的であり、好ましくは１０〜１５０μｍ
である。[0009] Examples of the plant fiber include jute fiber and kenaf fiber, and these may be used alone or in combination of two or more. The length of the vegetable fiber is too short or too long, the bending strength of the thermoformable core material obtained,
Since the mechanical strength such as the thickness recovery property is reduced, 3 to 20
0 mm is preferable, and more preferably 5 to 150 mm. The thickness of the plant fiber is generally 200 μm or less in diameter, preferably 10 to 150 μm
It is.
【００１０】上記耐熱性繊維を相互に結着する熱可塑性
樹脂としては、溶融状態で耐熱性繊維間に含浸し易く、
かつ、耐熱性繊維と結着し易いものが好ましく、例え
ば、ポリエチレン、ポリプロピレン、ポリスチレン、エ
チレン−酢酸ビニル共重合体、飽和ポリエステル、これ
らの変性物等が挙げられる。As the thermoplastic resin which binds the heat resistant fibers to each other, it is easy to impregnate the heat resistant fibers in a molten state,
Further, those which easily bind to heat-resistant fibers are preferable, and examples thereof include polyethylene, polypropylene, polystyrene, ethylene-vinyl acetate copolymer, saturated polyester, and modified products thereof.
【００１１】上記熱可塑性樹脂繊維としては、溶融時に
上記耐熱性繊維と結着するものが好ましく、例えば、ポ
リエチレン、ポリプロピレン、ポリスチレン等からなる
繊維が挙げられる。熱可塑性樹脂繊維の長さ及び太さ
は、上記耐熱性繊維に分散し易く、均一に混抄される程
度が好ましい。具体的には、長さは５〜２００ｍｍが好
ましく、より好ましくは２０〜１００ｍｍであり、太さ
は、直径が５〜７０μｍが好ましく、より好ましくは１
５〜４０μｍである。The thermoplastic resin fibers preferably bind to the heat-resistant fibers at the time of melting, and include, for example, fibers made of polyethylene, polypropylene, polystyrene and the like. The length and thickness of the thermoplastic resin fibers are preferably such that they are easily dispersed in the heat-resistant fibers and are uniformly mixed. Specifically, the length is preferably from 5 to 200 mm, more preferably from 20 to 100 mm, and the thickness is preferably from 5 to 70 μm in diameter, more preferably from 1 to 70 μm.
5 to 40 μm.
【００１２】上記耐熱性繊維或いは耐熱性繊維と熱可塑
性樹脂繊維との混抄繊維からなるマットを得る方法とし
ては、従来公知の任意の方法が採用されてよく、例え
ば、カードマシンに耐熱性繊維と必要に応じて熱可塑性
樹脂繊維を供給し、これらを解繊してマット状にした
後、ニードルパンチを打つ方法が一般的である。ニード
ルパンチは、得られる熱成形性芯材の機械的強度を向上
させるのに、１ｃｍ2あたり２〜１００箇所打たれるの
が好ましく、より好ましくは１ｃｍ2あたり１０〜５０
箇所である。As a method for obtaining a mat made of the heat-resistant fiber or a mixed fiber of the heat-resistant fiber and the thermoplastic resin fiber, any conventionally known method may be employed. Generally, a method of supplying thermoplastic resin fibers as necessary, defibrating the fibers into a mat shape, and punching a needle punch is used. Needle punch, to improve the mechanical strength of the thermoformable core material obtained is preferably beaten 1 cm 2 2 to 100 places per, more preferably per 1 cm 2 10 to 50
Part.
【００１３】上記マット状基材中の耐熱性繊維と、熱可
塑性樹脂（熱可塑性樹脂繊維を含む）の配合割合は、耐
熱性繊維が少なくなると、得られる熱成形性芯材の耐熱
性が低下し、多くなると、耐熱性繊維相互の結着力が低
下し、得られる熱成形性芯材の剛性が低下するので、耐
熱性繊維と熱可塑性樹脂が重量比で５：１〜１：５であ
るのが好ましい。The mixing ratio of the heat-resistant fiber and the thermoplastic resin (including the thermoplastic resin fiber) in the mat-like base material is such that as the heat-resistant fiber decreases, the heat resistance of the obtained thermoformable core material decreases. However, when the number increases, the binding force between the heat-resistant fibers decreases, and the rigidity of the obtained thermoformable core material decreases. Therefore, the weight ratio of the heat-resistant fibers to the thermoplastic resin is 5: 1 to 1: 5. Is preferred.
【００１４】また、マット状基材の見掛け密度は、小さ
くなると、得られる熱成形性芯材の機械的強度が低下
し、大きくなると、得られる熱成形性芯材の吸音性及び
軽量性が低下するので、０．０１〜０．２ｇ／ｃｍ3が
好ましく、マット状基材の坪量は、小さくなると、得ら
れる熱成形性芯材の機械的強度が低下し、大きくなる
と、得られる熱成形性芯材の軽量性が低下するので、２
００〜１５００ｇ／ｍ2が好ましく、より好ましくは３
００〜８００ｇ／ｍ2である。Further, when the apparent density of the mat-shaped base material is reduced, the mechanical strength of the obtained thermoformable core material is reduced, and when the apparent density is increased, the sound absorbing property and light weight of the obtained thermoformable core material are reduced. Therefore, the weight is preferably 0.01 to 0.2 g / cm 3, and when the basis weight of the mat-like base material is small, the mechanical strength of the obtained thermoformable core material is reduced. Since the lightness of the conductive core material decreases,
00 to 1500 g / m 2 is preferable, and 3 is more preferable.
It is 00 to 800 g / m 2 .
【００１５】上記マット状基材の表面には、貫通孔を有
する、耐熱剛性樹脂層（以下、「耐熱剛性樹脂層
（１）」と記す）及び熱活性樹脂層（以下、「熱活性樹
脂層（１）」と記す）とがこの順に積層されている。On the surface of the mat-like base material, a heat-resistant rigid resin layer (hereinafter referred to as "heat-resistant rigid resin layer (1)") and a heat-active resin layer (hereinafter, referred to as "heat-active resin layer") having through holes are provided. (1) ") are stacked in this order.
【００１６】上記耐熱剛性樹脂層（１）を構成する耐熱
剛性樹脂は、マット状基材中の熱可塑性樹脂より溶融温
度の高いものであり、３０℃以上高いものが好ましく、
５０℃以上高いものがより好ましい。これにより、後述
するように、得られる熱成形性芯材全体を加熱して、該
耐熱剛性樹脂以外の樹脂を溶融させることができる。こ
のような耐熱剛性樹脂としては、例えば、ポリブチレン
テレフタレート、ポリエチレンテレフタレート、ポリカ
ーボネート、ポリアミド、これらの変性物等が挙げられ
る。The heat-resistant rigid resin constituting the heat-resistant rigid resin layer (1) has a higher melting temperature than the thermoplastic resin in the mat-like base material, and preferably has a higher temperature by 30 ° C. or more.
Those having a temperature higher than 50 ° C. are more preferable. Thereby, as described later, the entire thermoformable core material obtained can be heated to melt resins other than the heat-resistant rigid resin. Examples of such a heat-resistant rigid resin include polybutylene terephthalate, polyethylene terephthalate, polycarbonate, polyamide, and modified products thereof.
【００１７】耐熱剛性樹脂層（１）の厚さは、薄くなる
と、熱成形性芯材の製造過程における加熱圧縮時、得ら
れる熱成形性芯材の熱成形時などにマット状基材中の耐
熱性繊維が耐熱剛性樹脂層（１）を突き破り易くなり、
厚くなると、得られる熱成形性芯材の軽量性が低下する
ので、３〜２５μｍが好ましい。When the thickness of the heat-resistant and rigid resin layer (1) is reduced, the thickness of the mat-shaped base material during heating and compression in the production process of the thermoformable core material and during thermoforming of the obtained thermoformable core material is reduced. The heat-resistant fiber easily breaks through the heat-resistant rigid resin layer (1),
When the thickness is large, the lightness of the obtained thermoformable core material is reduced, so that the thickness is preferably 3 to 25 μm.
【００１８】上記熱活性樹脂層（１）を構成する熱活性
樹脂は、その熱活性発現温度が上記耐熱剛性樹脂の溶融
温度より低いものであり、２０℃以上低いものが好まし
く、マット状基材中の熱可塑性樹脂の溶融温度と同程度
であるのがより好ましい。これにより、得られる熱成形
性芯材全体を加熱した際、耐熱剛性樹脂を溶融させるこ
となく、表面の熱活性樹脂を溶融活性化することができ
るので、熱成形性芯材の製造途中或いは熱成形性芯材を
熱成形する工程において加熱圧縮した際、熱活性樹脂が
マット状基材に含浸してしまうことがなく、後述する表
面材を強固に接着することができる。The heat-active resin constituting the heat-active resin layer (1) has a heat activation temperature lower than the melting temperature of the heat-resistant rigid resin, preferably 20 ° C. or more. More preferably, it is about the same as the melting temperature of the thermoplastic resin therein. With this, when the entire thermoformable core material obtained is heated, the heat-active resin on the surface can be melt-activated without melting the heat-resistant rigid resin. When heat-compressed in the step of thermoforming the moldable core material, the heat-active resin does not impregnate the mat-shaped base material, and the surface material described below can be firmly bonded.
【００１９】このような熱活性樹脂としては、例えば、
ポリエチレン、ポリプロピレン、エチレン−酢酸ビニル
共重合体、飽和ポリエステル、変性ポリエチレン、共重
合ポリアミド等が挙げられる。Examples of such a heat-active resin include, for example,
Examples include polyethylene, polypropylene, ethylene-vinyl acetate copolymer, saturated polyester, modified polyethylene, and copolyamide.
【００２０】熱活性樹脂のメルトフローレート（以下、
「ＭＦＲ」と記す）は、小さくなると、後述する表面材
を積層する際、熱活性樹脂を溶融活性化させても、熱活
性樹脂が表面材内部に含浸せずアンカー効果が得られ
ず、大きくなると、後述する表面材を積層する際、熱活
性樹脂のほとんどが表面材内部に含浸してしまい、いず
れの場合も表面材と熱活性樹脂層（１）との接着強度が
低下するので、０．５〜２０が好ましく、より好ましく
は２〜１５である。尚、上記ＭＦＲは、ＪＩＳ Ｋ ７
２１０に準拠し、温度１９０℃、荷重２１．２Ｎで測定
した値である。The melt flow rate of the heat-activated resin (hereinafter referred to as the melt flow rate)
When "MFR" is reduced, when the surface material described below is laminated, even if the heat-activated resin is melt-activated, the heat-activated resin does not impregnate the interior of the surface material, and the anchor effect is not obtained, and the value becomes large. In this case, when laminating a surface material described later, most of the thermoactive resin impregnates the inside of the surface material, and in any case, the adhesive strength between the surface material and the thermoactive resin layer (1) is reduced. It is preferably from 0.5 to 20, more preferably from 2 to 15. The above MFR is based on JIS K7
This is a value measured at a temperature of 190 ° C. and a load of 21.2 N in accordance with No. 210.
【００２１】熱活性樹脂層（１）の厚さは、薄くなる
と、後述する表面材を積層する際、表面材内部に含浸す
る熱活性樹脂の量が少なくなり、表面材と熱活性樹脂層
（１）との接着強度が低下し、厚くなると、得られる熱
成形性芯材の軽量性が低下し、また、後述する表面材を
積層する際、表面材内部に含浸する熱活性樹脂の量が多
くなり、表面材の風合が固くなるので、２０〜１００μ
ｍが好ましい。When the thickness of the heat-active resin layer (1) is reduced, the amount of the heat-active resin impregnated inside the surface material when laminating the surface material described later decreases, and the surface material and the heat-active resin layer (1) are laminated. When the adhesive strength with 1) is reduced and the thickness is increased, the lightness of the obtained thermoformable core material is reduced, and when laminating a surface material described later, the amount of the thermoactive resin impregnated inside the surface material is reduced. More, the texture of the surface material becomes harder, so 20 ~ 100μ
m is preferred.
【００２２】上記貫通孔の大きさは、小さくなると、得
られる熱成形性芯材の吸音性が低下し、大きくなると、
熱活性樹脂層（１）と後述する表面材との接着強度が低
下するので、貫通孔１つの開口面積が３〜１００ｍｍ2
に限定され、好ましくは１２〜５０ｍｍ2である。貫通
孔の形成割合は、少なくなると、得られる熱成形性芯材
の吸音性が低下し、多くなると、得られる熱成形性芯材
の曲げ強度や熱活性樹脂層と後述する表面材との接着強
度が低下するので、開口面積合計が、マット状基材一面
の面積に対して５〜８０％であるのが好ましく、より好
ましくは１０〜３０％であり、全体に均一に分散して形
成されているのが好ましい。When the size of the through hole is reduced, the sound absorbability of the obtained thermoformable core material is reduced.
Since the adhesive strength between the heat-active resin layer (1) and the surface material described below decreases, the opening area of one through hole is 3 to 100 mm 2.
And preferably 12 to 50 mm 2 . When the formation ratio of the through-holes decreases, the sound absorption of the obtained thermoformable core material decreases, and when the ratio increases, the bending strength of the obtained thermoformable core material and the adhesion between the thermoactive resin layer and the surface material described below. Since the strength is reduced, the total opening area is preferably from 5 to 80%, more preferably from 10 to 30%, with respect to the area of one surface of the mat-shaped base material. Is preferred.
【００２３】また、貫通孔の形状は特には限定されない
が、形成が容易であるので、開口形状が円形であるのが
好ましく、規則的に形成されているのが、後述する表面
材を接着した際、外観を損なうことがないので、より好
ましい。貫通孔の開口形状が円形である場合、その直径
は、２〜１５ｍｍが好ましく、より好ましくは４〜８ｍ
ｍであり、異なる大きさの貫通孔を組み合わせてもよ
い。The shape of the through-hole is not particularly limited, but it is preferable that the shape of the opening is circular because it is easy to form. At this time, the appearance is more preferable because the appearance is not impaired. When the opening shape of the through hole is circular, the diameter is preferably 2 to 15 mm, more preferably 4 to 8 m.
m, and through holes of different sizes may be combined.
【００２４】貫通孔は、耐熱剛性樹脂層（１）及び熱活
性樹脂層（１）を積層した後に形成するのが、形成が容
易であるとともに、貫通孔形成割合などが調整し易いの
で好ましい。貫通孔を形成する方法としては、例えば、
耐熱剛性樹脂層（１）及び熱活性樹脂層（１）とその他
必要に応じて積層された各層からなる積層シートを、凹
部を有するダイスと凸部を有するダイスとの間に供給
し、前記凸部により積層シートを打ち抜く機械的パンチ
ング法、前記積層シートを、耐熱剛性樹脂層（１）を構
成する耐熱剛性樹脂の溶融温度以上に加熱し、ロッドが
埋め込まれたロールと通常のロールとの間に該積層シー
トを供給し、溶融開口する方法、前記積層シートにレー
ザー光線を照射し、溶融開口する方法等が挙げられ、中
でも機械的パンチング法が、任意の大きさの貫通孔を精
度よく安定的に形成することができるので好ましい。It is preferable to form the through-holes after laminating the heat-resistant rigid resin layer (1) and the heat-active resin layer (1), because the formation is easy and the through-hole formation ratio is easily adjusted. As a method of forming a through hole, for example,
A laminated sheet composed of the heat-resistant rigid resin layer (1) and the heat-active resin layer (1) and other layers laminated as necessary is supplied between a dice having a concave portion and a dice having a convex portion. Mechanical punching method in which a laminated sheet is punched by a part, wherein the laminated sheet is heated to a temperature equal to or higher than the melting temperature of the heat-resistant rigid resin constituting the heat-resistant rigid resin layer (1), and between a roll in which a rod is embedded and a normal roll. The laminated sheet is supplied and melt-opened, a method of irradiating the laminated sheet with a laser beam and melt-opened, and the like, among which mechanical punching method is capable of accurately and stably forming through holes of any size. It is preferable because it can be formed into
【００２５】上記マット状基材の裏面には、耐熱剛性樹
脂層（以下、「耐熱剛性樹脂層（２）」と記す）と、熱
活性樹脂層（以下、「熱活性樹脂層（２）」と記す）と
がこの順に積層されている。The heat-resistant rigid resin layer (hereinafter referred to as “heat-resistant rigid resin layer (2)”) and the heat-active resin layer (hereinafter referred to as “heat-active resin layer (2)”) Are stacked in this order.
【００２６】上記耐熱剛性樹脂層（２）を構成する耐熱
剛性樹脂は、表面の耐熱剛性樹脂層（１）を構成する耐
熱剛性樹脂と同様ものが挙げられる。耐熱剛性樹脂層
（２）の厚さは、薄くなると、熱成形性芯材の製造過程
における加熱圧縮時、得られる熱成形性芯材の熱成形時
などにマット状基材中の耐熱性繊維が耐熱剛性樹脂層
（２）を突き破り易くなるため、非通気性が低下し、厚
くなると、得られる熱成形性芯材の軽量性が低下するの
で、３〜２５μｍが好ましい。The heat-resistant rigid resin constituting the heat-resistant rigid resin layer (2) is the same as the heat-resistant rigid resin constituting the surface heat-resistant rigid resin layer (1). When the thickness of the heat-resistant stiff resin layer (2) is reduced, the heat-resistant fiber in the mat-shaped base material is used at the time of heat compression in the production process of the thermoformable core material, thermoforming of the obtained thermoformable core material, and the like. Is preferably 3 to 25 [mu] m, because the air permeability is reduced because the heat-resistant rigid resin layer (2) is easily pierced.
【００２７】上記熱活性樹脂層（２）を構成する熱活性
樹脂は、表面の熱活性樹脂層（１）を構成する熱活性樹
脂と同様のものが挙げられ、これにより、得られる熱成
形性芯材全体を加熱した際、耐熱剛性樹脂を溶融させる
ことなく、裏面の熱活性樹脂を溶融活性化することがで
きるので、自動車用天井材等の成形品の通気遮断性を損
なうことなく、部材等に強固に熱接着することができ
る。尚、熱成形性芯材を部材等に固定する必要がない場
合は、熱活性樹脂層（２）のＭＦＲ等が上記範囲外のも
のでも好ましく使用される。熱活性樹脂層（２）の厚さ
は、２０〜１００μｍが好ましい。The heat-active resin constituting the heat-active resin layer (2) may be the same as the heat-active resin constituting the heat-active resin layer (1) on the surface. When the entire core material is heated, the heat-active resin on the back surface can be melt-activated without melting the heat-resistant stiff resin, so that the air-blocking properties of molded articles such as automotive ceiling materials are not impaired. Can be firmly heat bonded. When it is not necessary to fix the thermoformable core material to a member or the like, it is preferable to use a thermoactive resin layer (2) having an MFR or the like outside the above range. The thickness of the thermoactive resin layer (2) is preferably 20 to 100 μm.
【００２８】また、上記熱成形性芯材に積層された耐熱
剛性樹脂及び熱活性樹脂は、表面と裏面とで同一であっ
てもよく、異なっていてもよい。また、耐熱剛性樹脂層
及び熱活性樹脂層の厚さも、表面と裏面とで同一であっ
てもよく、異なっていてもよい。The heat-resistant rigid resin and the heat-active resin laminated on the thermoformable core material may be the same on the front surface and the back surface, or may be different. Further, the thickness of the heat-resistant rigid resin layer and the thickness of the heat-active resin layer may be the same on the front surface and the back surface, or may be different.
【００２９】さらに、上記熱成形性芯材の各層の間に
は、適宜他の樹脂層が形成されていてもよい。例えば、
層間接着強度を上げるためには、各層の間に接着性熱可
塑性樹脂層が形成されているのが好ましい。接着性熱可
塑性樹脂層を構成する接着性熱可塑性樹脂としては、各
層と接着可能なものであれば特には限定されず、例え
ば、酸変性ポリエチレン、共重合ポリアミド、共重合ポ
リエステル等が挙げられる。Further, another resin layer may be appropriately formed between the layers of the thermoformable core material. For example,
In order to increase the interlayer adhesive strength, it is preferable that an adhesive thermoplastic resin layer is formed between the layers. The adhesive thermoplastic resin constituting the adhesive thermoplastic resin layer is not particularly limited as long as it can adhere to each layer, and examples thereof include acid-modified polyethylene, copolymerized polyamide, and copolymerized polyester.
【００３０】本発明の熱成形性芯材の製造方法として
は、例えば、以下の方法が挙げられる。第１の方法とし
ては、熱可塑性樹脂、耐熱剛性樹脂及び熱活性樹脂をこ
の順に積層してなる積層シートを２枚作成し、２枚の積
層シートのうち１枚に貫通孔を形成し、耐熱性繊維から
なるマット或いは耐熱性繊維と熱可塑性樹脂繊維との混
抄繊維からなるマットの両面に、各積層シートの熱可塑
性樹脂層がマット側になるように配置し、耐熱剛性樹脂
の溶融温度以下の温度に加熱して、熱可塑性樹脂及び熱
活性樹脂を溶融させるとともに全体を厚さ方向に圧縮
し、耐熱剛性樹脂及びその外側にある熱活性樹脂をマッ
ト内に含浸させることなく、マット両面の熱可塑性樹脂
をマット内に含浸させた後、厚さ方向に拡開させる方法
が挙げられる。The method for producing the thermoformable core material of the present invention includes, for example, the following method. As a first method, two laminated sheets are formed by laminating a thermoplastic resin, a heat-resistant rigid resin, and a thermoactive resin in this order, and a through-hole is formed in one of the two laminated sheets to form a heat-resistant sheet. On both sides of a mat made of conductive fibers or a mat made of mixed fibers of heat-resistant fibers and thermoplastic resin fibers, so that the thermoplastic resin layer of each laminated sheet is on the mat side, the melting temperature of the heat-resistant rigid resin or less Heat to the temperature of, melt the thermoplastic resin and the thermo-active resin and compress the whole in the thickness direction, without impregnating the heat-resistant rigid resin and the thermo-active resin outside the mat inside the mat, After impregnating the mat with the thermoplastic resin, the mat may be expanded in the thickness direction.
【００３１】また、第２の方法としては、耐熱性繊維か
らなるマット或いは耐熱性繊維と熱可塑性樹脂繊維との
混抄繊維からなるマットの両面に熱可塑性樹脂を積層し
ておき、一方で、耐熱剛性樹脂及び熱活性樹脂を積層し
てなる積層シートを２枚作成し、２枚の積層シートのう
ち１枚に貫通孔を形成し、マットに積層した熱可塑性樹
脂層面に、各積層シートの耐熱剛性樹脂層が熱可塑性樹
脂層側になるように配置し、耐熱剛性樹脂の溶融温度以
下の温度に加熱して、熱可塑性樹脂及び熱活性樹脂を溶
融させるとともに全体を厚さ方向に圧縮し、耐熱剛性樹
脂及びその外側にある熱活性樹脂をマット内に含浸させ
ることなく、マット両面の熱可塑性樹脂をマット内に含
浸させた後、厚さ方向に拡開させる方法が挙げられる。As a second method, a thermoplastic resin is laminated on both sides of a mat made of heat-resistant fiber or a mat made of a mixed fiber of heat-resistant fiber and thermoplastic resin fiber. Two laminated sheets made by laminating a rigid resin and a thermo-active resin are created, a through hole is formed in one of the two laminated sheets, and the heat resistance of each laminated sheet is formed on the surface of the thermoplastic resin layer laminated on the mat. The rigid resin layer is arranged so as to be on the thermoplastic resin layer side, and is heated to a temperature equal to or lower than the melting temperature of the heat-resistant rigid resin to melt the thermoplastic resin and the thermoactive resin and compress the whole in the thickness direction, There is a method of impregnating the mat with the thermoplastic resin on both sides of the mat without impregnating the mat with the heat-resistant rigid resin and the thermoactive resin on the outside thereof, and then expanding the mat in the thickness direction.
【００３２】上記製造方法において、マット両面の熱可
塑性樹脂はマット内に含浸し、マットの耐熱性繊維を相
互に結着する。含浸工程において、熱可塑性樹脂全てを
マット内に含浸させる必要はなく、一部は含浸させずに
残しておいてもよい。そうすることにより、マットと耐
熱剛性樹脂層との接着強度、得られる熱成形性芯材の機
械的強度等を向上させることができる。上記第１の方法
は、マット両面の熱可塑性樹脂の一部を含浸させずに残
しておいても、表面の熱可塑性樹脂層に貫通孔が形成さ
れているので、得られる熱成形性芯材の吸音性を損なう
ことがなく、好ましい。In the above manufacturing method, the thermoplastic resin on both sides of the mat is impregnated in the mat and binds the heat resistant fibers of the mat to each other. In the impregnation step, it is not necessary to impregnate the entire thermoplastic resin into the mat, and a part of the mat may be left unimpregnated. By doing so, it is possible to improve the adhesive strength between the mat and the heat-resistant rigid resin layer, the mechanical strength of the obtained thermoformable core material, and the like. In the first method, even if a part of the thermoplastic resin on both sides of the mat is left without being impregnated, the through-hole is formed in the thermoplastic resin layer on the surface. This is preferable without impairing the sound absorbing property.
【００３３】マット両面の熱可塑性樹脂層の厚さは、薄
くなると、マット内に含浸しても耐熱性繊維相互の結着
力が不足し、得られる熱成形性芯材の機械的強度が低下
し、厚くなると、得られる熱成形性芯材の軽量性が低下
するので、５０〜５００μｍが好ましく、より好ましく
は７０〜３００μｍである。When the thickness of the thermoplastic resin layer on both sides of the mat is reduced, the bonding strength between the heat-resistant fibers becomes insufficient even when impregnated in the mat, and the mechanical strength of the obtained thermoformable core material decreases. When the thickness is large, the lightness of the obtained thermoformable core material is reduced. Therefore, the thickness is preferably 50 to 500 μm, more preferably 70 to 300 μm.
【００３４】上記熱可塑性樹脂、耐熱剛性樹脂及び熱活
性樹脂からなる積層シート、又は、耐熱剛性樹脂及び熱
活性樹脂からなる積層シートを得る方法としては、特に
は限定されず、従来公知の任意の方法が採用されてよ
く、例えば、共押出法、押出ラミネート法、ドライラミ
ネート法等が挙げられる。中でも、各層を構成する樹脂
をダイ内に同時押出した後、Ｔダイ等から吐出させる共
押出法が、経済的であり、好ましい。The method for obtaining the laminated sheet comprising the thermoplastic resin, the heat-resistant rigid resin and the heat-active resin, or the laminated sheet comprising the heat-resistant rigid resin and the heat-active resin is not particularly limited, and any conventionally known arbitrary method can be used. A method may be adopted, and examples thereof include a coextrusion method, an extrusion lamination method, and a dry lamination method. Among them, a co-extrusion method in which the resin constituting each layer is simultaneously extruded into a die and then discharged from a T-die or the like is economical and preferable.
【００３５】また、マットの両面に熱可塑性樹脂を積層
する方法としては、特には限定されず、従来公知の任意
の方法が採用されてよく、例えば、マットに熱可塑性樹
脂を押出ラミネートする方法、熱可塑性樹脂からなるフ
ィルムをマットに熱ラミネートする方法等が挙げられ
る。The method of laminating the thermoplastic resin on both sides of the mat is not particularly limited, and any conventionally known method may be employed. For example, a method of extrusion laminating the thermoplastic resin on the mat, A method of thermally laminating a film made of a thermoplastic resin on a mat may be used.
【００３６】上記圧縮の条件は特には限定されず、適宜
決定してよいが、圧縮圧力が０．２〜１ＭＰａであり、
圧縮時間が２〜１０秒であるのが好ましい。The conditions for the above-mentioned compression are not particularly limited and may be appropriately determined, but the compression pressure is 0.2 to 1 MPa,
The compression time is preferably between 2 and 10 seconds.
【００３７】上記拡開の方法としては、耐熱性繊維の弾
力で自然回復させてもよく、強制的に回復させてもよ
い。強制的に回復させる方法としては、例えば、テフロ
ン（登録商標）コーティングされた鋼板やガラスクロス
シートなどでマット全体を挟み、その両表面を真空吸引
する方法が挙げられる。拡開の程度は、得られる熱成形
性芯材の所望の空隙率、見掛け密度等により、適宜調整
するのが好ましい。As the above-mentioned spreading method, natural recovery may be performed by the elasticity of the heat-resistant fiber, or recovery may be forcibly performed. As a method of forcibly recovering, for example, a method of sandwiching the entire mat with a steel plate or a glass cloth sheet coated with Teflon (registered trademark) and vacuum-suctioning both surfaces thereof can be mentioned. The degree of expansion is preferably adjusted as appropriate depending on the desired porosity, apparent density, and the like of the obtained thermoformable core material.
【００３８】上記製造方法により得られた熱成形性芯材
は、従来公知の任意の方法により冷却される。冷却は自
然冷却又は強制冷却のいずれでもよいが、冷却速度、生
産性、冷却による熱可塑性樹脂の硬化の安定性等が調整
し易いので、強制冷却が好ましい。また、拡開の後に冷
却しても、拡開と冷却とを略同時に行ってもよい。The thermoformable core material obtained by the above production method is cooled by any conventionally known method. Cooling may be either natural cooling or forced cooling, but forced cooling is preferred because the cooling rate, productivity, and stability of the thermoplastic resin during cooling can be easily adjusted. Further, cooling may be performed after the expansion, or the expansion and the cooling may be performed substantially simultaneously.
【００３９】上記熱成形性芯材は、その貫通孔を有する
熱活性樹脂層面に、表面材が積層され、熱成形されて自
動車用天井材となされる。表面材の積層一体化は、熱成
形性芯材の熱成形時に同時に行ってもよく、熱成形の前
に行ってもよい。上記表面材としては、例えば、天然繊
維、合成繊維、これらの混抄繊維等からなる不織布が好
適に使用される。天然繊維としては、例えば、綿、羊
毛、麻等が挙げられ、合成繊維としては、例えば、ポリ
エステル、ポリアミド、ポリウレタン等が挙げられる。The thermoformable core material is formed by laminating a surface material on the surface of the thermoactive resin layer having the through-holes, and is thermoformed to form an automobile ceiling material. The lamination and integration of the surface material may be performed simultaneously with the thermoforming of the thermoformable core material, or may be performed before the thermoforming. As the surface material, for example, a non-woven fabric composed of natural fibers, synthetic fibers, and mixed fibers thereof is preferably used. Examples of the natural fiber include cotton, wool, hemp, and the like, and examples of the synthetic fiber include polyester, polyamide, and polyurethane.
【００４０】表面材として不織布を使用することによ
り、熱成形性芯材表面の熱活性樹脂の一部が表面材内部
に含浸されるので、アンカー効果により、熱活性樹脂層
と表面材との接着強度が優れたものとなる。By using a nonwoven fabric as the surface material, a part of the thermoactive resin on the surface of the thermoformable core material is impregnated inside the surface material. The strength becomes excellent.
【００４１】熱成形性芯材に表面材を積層する方法とし
ては、例えば、熱成形性芯材の熱活性樹脂層面に表面材
を重ね、加熱状態にてプレスする方法が挙げられる。ま
た、熱活性樹脂層と表面材との間に接着性熱可塑性樹脂
層を形成してもよい。As a method of laminating the surface material on the thermoformable core material, for example, there is a method in which the surface material is overlaid on the surface of the thermoactive resin layer of the thermoformable core material and pressed in a heated state. Further, an adhesive thermoplastic resin layer may be formed between the thermoactive resin layer and the surface material.
【００４２】[0042]
【発明の実施の形態】以下に実施例を掲げて本発明の態
様を更に詳しく説明するが、本発明はこれら実施例のみ
に限定されるものではない。DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The embodiments of the present invention will be described in more detail with reference to the following examples, but the present invention is not limited to these examples.
【００４３】（実施例１）長さ４０〜７５ｍｍ、直径９
μｍのガラス繊維と、長さ６４ｍｍ、太さ３５μｍ、溶
融温度１６２℃のポリプロピレン繊維とを、重量比が
３：２となるように混合し、カードマシンに供給して、
混抄繊維をマット状とし、２０箇所／ｃｍ2でニードル
パンチを打ち、坪量約５５０ｇ／ｃｍ2、厚さ約７．５
ｍｍの混抄マットを得た。得られた混抄マットの両面
に、溶融温度１３５℃、ＭＦＲ７の、少量の無水マレイ
ン酸変性ポリエチレンを含有する高密度ポリエチレンか
らなる厚さ１２０μｍの高密度ポリエチレンフィルムを
積層し、３層マットを得た。(Example 1) Length 40-75 mm, diameter 9
μm glass fiber and polypropylene fiber having a length of 64 mm, a thickness of 35 μm and a melting temperature of 162 ° C. are mixed so that the weight ratio becomes 3: 2, and supplied to a card machine,
The mixed fiber was made into a mat shape, and a needle punch was punched at 20 points / cm 2 to obtain a basis weight of about 550 g / cm 2 and a thickness of about 7.5.
mm was obtained. A 120 μm thick high-density polyethylene film made of high-density polyethylene containing a small amount of maleic anhydride-modified polyethylene having a melting temperature of 135 ° C. and an MFR of 7 was laminated on both sides of the obtained mixed mat to obtain a three-layer mat. .
【００４４】一方、溶融温度２３０℃の６−ナイロン
と、溶融温度１２５℃、ＭＦＲ１０のマレイン酸変性直
鎖状低密度ポリエチレンとを共押出し、２枚の２層フィ
ルムを得た。２枚の２層フィルムはいずれも６−ナイロ
ン層の厚さが２０μｍ、マレイン酸変性直鎖状低密度ポ
リエチレン層の厚さが６０μｍであった。得られた２層
フィルムのうち１枚に、開口面積２８ｍｍ2（開口形状
は直径６ｍｍの円）の貫通孔を１０ｍｍ間隔でパンチン
グにより打ち抜いた。Separately, 6-nylon having a melting temperature of 230 ° C. and maleic acid-modified linear low density polyethylene having a MFR of 10 and a melting temperature of 125 ° C. were co-extruded to obtain two two-layer films. In each of the two two-layer films, the thickness of the 6-nylon layer was 20 μm, and the thickness of the maleic acid-modified linear low-density polyethylene layer was 60 μm. One of the obtained two-layer films was punched out with through holes having an opening area of 28 mm 2 (the opening shape was a circle having a diameter of 6 mm) at intervals of 10 mm.
【００４５】次に、上記３層マットの一面に上記貫通孔
が形成された２層フィルムを、他面にもう１枚の２層フ
ィルムを、それぞれ６−ナイロン層側が３層マットに接
するように積層し、坪量約８５０ｇ／ｍ2、厚さ約８ｍ
ｍの７層マットを得た。Next, the two-layer film having the through-holes formed on one surface of the three-layer mat and the other two-layer film on the other surface, so that the 6-nylon layer side is in contact with the three-layer mat. Laminated, basis weight about 850 g / m 2 , thickness about 8 m
m-layer mat was obtained.
【００４６】得られた７層マットを、テフロンコーティ
ングされたガラスクロスシートの間に挟み、約２００℃
の熱風式加熱炉に供給し、５分間放置した。その後、７
層マットをガラスクロスシートで挟んだまま平板プレス
に移し、厚さが１ｍｍになるまで圧縮して、圧縮状態で
５秒間保持した後、平板プレスから取り外し、両面のガ
ラスクロスシート側から真空吸引して、厚さ方向に０．
５ｍｍ／秒で引っ張り、厚さ５．５ｍｍになるまで拡開
した。この拡開状態で３分間空冷した後にガラスクロス
シートを取り除き、熱成形性芯材を得た。得られた熱成
形性芯材は、厚さ約５．０ｍｍ、坪量約８５０ｇ／ｍ2
で、貫通孔の開口面積合計は、マット状基材一面の面積
に対して約２８％であり、上記７層マットの高密度ポリ
エチレンフィルムは、そのほとんどが混抄マット内に含
浸していたが、６―ナイロン層は含浸していなかった。The obtained seven-layer mat is sandwiched between glass cloth sheets coated with Teflon, and is heated at about 200 ° C.
And then left for 5 minutes. Then 7
The layer mat is transferred to a flat plate press while being sandwiched by glass cloth sheets, compressed to a thickness of 1 mm, kept in a compressed state for 5 seconds, removed from the flat plate press, and vacuum sucked from both sides of the glass cloth sheet. In the thickness direction.
It was pulled at a rate of 5 mm / sec and expanded to a thickness of 5.5 mm. After air cooling for 3 minutes in the expanded state, the glass cloth sheet was removed to obtain a thermoformable core material. The obtained thermoformable core material had a thickness of about 5.0 mm and a basis weight of about 850 g / m 2.
The total opening area of the through holes is about 28% of the area of one surface of the mat-like base material, and most of the seven-layer mat high-density polyethylene film was impregnated in the mixed mat. The 6-nylon layer was not impregnated.
【００４７】図１は、得られた熱成形性芯材を示した断
面模式図であり、熱成形性芯材１は、混抄マットに高密
度ポリエチレンフィルムが含浸してなるマット状基材２
の表面に、貫通孔３が形成された６−ナイロン層４及び
マレイン酸変性直鎖状低密度ポリエチレン層５がこの順
に積層一体化され、裏面に、貫通孔が形成されず、非通
気性の６−ナイロン層６及びマレイン酸変性直鎖状低密
度ポリエチレン層７がこの順に積層一体化されてなる。FIG. 1 is a schematic cross-sectional view showing the obtained thermoformable core material. The thermoformable core material 1 is a mat-like base material 2 obtained by impregnating a mixed mat with a high-density polyethylene film.
A 6-nylon layer 4 having a through hole 3 formed thereon and a maleic acid-modified linear low-density polyethylene layer 5 are laminated and integrated in this order on the front surface, and no through hole is formed on the back surface, and the air-impermeable material A 6-nylon layer 6 and a maleic acid-modified linear low-density polyethylene layer 7 are laminated and integrated in this order.
【００４８】（実施例２）溶融温度１３５℃、ＭＦＲ７
の、少量の無水マレイン酸変性ポリエチレンを含有する
高密度ポリエチレンと、溶融温度２３０℃の６−ナイロ
ンと、溶融温度８０〜１１５℃の共重合ポリアミドとを
この順に共押出し、２枚の３層フィルムを得た。２枚の
３層フィルムはいずれも高密度ポリエチレン層の厚さが
１２０μｍ、６−ナイロン層の厚さが２０μｍ、共重合
ポリアミド層の厚さが６０μｍであった。得られた３層
フィルムのうち１枚に、開口面積２８ｍｍ2（開口形状
は直径６ｍｍの円）の貫通孔を１０ｍｍ間隔でパンチン
グにより打ち抜いた。Example 2 Melting temperature 135 ° C., MFR 7
High-density polyethylene containing a small amount of maleic anhydride-modified polyethylene, 6-nylon having a melting temperature of 230 ° C., and copolyamide having a melting temperature of 80 to 115 ° C. in this order, and extruding two three-layer films. I got In each of the two three-layer films, the high-density polyethylene layer had a thickness of 120 µm, the 6-nylon layer had a thickness of 20 µm, and the copolymerized polyamide layer had a thickness of 60 µm. One of the obtained three-layer films was punched out with through holes having an opening area of 28 mm 2 (the opening shape was a circle having a diameter of 6 mm) at intervals of 10 mm.
【００４９】次に、実施例１と同様の混抄マットの一面
に上記貫通孔が形成された３層フィルムを、他面にもう
１枚の３層フィルムを、それぞれ高密度ポリエチレン層
側が混抄マットに接するように積層し、坪量約８５０ｇ
／ｍ2、厚さ約８ｍｍの７層マットを得た。得られた７
層マットから、実施例１と同様にして熱成形性芯材を得
た。得られた熱成形性芯材は、厚さ約５．０ｍｍ、坪量
約８５０ｇ／ｍ2で、貫通孔の開口面積合計は、マット
状基材一面の面積に対して約２８％であり、上記７層マ
ットの高密度ポリエチレン層は、そのほとんどが混抄マ
ット内に含浸していたが、６―ナイロン層は含浸してい
なかった。Next, a three-layer film having the above-mentioned through-holes formed on one surface of the same mixing mat as in Example 1, another three-layer film on the other surface, and the high-density polyethylene layer side as the mixing mat. Laminated to be in contact with each other, weighing about 850 g
/ M 2 and a 7-layer mat having a thickness of about 8 mm. 7 obtained
From the layer mat, a thermoformable core material was obtained in the same manner as in Example 1. The obtained thermoformable core material had a thickness of about 5.0 mm, a basis weight of about 850 g / m 2 , and the total opening area of the through holes was about 28% with respect to the area of one surface of the mat-like base material. Most of the high-density polyethylene layer of the seven-layer mat was impregnated in the mixed mat, but the 6-nylon layer was not impregnated.
【００５０】（比較例１）実施例１と同様の混抄マット
の両面に、溶融温度１３５℃、ＭＦＲ７の、少量の無水
マレイン酸変性ポリエチレンを含有する高密度ポリエチ
レンからなる厚さ１００μｍの高密度ポリエチレンフィ
ルムを積層し、３層マットを得た。Comparative Example 1 A high-density polyethylene having a melting temperature of 135 ° C., a MFR of 7, and a high-density polyethylene containing a small amount of maleic anhydride-modified polyethylene and a thickness of 100 μm was formed on both sides of the same mixed mat as in Example 1. The films were laminated to obtain a three-layer mat.
【００５１】一方、溶融温度１３５℃、ＭＦＲ２の、少
量の無水マレイン酸変性ポリエチレンを含有する高密度
ポリエチレンと、溶融温度１２５℃、ＭＦＲ１０のマレ
イン酸変性直鎖状低密度ポリエチレンとを共押出し、２
枚の２層フィルムを得た。２枚の２層フィルムはいずれ
も高密度ポリエチレン層の厚さが１３０μｍ、マレイン
酸変性直鎖状低密度ポリエチレン層の厚さが６０μｍで
あった。On the other hand, a high-density polyethylene containing a small amount of maleic anhydride-modified polyethylene having a melting temperature of 135 ° C. and MFR2 and a maleic acid-modified linear low-density polyethylene having a melting temperature of 125 ° C. and MFR10 are coextruded.
Two bilayer films were obtained. In each of the two two-layer films, the thickness of the high-density polyethylene layer was 130 μm, and the thickness of the maleic acid-modified linear low-density polyethylene layer was 60 μm.
【００５２】次に、上記３層マットの両面に上記２層フ
ィルムを、それぞれ高密度ポリエチレン層側が３層マッ
トに接するように積層し、坪量約９２０ｇ／ｍ2、厚さ
約８．３ｍｍの７層マットを得た。得られた７層マット
から、実施例１と同様にして熱成形性芯材を得た。得ら
れた熱成形性芯材は、厚さ約５．０ｍｍ、坪量約９２０
ｇ／ｍ2であり、上記７層マットの高密度ポリエチレン
フィルムは、そのほとんどが混抄マット内に含浸してお
り、その上の高密度ポリエチレン層及びマレイン酸変性
直鎖状低密度ポリエチレン層も１部含浸していた。Next, the two-layer film was laminated on both sides of the three-layer mat so that the high-density polyethylene layer side was in contact with the three-layer mat, respectively, and had a basis weight of about 920 g / m 2 and a thickness of about 8.3 mm. A seven-layer mat was obtained. From the obtained seven-layer mat, a thermoformable core material was obtained in the same manner as in Example 1. The obtained thermoformable core material had a thickness of about 5.0 mm and a basis weight of about 920.
g / m 2 , and most of the seven-layer mat high-density polyethylene film is impregnated in the blending mat, and the high-density polyethylene layer and the maleic acid-modified linear low-density polyethylene layer on the mat also have one layer. Part was impregnated.
【００５３】自動車用天井材の作成 実施例及び比較例で得られた熱成形性芯材の、実施例１
及び２については貫通孔が形成された面に、比較例１に
ついてはその一面に、ポリエステル繊維からなる坪量約
２００ｇ／ｍ2の不織布を配置し、周縁８箇所をホッチ
キスで仮固定した。次に、遠赤外線ヒーター式加熱炉に
より、不織布の表面温度が約１９０℃、その反対側の表
面温度が約１８０℃になるように加熱して、常温状態の
プレス機に移した後、プレス成形するとともに熱成形性
芯材と不織布とを積層一体化し、この状態で２０秒間保
持した後、プレス機から取り出し、自動車用天井材を得
た。Preparation of ceiling material for automobile Example 1 of the thermoformable core material obtained in Examples and Comparative Examples.
In Nos. 2 and 3, a nonwoven fabric made of polyester fiber having a basis weight of about 200 g / m 2 was arranged on the surface where the through-holes were formed, and on one surface in Comparative Example 1, and eight peripheral edges were temporarily fixed with a stapler. Next, the non-woven fabric is heated by a far-infrared heater type heating furnace so that the surface temperature of the non-woven fabric is about 190 ° C. and the surface temperature on the opposite side is about 180 ° C., transferred to a press at room temperature, and then press-molded. At the same time, the thermoformable core material and the nonwoven fabric were laminated and integrated, and held in this state for 20 seconds, and then taken out of the press to obtain an automobile ceiling material.
【００５４】表面材と熱成形性芯材の接着強度の評価 得られた自動車用天井材のフラット部位から四角形の試
料を切り出し、その一角の不織布を把持し、熱成形性芯
材から不織布を９０°剥離して、その結果を表１に示し
た。 ○：熱成形性芯材と不織布との接着強度が強く、不織布
が材料破壊した。 ×：熱成形性芯材と不織布との間で剥離した。Evaluation of Adhesive Strength between Surface Material and Thermoformable Core Material A rectangular sample was cut out from a flat portion of the obtained ceiling material for an automobile, and the nonwoven fabric of one corner was gripped. The film was peeled off and the results are shown in Table 1. ：: The adhesive strength between the thermoformable core material and the nonwoven fabric was strong, and the nonwoven fabric was destroyed. ×: Peeled between the thermoformable core material and the nonwoven fabric.
【００５５】自動車用天井材の吸音性の評価 得られた自動車用天井材の不織布側からの吸音特性を、
ＪＩＳ Ａ １４０５に準拠して測定し、２．５ｋＨ
ｚ、４ｋＨｚ及び６．３ｋＨｚでの吸音率を表１に示し
た。Evaluation of Sound Absorption of Automotive Ceiling Material The sound absorbing characteristics of the obtained automotive ceiling material from the nonwoven fabric side were
Measured in accordance with JIS A 1405, 2.5 kHz
Table 1 shows the sound absorption coefficients at z, 4 kHz and 6.3 kHz.
【００５６】自動車用天井材の非通気性の評価 得られた自動車用天井材のフラット部位の透気度（ｃｍ
3／ｃｍ2・秒）を、デンソメータにより測定し、その値
を表１に示した。Evaluation of non-breathability of automotive ceiling material Air permeability (cm) of the flat portion of the obtained automotive ceiling material
3 / cm 2 · sec) was measured with a densometer, and the value is shown in Table 1.
【００５７】[0057]
【表１】 [Table 1]
【００５８】[0058]
【発明の効果】本発明の熱成形性芯材は、軽量で、剛
性、耐熱性、熱賦形性に優れるとともに、裏面に、製造
過程、熱成形過程において溶融しない耐熱剛性樹脂層を
有しているので、非通気性にも優れている。さらに、表
面側からの音は熱成形性芯材の貫通孔を通じて多孔質体
であるマット状基材に到達するので、効果的に音を減衰
させることができ、優れた吸音性を有している。また、
表面にも、製造過程、熱成形過程において溶融しない耐
熱剛性樹脂層が形成されているので、表面材を接着する
ための熱活性樹脂層がマット状基材に含浸してしまうこ
とがなく、表面材との接着強度を損なうことがない。本
発明の熱成形性芯材は、上記の通りの構成であるので、
特に自動車用天井材として好適に使用することができ
る。The thermoformable core material of the present invention is lightweight, excellent in rigidity, heat resistance and heat shaping properties, and has a heat-resistant rigid resin layer on the back surface which does not melt in the manufacturing process and thermoforming process. It is also excellent in non-breathability. Furthermore, since the sound from the surface side reaches the mat-shaped base material which is a porous body through the through holes of the thermoformable core material, the sound can be effectively attenuated, and has excellent sound absorbing properties. I have. Also,
A heat-resistant rigid resin layer that does not melt during the manufacturing process and thermoforming process is also formed on the surface, so the mat-type base material is not impregnated with the thermoactive resin layer for bonding the surface material. There is no loss of adhesive strength with the material. Since the thermoformable core material of the present invention has the configuration as described above,
In particular, it can be suitably used as a ceiling material for automobiles.
【００５９】[0059]
【図１】実施例１で得られた本発明の熱成形性芯材の断
面模式図である。FIG. 1 is a schematic sectional view of a thermoformable core material of the present invention obtained in Example 1.
１ 熱成形性芯材 ２ マット状基材 ３ 貫通孔 ４、６ ６−ナイロン層 ５、７ マレイン酸変性直鎖状低密度ポリエチレン層 DESCRIPTION OF SYMBOLS 1 Thermoformable core material 2 Matt-shaped base material 3 Through hole 4, 66 6-nylon layer 5, 7 Maleic acid-modified linear low density polyethylene layer
フロントページの続き Ｆターム(参考） 3D023 BA01 BB03 BC00 BD01 BE04 BE06 BE09 BE19 BE31 4F100 AA00A AC00A AG00A AJ02A AK01A AK01B AK01D AK05A AK48B AK48D AK63C AK63E AL07C AL07E AR00C AR00E BA05 BA06 BA10C BA10E BA25 BA32 DC11B DC11C DG01A DG06A DG18A EC09A EH41A EJ82A GB33 HB00E JA04B JA04D JB16A JH01 JJ03 JJ03A JJ03B JJ03D JK01 JK01B JL01 JL03 JL12C JL12E YY00B YY00CContinued on the front page F-term (reference) 3D023 BA01 BB03 BC00 BD01 BE04 BE06 BE09 BE19 BE31 4F100 AA00A AC00A AG00A AJ02A AK01A AK01B AK01D AK05A AK48B AK48D AK63C AK63E AL07C AL07E AR10CBA10A06 BA01 DC GB33 HB00E JA04B JA04D JB16A JH01 JJ03 JJ03A JJ03B JJ03D JK01 JK01B JL01 JL03 JL12C JL12E YY00B YY00C
Claims (5)
されてなるマット状基材の一面に、前記熱可塑性樹脂よ
り溶融温度の高い耐熱剛性樹脂からなる耐熱剛性樹脂層
と、熱活性樹脂からなる熱活性樹脂層とがこの順に積層
され、かつ、該耐熱剛性樹脂層及び熱活性樹脂層に開口
面積が３〜１００ｍｍ2の貫通孔が分散して形成されて
おり、他面に、前記熱可塑性樹脂より溶融温度の高い耐
熱剛性樹脂からなる耐熱剛性樹脂層と、熱活性樹脂から
なる熱活性樹脂層とがこの順に積層されてなることを特
徴とする熱成形性芯材。1. A heat-resistant stiff resin layer made of a heat-resistant stiff resin having a higher melting temperature than the thermoplastic resin, on one surface of a mat-shaped base material in which heat-resistant fibers are bonded to each other with a thermoplastic resin. A heat-active resin layer made of a resin is laminated in this order, and through-holes having an opening area of 3 to 100 mm 2 are dispersedly formed in the heat-resistant rigid resin layer and the heat-active resin layer. A thermoformable core material comprising: a heat-resistant stiff resin layer made of a heat-resistant stiff resin having a higher melting temperature than the thermoplastic resin; and a heat-active resin layer made of a heat-active resin, laminated in this order.
一面の面積に対して５〜８０％であることを特徴とす
る、請求項１に記載の熱成形性芯材。2. The thermoformable core material according to claim 1, wherein the total opening area of the through holes is 5 to 80% with respect to the area of one surface of the mat-shaped base material.
ることを特徴とする、請求項１又は２に記載の熱成形性
芯材。3. The thermoformable core material according to claim 1, wherein the heat-resistant fiber is an inorganic fiber or a vegetable fiber.
れていることを特徴とする、請求項１〜３のいずれか１
項に記載の熱成形性芯材。4. The method according to claim 1, wherein a thermoplastic resin fiber is mixed with the heat-resistant fiber.
Item 6. The thermoformable core material according to item 1.
成形性芯材の貫通孔を有する熱活性樹脂層面に表面材が
積層され、熱成形されてなることを特徴とする自動車用
天井材。5. An automobile obtained by laminating a surface material on a surface of a thermoactive resin layer having a through hole of the thermoformable core material according to claim 1 and thermoforming. Ceiling material.
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| WO2005097547A1 (en) * | 2004-04-09 | 2005-10-20 | Hayashi Engineering Inc. | Molded spreading interior trim material for automobile |
| JP2007055306A (en) * | 2005-08-22 | 2007-03-08 | Sanwa Kogyo Kk | Interior material for vehicle and its manufacturing method |
| WO2008155962A1 (en) * | 2007-06-19 | 2008-12-24 | Hayashi Engineering Inc. | Fender liner and process for producing the same |
| JP2012106422A (en) * | 2010-11-18 | 2012-06-07 | Sekisui Techno Seikei Kk | Thermoplastic resin foam molding and method of manufacturing the same |
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| WO2005097547A1 (en) * | 2004-04-09 | 2005-10-20 | Hayashi Engineering Inc. | Molded spreading interior trim material for automobile |
| CN100450823C (en) * | 2004-04-09 | 2009-01-14 | 株式会社林技术研究所 | Molded spreading interior trim material for automobile |
| AU2005230324B2 (en) * | 2004-04-09 | 2010-02-25 | Hayashi Engineering Inc. | Molded Interior Trim Installation Material for Automobile |
| JP2007055306A (en) * | 2005-08-22 | 2007-03-08 | Sanwa Kogyo Kk | Interior material for vehicle and its manufacturing method |
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| WO2008155962A1 (en) * | 2007-06-19 | 2008-12-24 | Hayashi Engineering Inc. | Fender liner and process for producing the same |
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| JP2016028893A (en) * | 2008-04-14 | 2016-03-03 | スリーエム イノベイティブ プロパティズ カンパニー | Multilayer sound absorbing sheet |
| JP2012106422A (en) * | 2010-11-18 | 2012-06-07 | Sekisui Techno Seikei Kk | Thermoplastic resin foam molding and method of manufacturing the same |
| WO2020261352A1 (en) * | 2019-06-25 | 2020-12-30 | 河西工業株式会社 | Interior component for automobile |
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