JP2008195128A - Laminate sheet for vehicle interior finishing material, interior finishing material for vehicle, and method and device for manufacturing laminate sheet for vehicle interior finishing material - Google Patents

Laminate sheet for vehicle interior finishing material, interior finishing material for vehicle, and method and device for manufacturing laminate sheet for vehicle interior finishing material Download PDF

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JP2008195128A
JP2008195128A JP2007030265A JP2007030265A JP2008195128A JP 2008195128 A JP2008195128 A JP 2008195128A JP 2007030265 A JP2007030265 A JP 2007030265A JP 2007030265 A JP2007030265 A JP 2007030265A JP 2008195128 A JP2008195128 A JP 2008195128A
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vehicle interior
laminated sheet
foam board
die
polypropylene resin
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JP5183932B2 (en
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Akira Kodama
亮 小玉
Hiroshi Yoshida
裕志 吉田
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TS Tech Co Ltd
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Priority to EP20080711042 priority patent/EP2123515A1/en
Priority to US12/526,309 priority patent/US8449019B2/en
Priority to PCT/JP2008/052163 priority patent/WO2008096860A1/en
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a laminate sheet for a vehicle interior finishing member in which a polypropylene resin foam board of high foaming extent having interconnected cells is used as a core member, and further provide a relevant interior finishing material for a vehicle, and a method of producing the laminate sheet for the interior finishing material, and a device therefor. <P>SOLUTION: There is provided the laminate sheet 1 for a vehicle interior finishing material having the polypropylene resin foam board 2. The polypropylene resin foam board 2 is obtained by extrusion forming into a plate configuration and exhibits an interconnected cell ratio of 50% or higher and a foaming magnification of 10 to 50. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

本発明は車両内装材用積層シート，車両用内装材，車両内装材用積層シートの製造方法及びその装置に係り、特に連続気泡の高発泡倍率ポリプロピレン系樹脂発泡ボードを用いた車両内装材用積層シート，車両用内装材，車両内装材用積層シートの製造方法及びその装置に関する。   The present invention relates to a laminated sheet for vehicle interior materials, a vehicle interior material, a method for manufacturing a laminated sheet for vehicle interior materials, and an apparatus therefor, and more particularly, a laminate for vehicle interior materials using an open cell, high expansion ratio polypropylene resin foam board. The present invention relates to a method for manufacturing a seat, a vehicle interior material, a laminated sheet for vehicle interior material, and an apparatus therefor.

従来より、車両等のルーフパネルの室内側には、断熱効果や吸音効果を得ることを目的として、合成樹脂材等から構成された車両用ルーフ材が配設され、この車両用ルーフ材の室内側は表皮材で被覆されている。このような車両用ルーフ材を構成する自動車内装材用積層シートとして、連続気泡率が５０％以上である変性ポリフェニレンエーテル系樹脂発泡シートの一面にその表面に開口する穴部が形成されており、少なくとも穴部形成面に、形態保持繊維及び熱可塑性樹脂繊維よりなる不織布からなる表面シートが積層一体化されてなるものが提案されている（例えば、特許文献１参照）。   Conventionally, a vehicle roof material made of a synthetic resin material or the like has been disposed on the indoor side of a roof panel of a vehicle or the like for the purpose of obtaining a heat insulation effect and a sound absorption effect. The inside is covered with a skin material. As a laminated sheet for automobile interior materials constituting such a vehicle roof material, a hole is formed on one surface of the modified polyphenylene ether-based resin foam sheet having an open cell ratio of 50% or more. It has been proposed that a surface sheet made of a nonwoven fabric made of shape-retaining fibers and thermoplastic resin fibers is laminated and integrated at least on the hole forming surface (see, for example, Patent Document 1).

特許文献１に記載の自動車内装材用積層シートは、その変性ポリフェニレンエーテル系樹脂発泡シートの連続気泡率が５０％以上であって、隣接する気泡相互が連続している連続気泡を多く含むため、外部からの音が変性ポリフェニレンエーテル系樹脂発泡シートへ浸入して吸収され、高い吸音効果を得ることができる。また、音の振動エネルギーを穴部を通じて変性ポリフェニレンエーテル系樹脂発泡シートの連続気泡に円滑に誘導し、連続気泡の気泡壁を振動させることによって振動エネルギーを熱エネルギーに変換して優れた吸音性を発揮させることができる。   Since the laminated sheet for automobile interior materials described in Patent Document 1 has an open cell ratio of the modified polyphenylene ether-based resin foam sheet of 50% or more and includes many open cells in which adjacent cells are continuous, Sound from the outside penetrates into the modified polyphenylene ether resin foam sheet and is absorbed, and a high sound absorption effect can be obtained. In addition, the vibration energy of sound is smoothly guided to the open cells of the modified polyphenylene ether resin foam sheet through the hole, and the vibration energy is converted into thermal energy by vibrating the bubble wall of the open cells, resulting in excellent sound absorption. It can be demonstrated.

特開２００５−１９９８９１号公報（第２欄、図１）Japanese Patent Laying-Open No. 2005-199891 (second column, FIG. 1)

しかしながら、特許文献１の自動車内装材用積層シートでは、発泡シートの材料として変性ポリフェニレンエーテル系樹脂を用いているため、積層シートの原料コストが高くなるという問題があった。
そこで、コスト面において優れた汎用樹脂から形成された連続気泡の発泡シートを備えた車両用ルーフ材用の自動車内装材用積層シートの開発が望まれている。特に、ポリプロピレンは、汎用樹脂の中でも、熱的に安定で耐熱性，断熱性が高く、優れた機械的性質を有するため、ポリプロピレンから形成された連続気泡の発泡シートを備えた車両用ルーフ材用の自動車内装材用積層シートの開発が望まれている。
しかし、ポリプロピレンから連続気泡の発泡体を得ることは技術的に難しいことが知られている。ポリプロピレンの発泡シートを用いた車両用ルーフ材用の自動車内装材用積層シートとしては独立気泡のものしか知られておらず、ポリプロピレンから形成された連続気泡の発泡シートを備えた車両用ルーフ材用の自動車内装材用積層シートは知られていない。既存のポリプロピレンから形成された独立気泡の発泡シートを用いた車両用ルーフ材用の自動車内装材用積層シートでは、気泡が独立気泡であるために吸音性を高めることが出来なかった。
更に、既存のポリプロピレンから形成された独立気泡の発泡シートを用いた車両用ルーフ材用の自動車内装材用積層シートでは、１５倍以上の発泡倍率とすることが難しいため、軽量化も難しい状況であった。 However, in the laminated sheet for automobile interior materials of Patent Document 1, since a modified polyphenylene ether-based resin is used as the material of the foam sheet, there is a problem that the raw material cost of the laminated sheet increases.
Therefore, development of a laminated sheet for automobile interior material for a vehicle roof material provided with an open-cell foamed sheet formed from a general-purpose resin excellent in cost is desired. In particular, polypropylene, among general-purpose resins, is thermally stable, has high heat resistance and heat insulation properties, and has excellent mechanical properties. Therefore, it is used for vehicle roof materials equipped with open-cell foamed sheets formed from polypropylene. Development of laminated sheets for automobile interior materials is desired.
However, it is known that it is technically difficult to obtain an open cell foam from polypropylene. Only laminated cells are known as laminated sheets for automobile interior materials for vehicle roof materials using polypropylene foam sheets, and for vehicle roof materials equipped with open-cell foam sheets made of polypropylene. No laminated sheet for automobile interior materials is known. In a laminated sheet for automobile interior materials for a vehicle roof material using a closed cell foam sheet formed from an existing polypropylene, the sound absorbing property cannot be increased because the bubbles are closed cells.
Furthermore, it is difficult to reduce the weight of the laminated sheet for automobile interior materials for vehicle roof materials using closed-cell foamed sheets formed from existing polypropylene because it is difficult to achieve a foaming ratio of 15 times or more. there were.

本発明は、上記事情に鑑みてなされたものであって、その目的は、連続気泡の高発泡倍率ポリプロピレン系樹脂発泡ボードを芯材とした車両内装材用積層シート，車両用内装材，車両内装材用積層シートの製造方法及びその装置を提供することにある。
本発明の他の目的は、ポリプロピレン系樹脂であるにも拘らず、吸音性が高いと同時に、軽量でかつ充分な剛性を備えた車両内装材用積層シート，車両用内装材，車両内装材用積層シートの製造方法及びその装置を提供することにある。 The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a laminated sheet for a vehicle interior material, a vehicle interior material, and a vehicle interior having an open-cell high expansion ratio polypropylene resin foam board as a core material. It is providing the manufacturing method of the laminated sheet for materials, and its apparatus.
Another object of the present invention is a laminated sheet for vehicle interior materials, an interior material for vehicles, and an interior material for vehicles, which has high sound absorption and is light and has sufficient rigidity, despite being a polypropylene resin. It is providing the manufacturing method and apparatus of a laminated sheet.

前記課題は、請求項１に係るポリプロピレン系樹脂発泡ボードを備えた車両内装材用積層シートによれば、前記ポリプロピレン系樹脂発泡ボードは、板状に押出成形されてなり、連続気泡率が５０％以上で、発泡倍率が１０倍〜５０倍であること、により解決される。
このように構成されているので、汎用樹脂であるポリプロピレン系樹脂を用いて、吸音性，剛性が高くかつ軽量な車両内装材用積層シートを得ることができる。つまり、ポリプロピレン系樹脂であるにも拘らず、発泡ボードが連続気泡であるため吸音性が高く、また高倍発泡であるため軽量化を図ることが可能である。
発泡倍率が５０倍より大きくなると、車両用ルーフ材として使用するために必要な剛性が得られなくなり、発泡倍率が１０倍より小さくなると、車両用ルーフ材として使用するために必要な軽量性が得られなくなる。また、連続気泡率が５０％より小さくなると、十分な吸音性が得られなくなる。 According to the laminate sheet for a vehicle interior material provided with the polypropylene resin foam board according to claim 1, the problem is that the polypropylene resin foam board is extruded into a plate shape and has an open cell ratio of 50%. This is solved by the fact that the expansion ratio is 10 to 50 times.
Since it is comprised in this way, the laminated sheet for vehicle interior materials which has high sound-absorbing property, rigidity, and lightweight can be obtained using the polypropylene resin which is general purpose resin. That is, despite the fact that it is a polypropylene resin, it is possible to reduce the weight because the foamed board is open-celled and has high sound absorption, and because it is highly double foamed.
If the expansion ratio is greater than 50 times, the rigidity required for use as a vehicle roof material cannot be obtained, and if the expansion ratio is less than 10 times, the lightness required for use as a vehicle roof material is obtained. It becomes impossible. Further, when the open cell ratio is less than 50%, sufficient sound absorbing properties cannot be obtained.

また、前記発泡倍率が、３０倍〜３５倍であるように構成すると好適である。３５倍以下にすることにより、汎用樹脂であるポリプロピレン系樹脂からなる吸音性，剛性が高くかつ軽量な車両内装材用積層シートの剛性を、より確保することが可能となる。また、３０倍以上にすることにより、汎用樹脂であるポリプロピレン系樹脂からなる吸音性，剛性が高くかつ軽量な車両内装材用積層シートの軽量性を、確保することが可能となる。
また、前記ポリプロピレン系樹脂発泡ボードは、両面にスキン層が形成されていてもよい。
このように構成することにより、押出発泡を行って発泡ボードを得た後のスライス工程を省略することができる。 Further, it is preferable that the expansion ratio is 30 to 35 times. By setting it to 35 times or less, it is possible to further ensure the rigidity of the laminated sheet for vehicle interior materials, which is made of polypropylene resin, which is a general-purpose resin, and has high sound absorption and rigidity. Moreover, by making it 30 times or more, it becomes possible to ensure the lightweight property of the laminated sheet for vehicle interior materials, which is made of polypropylene resin, which is a general-purpose resin, and has high sound absorption and rigidity.
The polypropylene resin foam board may have a skin layer formed on both sides.
By comprising in this way, the slice process after performing extrusion foaming and obtaining a foam board can be skipped.

また、前記ポリプロピレン系樹脂発泡ボードの両面にシート状の補強材を備えていてもよい。
このように構成すると、高発泡倍率のポリプロピレン系樹脂発泡ボードを備えた車両内装材用積層シートの剛性を更に高めることができる。 Moreover, you may equip the both surfaces of the said polypropylene resin foam board with the sheet-like reinforcement material.
If comprised in this way, the rigidity of the laminated sheet for vehicle interior materials provided with the polypropylene-type resin foam board of high expansion ratio can further be improved.

請求項１〜４いずれか記載の車両内装材用積層シートの表面に表皮材が積層一体化されたものを熱成形してなる車両用内装材としてもよい。
このように構成すると、従来は不可能であった連続気泡で高発泡倍率のポリプロピレン系樹脂発泡ボードを備えた車両用内装材を得ることができる。その結果、汎用樹脂であるポリプロピレン系樹脂からなり吸音性，剛性が高く軽量な車両用内装材を得ることができる。 It is good also as a vehicle interior material formed by thermoforming what laminated | stacked skin material on the surface of the laminated sheet for vehicle interior materials in any one of Claims 1-4.
If comprised in this way, the interior material for vehicles provided with the polypropylene resin foam board of the open cell and the high expansion ratio which was impossible conventionally can be obtained. As a result, it is possible to obtain a vehicle interior material that is made of polypropylene resin, which is a general-purpose resin, and has high sound absorption and rigidity and is lightweight.

前記課題は、請求項６に係るポリプロピレン系樹脂発泡ボードを備えた車両内装材用積層シートの製造方法によれば、ポリプロピレン系樹脂，核形成剤及び揮発性ガス発泡剤を押出機に供給し、該押出機内で溶融した樹脂混合物を高圧高温下で混練する混練工程と、前記樹脂混合物を、前記押出機出口に設けられた断面略矩形のスリットを有するダイスより低圧下に押出し、略板状に押出発泡させる押出工程と、押出発泡された前記樹脂混合物を、前記ダイスに連結され、断面が前記ダイスの前記スリットより大きい略矩形に形成されたスリットを有する冷却サイザーに接触させ、引取りながら冷却固化させて、略板状の前記発泡ボードを得る冷却工程と、前記発泡ボードにシート状の補強材を積層して車両内装材用積層シートを得る積層工程と、を備えていること、により解決される。
このように構成されているので、従来は不可能であったポリプロピレン系樹脂を用いて連続気泡で高発泡倍率の発泡ボードを得ることができる。その結果、汎用樹脂であるポリプロピレン系樹脂からなり吸音性，剛性が高く軽量な車両内装材用積層シートを得ることができる。
また、発泡剤として揮発性ガスを用いるガス発泡成形によるため、化学分解型発泡剤を用いる化学発泡成形では不可能な高倍率発泡が可能となり、発泡倍率１０倍〜５０倍の高倍率発泡ボードを得ることができ、軽量な車両内装材用積層シートを得ることができる。 According to the method for producing a laminated sheet for a vehicle interior material provided with the polypropylene resin foam board according to claim 6, the problem is to supply a polypropylene resin, a nucleating agent and a volatile gas foaming agent to the extruder, A kneading step of kneading the resin mixture melted in the extruder under high pressure and high temperature, and extruding the resin mixture under a low pressure from a die having a slit having a substantially rectangular cross section provided at the extruder outlet, and forming a substantially plate shape Extrusion process for extrusion foaming, and the extruded and foamed resin mixture is connected to the die and brought into contact with a cooling sizer having a cross section formed in a substantially rectangular shape larger than the slit of the die, and cooled while being drawn. A cooling process for solidifying to obtain the substantially foamed foam board, and a laminate for obtaining a laminated sheet for a vehicle interior material by laminating a sheet-like reinforcing material on the foamed board When, that it comprises a, it is solved by.
Since it is comprised in this way, the foam board of a high foaming ratio can be obtained by an open cell using the polypropylene resin which was impossible conventionally. As a result, it is possible to obtain a laminated sheet for vehicle interior material that is made of polypropylene resin, which is a general-purpose resin, and has high sound absorption and rigidity and is lightweight.
In addition, since it is based on gas foam molding using a volatile gas as a foaming agent, high-magnification foaming that is impossible with chemical foam molding using a chemical decomposition-type foaming agent is possible. It is possible to obtain a lightweight laminated sheet for vehicle interior materials.

また、前記混練工程は、前記押出機出口付近の前記樹脂混合物の温度を１５４℃〜１５７℃に維持して行い、前記押出工程は、前記ダイスの前記スリット内の温度を１５４℃〜１５７℃，前記ダイスの前記スリット内の圧力を８０ｋｇ／ｃｍ２以上に維持して行ってもよい。
このように構成すると、気泡が不安定になる粘度領域及びダイス又は押出機内で固化して圧力・トルクが上昇する粘度領域以外の、安定成形粘度領域で、押出工程を行うことができる。また、前記ダイスの前記スリット内の圧力を８０ｋｇ／ｃｍ２以上に維持するため、溶融樹脂混合物がダイス内で発泡することを防止できる。 The kneading step is performed while maintaining the temperature of the resin mixture in the vicinity of the extruder outlet at 154 ° C. to 157 ° C., and the extruding step is performed at a temperature in the slit of the die of 154 ° C. to 157 ° C., The pressure in the slit of the die may be maintained at 80 kg / cm 2 or more.
If comprised in this way, an extrusion process can be performed in the stable shaping | molding viscosity area | region other than the viscosity area | region where a bubble becomes unstable, and the viscosity area | region which solidifies within a die or an extruder and a pressure and a torque rise. Moreover, since the pressure in the slit of the die is maintained at 80 kg / cm 2 or more, the molten resin mixture can be prevented from foaming in the die.

前記課題は、請求項８に係るポリプロピレン系樹脂発泡ボードを備えた車両内装材用積層シートの製造装置によれば、溶融したポリプロピレン系樹脂混合物を高圧高温下で混練する押出機と、該押出機出口に連結され、前記溶融した樹脂混合物を低圧下に送出し発泡させるダイスと、該ダイスに連結され発泡した前記樹脂混合物を冷却させて前記発泡ボードを得る冷却サイザーと、を備え、前記ダイス及び前記冷却サイザーは、それぞれ断面略矩形のスリットを備え、それぞれの該スリットは、互いに連結して、前記ダイスから前記冷却サイザーに至る前記発泡ボードの通路を形成し、前記冷却サイザーの前記スリットは、前記ダイスの前記スリットよりも断面が大きく形成されていること、により解決される。
このように構成されているので、ポリプロピレン樹脂発泡ボードを略板状に押出発泡することができ、従来は不可能であったポリプロピレン系樹脂を用いた連続気泡の高発泡倍率の発泡ボードを得ることができる。その結果、汎用樹脂であるポリプロピレン系樹脂からなり吸音性，剛性が高く軽量な車両内装材用積層シートを得ることができる。
また、発泡した樹脂を上下左右を規制する冷却サイザーに通して板状の発泡ボードを得るサイザー法によるため、筒状のボードを作り一部をカッター等で切ることで板状のボードを得るマンドレル法では製造できない肉厚，高発泡倍率の発泡ボードを得ることができ、剛性が高く軽量な車両内装材用積層シートを得ることができる。 According to the apparatus for manufacturing a laminated sheet for vehicle interior material provided with the polypropylene resin foam board according to claim 8, the object is an extruder for kneading a molten polypropylene resin mixture under high pressure and high temperature, and the extruder A die connected to an outlet, for sending the foamed resin mixture under low pressure and foamed, and a cooling sizer for cooling the foamed resin mixture connected to the die to obtain the foamed board, the die and Each of the cooling sizers includes slits having a substantially rectangular cross section, and the slits are connected to each other to form a passage of the foam board from the die to the cooling sizer, and the slits of the cooling sizer are This is solved by the fact that the cross section is formed larger than the slit of the die.
Since it is configured in this way, it is possible to extrude and foam a polypropylene resin foam board into a substantially plate shape, and to obtain a foam board with open cell and high expansion ratio using a polypropylene resin, which was impossible in the past Can do. As a result, it is possible to obtain a laminated sheet for vehicle interior material that is made of polypropylene resin, which is a general-purpose resin, and has high sound absorption and rigidity and is lightweight.
Also, because of the sizer method that obtains a plate-like foam board by passing the foamed resin through a cooling sizer that regulates the top, bottom, left and right, a mandrel that produces a plate-like board by making a cylindrical board and cutting a part with a cutter etc. A foamed board with a wall thickness and a high foaming ratio that cannot be manufactured by the above method can be obtained, and a laminated sheet for vehicle interior material having high rigidity and light weight can be obtained.

請求項１の発明によれば、汎用樹脂であるポリプロピレン系樹脂を用いて、吸音性，剛性が高くかつ軽量な車両内装材用積層シートを得ることができる。
請求項２の発明によれば、汎用樹脂であるポリプロピレン系樹脂からなる吸音性，剛性が高くかつ軽量な車両内装材用積層シートの剛性や軽量性を、確保することが可能となる。
請求項３の発明によれば、発泡ボードを得た後の後工程を省略でき、製造工程が容易となる。
請求項４の発明によれば、高発泡倍率のポリプロピレン系樹脂発泡ボードを備えた車両内装材用積層シートの剛性を更に高めることができる。
請求項５の発明によれば、従来は不可能であった連続気泡で高発泡倍率のポリプロピレン系樹脂発泡ボードを備えた車両用内装材を得ることができる。その結果、汎用樹脂であるポリプロピレン系樹脂からなり吸音性，剛性が高く軽量な車両用内装材を得ることができる。
請求項６の発明によれば、従来は不可能であったポリプロピレン系樹脂を用いて連続気泡で高発泡倍率の発泡ボードを得ることができる。その結果、汎用樹脂であるポリプロピレン系樹脂からなり吸音性，剛性が高く軽量な車両内装材用積層シートを得ることができる。
請求項７の発明によれば、気泡が不安定になる粘度領域及びダイス又は押出機内で固化して圧力・トルクが上昇する粘度領域以外の、安定成形粘度領域で、押出工程を行うことができる。また、溶融樹脂混合物がダイス内で発泡することを防止できる。
請求項８の発明によれば、ポリプロピレン樹脂発泡ボードを略板状に押出発泡することができ、従来は不可能であったポリプロピレン系樹脂を用いた連続気泡の高発泡倍率の発泡ボードを得ることができる。その結果、汎用樹脂であるポリプロピレン系樹脂からなり吸音性，剛性が高く軽量な車両内装材用積層シートを得ることができる。
また、筒状のボードを作り一部をカッター等で切ることで板状のボードを得るマンドレル法では製造できない肉厚，高発泡倍率の発泡ボードを得ることができ、剛性が高く軽量な車両内装材用積層シートを得ることができる。 According to the first aspect of the present invention, a laminated sheet for vehicle interior materials can be obtained using a polypropylene resin, which is a general-purpose resin, having high sound absorption and rigidity and being lightweight.
According to the second aspect of the invention, it is possible to ensure the rigidity and lightness of the laminated sheet for vehicle interior material, which is made of a polypropylene resin, which is a general-purpose resin, and has high sound absorption and rigidity.
According to invention of Claim 3, the post process after obtaining a foam board can be abbreviate | omitted, and a manufacturing process becomes easy.
According to invention of Claim 4, the rigidity of the laminated sheet for vehicle interior materials provided with the polypropylene resin foam board of high expansion ratio can further be improved.
According to the invention of claim 5, it is possible to obtain an interior material for a vehicle provided with a polypropylene-based resin foam board having open cells and high expansion ratio, which has been impossible in the past. As a result, it is possible to obtain a vehicle interior material that is made of polypropylene resin, which is a general-purpose resin, and has high sound absorption and rigidity and is lightweight.
According to the sixth aspect of the present invention, it is possible to obtain a foamed board with open cells and a high foaming ratio by using a polypropylene resin, which has been impossible in the past. As a result, it is possible to obtain a laminated sheet for vehicle interior material that is made of polypropylene resin, which is a general-purpose resin, and has high sound absorption and rigidity and is lightweight.
According to the invention of claim 7, the extrusion process can be performed in a stable molding viscosity region other than a viscosity region where bubbles become unstable and a viscosity region where pressure or torque is increased by solidifying in a die or an extruder. . Further, the molten resin mixture can be prevented from foaming in the die.
According to the invention of claim 8, a polypropylene resin foam board can be extruded and foamed into a substantially plate shape, and an open cell high expansion ratio foam board using a polypropylene resin, which has been impossible in the past, is obtained. Can do. As a result, it is possible to obtain a laminated sheet for vehicle interior material that is made of polypropylene resin, which is a general-purpose resin, and has high sound absorption and rigidity and is lightweight.
In addition, it is possible to obtain a foam board with a wall thickness and high expansion ratio that cannot be manufactured by the mandrel method, in which a cylindrical board is made and a part of the board is cut with a cutter or the like. A laminated sheet for materials can be obtained.

以下、本発明の実施形態について、図を参照して説明する。なお、以下に説明する構成は、本発明を限定するものではなく、本発明の趣旨に沿って各種改変することができることは勿論である。
図１〜図３は本発明の一実施形態に係るものであり、図１は本発明の一実施形態に係る車両内装材用積層シートの縦断面図，図２は本発明の一実施形態に係る車両内装材用積層シートの製造工程のうち、押出発泡成形工程のフローを示す説明図，図３は本発明の一実施形態に係る車両内装材用積層シートの製造工程のうち、積層工程のフローを示す説明図である。 Embodiments of the present invention will be described below with reference to the drawings. In addition, the structure demonstrated below does not limit this invention, Of course, it can change variously along the meaning of this invention.
1 to 3 relate to an embodiment of the present invention, FIG. 1 is a longitudinal sectional view of a laminated sheet for vehicle interior materials according to an embodiment of the present invention, and FIG. 2 illustrates an embodiment of the present invention. FIG. 3 is an explanatory view showing a flow of an extrusion foam molding process in the manufacturing process of the laminated sheet for vehicle interior material according to the present invention. FIG. 3 shows the lamination process in the manufacturing process of the laminated sheet for vehicle interior material according to the embodiment of the present invention. It is explanatory drawing which shows a flow.

本実施形態は、車両内装材用積層シート，車両用内装材，車両内装材用積層シートの製造方法及びその装置に関する発明である。本実施形態は、車両用内装材として、車両のルーフパネルの室内側の面に配設されるルーフライニングに基づいて説明するが、これに限らず、トランクルーム内，エンジンルーム内等の吸音材、ドア部材の吸音材等に同様に適用可能である。   The present embodiment is an invention relating to a laminated sheet for vehicle interior materials, a vehicle interior material, a method for producing a laminated sheet for vehicle interior materials, and an apparatus therefor. The present embodiment will be described based on roof lining disposed on the interior side surface of the vehicle roof panel as the vehicle interior material, but is not limited to this, and a sound absorbing material in the trunk room, the engine room, etc., It can be similarly applied to a sound absorbing material for a door member.

本実施形態の車両内装材用積層シート１は、図１に示すように、ポリプロピレン系樹脂からなる発泡ボード２と、発泡ボード２の室内側及びルーフパネル側（室外側）にそれぞれ積層される補強材３，４と、発泡ボード２と補強材３，４とを接着する接着層５，６と、これらを室内側の不図示の表皮材に接着する表皮側接着層７と、が積層された積層体である。
発泡ボード２は、無架橋のポリプロピレン系樹脂を基材として、核形成材及び揮発性ガス発泡剤を用いたガス発泡法及び、押出機を用いたサイザー法により押出成形されてなる略平板状発泡体である。発泡ボード２は、その両面に、押出発泡時に形成されるスキン層を備えた状態となっている。 As shown in FIG. 1, a laminated sheet 1 for a vehicle interior material according to the present embodiment includes a foam board 2 made of a polypropylene resin, and a reinforcement laminated on the indoor side and the roof panel side (outdoor side) of the foam board 2. The materials 3 and 4, the adhesive layers 5 and 6 for bonding the foam board 2 and the reinforcing materials 3 and 4, and the skin side adhesive layer 7 for bonding them to a skin material (not shown) on the indoor side were laminated. It is a laminate.
The foam board 2 is a substantially flat foam formed by extrusion molding using a non-crosslinked polypropylene resin as a base material by a gas foaming method using a nucleating material and a volatile gas foaming agent and a sizer method using an extruder. Is the body. The foam board 2 is in a state of having skin layers formed during extrusion foaming on both sides.

本実施形態の発泡ボード２に用いるポリプロピレン系樹脂としては、無架橋のポリプロピレン系樹脂を用いる。この樹脂は、プロピレン単独重合体またはプロピレン重合単位を５０重量％以上含有するプロピレン−オレフィン共重合体である。プロピレンと共重合されるプロピレン以外のオレフィンとしては、特に限定されないが、炭素数２〜１２のオレフィンが好ましく用いられる。具体的には、エチレン、１−ブテン、１−ペンテン、１−ヘキセン、１−オクテン、１−デセン、４−メチル−１−ペンテン、３−メチル−１−ペンテン等が挙げられ、これらのオレフィンは１種のみならず２種であってもよい。   As a polypropylene resin used for the foam board 2 of this embodiment, a non-crosslinked polypropylene resin is used. This resin is a propylene homopolymer or a propylene-olefin copolymer containing 50% by weight or more of propylene polymerized units. The olefin other than propylene copolymerized with propylene is not particularly limited, but an olefin having 2 to 12 carbon atoms is preferably used. Specific examples include ethylene, 1-butene, 1-pentene, 1-hexene, 1-octene, 1-decene, 4-methyl-1-pentene, 3-methyl-1-pentene, and the like. May be not only one but also two.

本実施形態の無架橋のポリプロピレン系樹脂としては、平均的なポリプロピレン系樹脂に対比して、メルトフローレートが小さく、溶融張力が高いものを用いる。また、ひずみ硬化性として、樹脂が溶融した状態で延伸され、切断する直前に急激に粘度が上昇する現象（ストレインハードニング現象）を示すものが好ましい。更に、発泡した樹脂の最高粘度に到達するまでに結晶化が始まる程度の半結晶化時間を有するものを用いると好ましい。
なお、これらの物性は、特開２００６−４５３５６号公報等に記載された公知の測定方法により測定される。 As the non-crosslinked polypropylene resin of this embodiment, a resin having a low melt flow rate and a high melt tension is used as compared with an average polypropylene resin. Further, the strain hardening property is preferably one that exhibits a phenomenon (strain hardening phenomenon) in which the resin is stretched in a molten state and the viscosity is rapidly increased immediately before cutting. Furthermore, it is preferable to use a resin having a half crystallization time such that crystallization starts until the maximum viscosity of the foamed resin is reached.
These physical properties are measured by a known measuring method described in JP-A-2006-45356.

核形成材としては、タルク、重曹系発泡剤、クエン酸系発泡剤等を用いる。また、揮発性ガス発泡剤としては、高倍発泡に適したｎ−ブタン，イソブタン，ペンタン等を用いる。窒素や炭酸ガス等の無機ガスは、環境適合性に優れるが、ポリプロピレンに対する溶解度が低い為に高倍発泡ボードの製造に適していないからである。特に、本実施形態では、１０倍以上に高倍発泡させるため、ポリプロピレンに対する溶解度が高いｎ―ブタン又はイソブタンを用いると好適である。プロパンやペンタンもポリプロピレンに対する溶解度は高いが、無臭のものがなく、また価格が高いからである。   As the nucleation material, talc, baking soda foaming agent, citric acid foaming agent and the like are used. As the volatile gas blowing agent, n-butane, isobutane, pentane and the like suitable for high-magnification foaming are used. This is because inorganic gases such as nitrogen and carbon dioxide gas are excellent in environmental compatibility, but are not suitable for the production of high-magnification foamed boards because of their low solubility in polypropylene. In particular, in the present embodiment, it is preferable to use n-butane or isobutane having a high solubility in polypropylene in order to foam 10 times or more. Propane and pentane are also highly soluble in polypropylene, but are odorless and expensive.

発泡ボード２は、連続気泡率が５０〜９８％、好ましくは７０％以上、発泡倍率が１０〜５０倍、好ましくは３０〜３５倍である。また、発泡直後の厚みは、４〜２０ｍｍ、好ましくは１２〜１６ｍｍ、更に好ましくは１２〜１４ｍｍである。
ここで、独立気泡とは、気泡壁によって全て囲まれて他の気泡と連通していない気泡のことをいう。連続気泡とは、独立気泡以外の気泡の全てをいい、具体的には、気泡壁に貫通孔が形成されており、この貫通孔を通じて他の気泡と連通状態にある気泡をいう。発泡ボード２の連続気泡率は、ＡＳＴＭ Ｄ２８５６−８７に準拠して測定されたものをいう。 The foam board 2 has an open cell ratio of 50 to 98%, preferably 70% or more, and a foaming ratio of 10 to 50 times, preferably 30 to 35 times. The thickness immediately after foaming is 4 to 20 mm, preferably 12 to 16 mm, and more preferably 12 to 14 mm.
Here, the closed cell refers to a bubble that is completely surrounded by a bubble wall and does not communicate with other bubbles. The term “open cell” refers to all bubbles other than closed cells. Specifically, a through-hole is formed in the bubble wall, and the bubble is in communication with other bubbles through the through-hole. The open cell ratio of the foam board 2 refers to that measured in accordance with ASTM D2856-87.

補強材３，４は、例えば、不織布、ポリエステル１００％スパンボンド、ガラス繊維、炭素繊維、バサルト繊維、天然繊維、有機繊維等から形成される。
また、接着層５，６，表皮側接着層７は、オレフィン系熱可塑性樹脂のホットメルトフィルムで、ポリプロピレンに接着するもの等から形成されている。
更に、本実施形態の車両内装材用積層シート１は、例えば車両用ルーフに用いる場合には、表皮側接着層７の補強剤４逆側の面に、不図示の不織布、織布、編布等からなる表皮材を積層し、この積層した状態で加熱し、その後、冷間プレスによって所望形状に成形されて、車両用内装材の一例である車両用ルーフ材として用いられる。 The reinforcing materials 3 and 4 are made of, for example, a nonwoven fabric, 100% polyester spunbond, glass fiber, carbon fiber, basalt fiber, natural fiber, or organic fiber.
The adhesive layers 5 and 6 and the skin side adhesive layer 7 are formed from a hot melt film of an olefin-based thermoplastic resin that adheres to polypropylene.
Furthermore, when the laminated sheet 1 for vehicle interior materials according to the present embodiment is used for a vehicle roof, for example, a non-illustrated nonwoven fabric, woven fabric, knitted fabric is provided on the surface of the skin side adhesive layer 7 on the side opposite to the reinforcing agent 4. A skin material made of, for example, is laminated, heated in this laminated state, and then formed into a desired shape by cold pressing, and used as a vehicle roof material which is an example of a vehicle interior material.

次に、以上の構成に係る車両内装材用積層シート１の製造装置について、図２，図３に従って説明する。車両内装材用積層シート１の製造装置は、図２，図３に示すように、公知の平行タンデム式のタンデム押出機２１，ダイス２２，発泡ボード２を冷却する冷却サイザー２３，公知の引取機２４と、発泡ボード２に接着層５，６及び補強材３，４をラミネートする公知の積層装置２５と、を備えている。
ダイス２２は、タンデム押出機２１後端の成形材料が押出される出口に連結固定されており、図２に示すように、内部に、タンデム押出機２１の出口と冷却サイザー２３のスリットとをつなぐスリット断面が長尺矩形のスリットが形成されている。 Next, the manufacturing apparatus of the laminated sheet 1 for vehicle interior materials which concerns on the above structure is demonstrated according to FIG. 2, FIG. As shown in FIGS. 2 and 3, the manufacturing apparatus of the laminated sheet 1 for vehicle interior materials includes a known parallel tandem tandem extruder 21, a die 22, a cooling sizer 23 for cooling the foam board 2, and a known take-up machine. 24 and a known laminating device 25 for laminating the adhesive layers 5 and 6 and the reinforcing materials 3 and 4 on the foam board 2.
The die 22 is connected and fixed to the outlet through which the molding material at the rear end of the tandem extruder 21 is extruded, and connects the outlet of the tandem extruder 21 and the slit of the cooling sizer 23 inside as shown in FIG. A slit having a long rectangular cross section is formed.

冷却サイザー２３は、ダイス２２端部に連結固定されており、図２に示すように、内部に、一方の端部がダイス２２のスリットに連続し他方の端部が開口となった、断面が長尺矩形のスリットが形成されている。
これにより、ダイス２２で発泡する発泡ボード２を、スムーズに冷却サイザー２３に誘導し、１０〜５０倍、好ましくは３０〜３５倍，発泡直後の厚み４〜２０ｍｍ、好ましくは１２〜１６ｍｍ、更に好ましくは１２〜１４ｍｍの板状に形成できる。 The cooling sizer 23 is connected and fixed to the end portion of the die 22, and as shown in FIG. 2, one end portion is continuous with the slit of the die 22 and the other end portion is opened. A long rectangular slit is formed.
Thereby, the foam board 2 foamed by the die 22 is smoothly guided to the cooling sizer 23, 10 to 50 times, preferably 30 to 35 times, the thickness immediately after foaming is 4 to 20 mm, preferably 12 to 16 mm, and more preferably. Can be formed in a plate shape of 12 to 14 mm.

次に、以上の構成に係る車両内装材用積層シート１の製造方法について、図２，図３に従って説明する。最初に、図２のように、ステップＳ１で押出発泡成形工程を行う。この工程では、まず、タンデム押出機２１内で樹脂混合物を混練する混練工程を行う。即ち、ホッパーから無架橋のポリプロピレン系樹脂及び核形成材をタンデム押出機２１の第一段の押出機に供給し、樹脂を溶融させる。第一の押出機内の溶融樹脂へ、液化ガスの状態の揮発性ガスを圧力１５０〜２００ｋｇ／ｃｍ２で供給する。第一段の押出機で樹脂を溶融させ、溶融樹脂と揮発性ガスとを混練して混合した後、この混合物を第二段の押出機に送って更に混練を行う。第二段の押出機では、樹脂混合物の温度を１５４〜１５７℃に均一化させて樹脂混合物を適切な粘度に調整すると共に、揮発性ガスを樹脂混合物中に分散させる。 Next, the manufacturing method of the laminated sheet 1 for vehicle interior materials which concerns on the above structure is demonstrated according to FIG. 2, FIG. First, as shown in FIG. 2, an extrusion foaming process is performed in step S1. In this step, first, a kneading step of kneading the resin mixture in the tandem extruder 21 is performed. That is, non-crosslinked polypropylene resin and nucleation material are supplied from the hopper to the first stage extruder of the tandem extruder 21 to melt the resin. A volatile gas in a liquefied gas state is supplied to the molten resin in the first extruder at a pressure of 150 to 200 kg / cm 2 . The resin is melted by the first stage extruder, the molten resin and the volatile gas are kneaded and mixed, and then the mixture is sent to the second stage extruder for further kneading. In the second stage extruder, the temperature of the resin mixture is made uniform at 154 to 157 ° C. to adjust the resin mixture to an appropriate viscosity, and volatile gas is dispersed in the resin mixture.

次いで、樹脂混合物をタンデム押出機２１後端開口に連結されたダイス２２に送る押出工程を行う。ダイス２２は、スリット内の温度が樹脂温と同様の１５４〜１５７℃，圧力が８０ｋｇ／ｃｍ２以上に維持されている。圧力を８０ｋｇ／ｃｍ２以上に維持するのは、スリット内の圧力が８０ｋｇ／ｃｍ２未満になると溶融樹脂がダイ内発泡するからである。
このように、樹脂混合物をダイス２２のスリットに送って、樹脂混合物をダイス２２より低圧下に押出し、発泡させる。樹脂混合物はダイス２２から出る瞬間に発泡する。その後、樹脂混合物を冷却固化させる冷却工程を行う。発泡した樹脂混合物は、冷却サイザー２３へ進み、上下左右が冷却サイザー２３のスリット内壁に接触することにより、板状体となって冷却固化され、発泡ボード２が成形される。この発泡ボード２は、厚みが４〜２０ｍｍ，好ましくは１２〜１６ｍｍ，更に好ましくは１２〜１４ｍｍになるように押出発泡され、両面にスキン層が形成された状態となっている。
その後、発泡ボード２を引取機２４により順次引取る。 Subsequently, the extrusion process which sends the resin mixture to the die | dye 22 connected with the rear-end opening of the tandem extruder 21 is performed. In the die 22, the temperature in the slit is maintained at 154 to 157 ° C., which is the same as the resin temperature, and the pressure is maintained at 80 kg / cm 2 or more. The reason why the pressure is maintained at 80 kg / cm 2 or more is that the molten resin foams in the die when the pressure in the slit becomes less than 80 kg / cm 2 .
In this way, the resin mixture is sent to the slit of the die 22, and the resin mixture is extruded under a low pressure from the die 22 to be foamed. The resin mixture foams as soon as it exits the die 22. Thereafter, a cooling step for cooling and solidifying the resin mixture is performed. The foamed resin mixture proceeds to the cooling sizer 23, and the top, bottom, left and right contact with the inner wall of the slit of the cooling sizer 23 to form a plate-like body, which is cooled and solidified to form the foamed board 2. The foam board 2 is extruded and foamed to have a thickness of 4 to 20 mm, preferably 12 to 16 mm, and more preferably 12 to 14 mm, and a skin layer is formed on both sides.
Thereafter, the foam board 2 is sequentially taken out by the take-up machine 24.

次いで、ステップＳ２，Ｓ３の積層工程を行う。冷却固化した発泡ボード２を、公知の手順により所定単位の長さに切断し、養生する（ステップＳ２）。
ステップＳ３の積層工程では、補強材３，４，接着層５，６，表皮側接着層７を含む副資材を、スキン層が両面に形成された発泡ボード２の両面に積層し、エアーオーブンで接着層５，６の融点以上の温度に加熱する。その後ホットプレス，コールドプレスにより圧縮，冷却することにより、車両内装材用積層シート１を構成する積層体を得る。
積層工程では、元々１０〜２０ｍｍ，好ましくは１２〜１４ｍｍの厚みに形成されていた発泡ボード２を、２／３〜３／４の厚みになるように圧縮する。本実施形態では、１２〜１４ｍｍの厚みの発泡ボード２を厚み８ｍｍまで圧縮する。
積層工程では、発泡ボード２の両面にスキン層が形成されたものに副資材を積層するので、スライス工程を省くことができる。
次いで、スリッター及び定尺カット機で所定の寸法に切断し、車両内装材用積層シート１を得て、車両内装材用積層シートの製造工程を終了する。なお、車両内装材用積層シートの製造工程の後、表皮側接着層７の補強材４逆側の面に不図示の表皮材を積層し、公知の方法で所望の形状に熱成形することにより、車両用内装材が得られる。 Next, a stacking process of steps S2 and S3 is performed. The cooled and solidified foam board 2 is cut into a predetermined unit length by a known procedure and cured (step S2).
In the laminating step of step S3, the auxiliary material including the reinforcing material 3, 4, the adhesive layer 5, 6, and the skin side adhesive layer 7 is laminated on both surfaces of the foam board 2 on which the skin layer is formed on both surfaces. Heat to a temperature equal to or higher than the melting point of the adhesive layers 5 and 6. Thereafter, the laminated body constituting the laminated sheet 1 for vehicle interior materials is obtained by compression and cooling by hot pressing and cold pressing.
In the laminating step, the foam board 2 originally formed to have a thickness of 10 to 20 mm, preferably 12 to 14 mm is compressed to a thickness of 2/3 to 3/4. In this embodiment, the foam board 2 having a thickness of 12 to 14 mm is compressed to a thickness of 8 mm.
In the laminating step, the auxiliary material is laminated on the foam board 2 on which the skin layers are formed, so that the slicing step can be omitted.
Subsequently, it cut | disconnects to a predetermined dimension with a slitter and a fixed cut machine, the laminated sheet 1 for vehicle interior materials is obtained, and the manufacturing process of the laminated sheet for vehicle interior materials is complete | finished. In addition, after the manufacturing process of the laminated sheet for vehicle interior materials, a non-illustrated skin material is laminated on the surface on the opposite side of the reinforcing material 4 of the skin-side adhesive layer 7, and thermoformed into a desired shape by a known method. An interior material for a vehicle is obtained.

本実施形態の製造方法では、ステップＳ１の押出発泡成形工程で、第二段の押出機内の樹脂の温度を１５４〜１５７℃に維持する。図４は、樹脂温度と成形安定性の関係を示すグラフである。図４の実線グラフに示すように、樹脂は粘度ρ１以下で気泡が不安定になり、粘度ρ２以上でダイス２２，タンデム押出機２１内で固化して圧力・トルクが上昇し、タンデム押出機２１の運転が不可能になる。本実施形態で用いる半結晶性ポリプロピレンの場合、樹脂温度が１５４℃のときに粘度ρ１，樹脂温度が１５７℃のときに粘度ρ２になるため、本実施形態では、第二段の押出機内の樹脂の温度を１５４〜１５７℃に維持している。なお、本実施形態のポリプロピレン系樹脂の安定成形温度は、１５５℃±１．５℃である。
また、ポリプロピレンは、融点以上では流動するため、押出発泡後に気泡壁を直ちに固化し安定させる。１０倍以上の高倍発泡の発泡体を得るためには、融点に近い温度で押出すことが必要である。 In the manufacturing method of the present embodiment, the temperature of the resin in the second stage extruder is maintained at 154 to 157 ° C. in the extrusion foaming process of step S1. FIG. 4 is a graph showing the relationship between resin temperature and molding stability. As shown in the solid line graph of FIG. 4, the resin becomes unstable when the viscosity is ρ 1 or less, and when the viscosity is ρ 2 or more, the resin is solidified in the die 22 and the tandem extruder 21 to increase the pressure / torque. The machine 21 cannot be operated. In the case of the semicrystalline polypropylene used in the present embodiment, the viscosity ρ 1 when the resin temperature is 154 ° C. and the viscosity ρ 2 when the resin temperature is 157 ° C. The temperature of the resin is maintained at 154-157 ° C. The stable molding temperature of the polypropylene resin of this embodiment is 155 ° C. ± 1.5 ° C.
Also, since polypropylene flows above the melting point, the cell walls immediately solidify and stabilize after extrusion foaming. In order to obtain a foam having a high-fold expansion of 10 times or more, it is necessary to extrude at a temperature close to the melting point.

次に、本発明に係る車両内装材用積層シートを実施例により更に詳細に説明する。
（実施例１）
図２の押出発泡成形工程Ｓ１により、厚みが１２〜１４ｍｍ，発泡倍率が３０〜３５倍の両面スキン付の発泡ボード２を得た。
補強材３，４にスパンボンド（ポリエチレン／ポリエチレンテレフタレート，２３ｇ／ｍ２）、接着層５，６にオレフィン系熱可塑性樹脂のホットメルトフィルム、表皮側接着層７にホットメルトフィルムを用い、図３の積層工程Ｓ２，Ｓ３により、発泡ボード２を、その一般面の厚みが８ｍｍになるように圧縮して、図１に示す車両内装材用積層シート１を得た。
この車両内装材用積層シート１では、発泡ボード２以外の副資材，即ち補強材３，４，接着層５，６，表皮側接着層７の層の目付の合計は１３６ｇ／ｍ２であった。 Next, the laminated sheet for vehicle interior materials according to the present invention will be described in more detail with reference to examples.
(Example 1)
The foamed board 2 with a double-sided skin having a thickness of 12 to 14 mm and a foaming ratio of 30 to 35 was obtained by the extrusion foaming step S1 of FIG.
Spunbond (polyethylene / polyethylene terephthalate, 23 g / m 2 ) is used for the reinforcing materials 3 and 4, a hot-melt film of an olefin-based thermoplastic resin is used for the adhesive layers 5 and 6, and a hot-melt film is used for the skin-side adhesive layer 7. In the lamination steps S2 and S3, the foam board 2 was compressed so that the thickness of the general surface thereof was 8 mm, and the laminated sheet 1 for vehicle interior materials shown in FIG. 1 was obtained.
In this laminated sheet 1 for vehicle interior materials, the total weight of sub-materials other than the foam board 2, that is, the reinforcing materials 3, 4, the adhesive layers 5, 6, and the skin-side adhesive layer 7 was 136 g / m 2 . .

本実施例で得た車両内装材用積層シート１について、公知の方法で吸音性，剛性を測定し、所定の目標値と対比した。また、生産性の効率性を表す指標として、原材料購入費を車両内装材用積層シート１についてそれぞれ計算し、所定の目標値と対比した。
吸音性については、厚み１２ｍｍ以上のものが基準を満足していた。剛性については、発泡倍率３５倍以下のものが基準を満足していた。
以上より、発泡倍率３０倍で厚み１２ｍｍのもの，及び発泡倍率３５倍で厚み１２〜１４ｍｍのものが、車両内装材用積層シート１の軽量性，吸音性，剛性のすべての面で基準を満足していた。
また、生産上の効率性については、車両内装材用積層シート１の品質として生産上の効率性も考慮すると、発泡倍率３５倍で厚み１２ｍｍのものが車両内装材用積層シート１の軽量性，吸音性，剛性，生産上の効率性のすべての面で優れていた。 About the laminated sheet 1 for vehicle interior materials obtained in the present Example, the sound-absorbing property and rigidity were measured by a well-known method, and compared with the predetermined target value. Further, as an index representing the efficiency of productivity, the raw material purchase cost was calculated for each laminated sheet 1 for vehicle interior materials, and compared with a predetermined target value.
As for sound absorption, those with a thickness of 12 mm or more satisfied the standard. Regarding the rigidity, those having an expansion ratio of 35 times or less satisfied the standard.
From the above, the one with a foaming ratio of 30 times and a thickness of 12 mm and the one with a foaming ratio of 35 times and a thickness of 12 to 14 mm satisfy the standards in all aspects of the light weight, sound absorption and rigidity of the laminated sheet 1 for vehicle interior materials. Was.
As for the production efficiency, considering the production efficiency as the quality of the laminated sheet 1 for vehicle interior materials, the foaming factor of 35 times and the thickness of 12 mm is the light weight of the laminated sheet 1 for vehicle interior materials, It was excellent in all aspects of sound absorption, rigidity, and production efficiency.

（実施例２）
本実施例では、押出発泡成形工程Ｓ１による発泡直後の厚みを２０ｍｍとしたこと以外は実施例１と同様の方法で、発泡ボード２を作製した。
この発泡ボード２を、スキン層より図５に示すように、２ｍｍ間隔でスライスして、試験片Ｉ〜試験片Ｖを得、各試験片の連続気泡率を測定した。
各試験片の連続気泡率及び発泡倍率を、表１に示す。 (Example 2)
In this example, a foam board 2 was produced in the same manner as in Example 1 except that the thickness immediately after foaming in the extrusion foam molding step S1 was 20 mm.
As shown in FIG. 5, the foam board 2 was sliced at intervals of 2 mm to obtain test pieces I to V, and the open cell ratio of each test piece was measured.
Table 1 shows the open cell ratio and expansion ratio of each test piece.

Figure 2008195128
Figure 2008195128

表１より、本実施例の発泡ボード２の連続気泡率の平均は８８．７５％，発泡倍率の平均は２８．７３倍であり、本実施例の車両内装材用積層シートの製造方法によれば、連続気泡率が５０％以上で高発泡倍率のポリプロピレン系樹脂の発泡ボード２が製造できることが分かった。   From Table 1, the average open cell ratio of the foam board 2 of this example is 88.75%, and the average of the foaming ratio is 28.73 times. According to the manufacturing method of the laminated sheet for vehicle interior materials of this example. For example, it was found that a foamed board 2 made of a polypropylene resin having an open cell ratio of 50% or more and a high expansion ratio can be produced.

本発明の一実施形態に係る車両内装材用積層シートの縦断面図である。It is a longitudinal cross-sectional view of the laminated sheet for vehicle interior materials which concerns on one Embodiment of this invention. 本発明の一実施形態に係る車両内装材用積層シートの製造工程のうち、押出発泡成形工程のフローを示す説明図である。It is explanatory drawing which shows the flow of an extrusion foam molding process among the manufacturing processes of the laminated sheet for vehicle interior materials which concerns on one Embodiment of this invention. 本発明の一実施形態に係る車両内装材用積層シートの製造工程のうち、積層工程のフローを示す説明図である。It is explanatory drawing which shows the flow of a lamination process among the manufacturing processes of the laminated sheet for vehicle interior materials which concerns on one Embodiment of this invention. 樹脂温度と成形安定性の関係を示すグラフである。It is a graph which shows the relationship between resin temperature and molding stability. 発泡ボードの連続気泡率測定のための試験片の切出し方法を示す説明図である。It is explanatory drawing which shows the cutting-out method of the test piece for the open cell rate measurement of a foam board.

符号の説明Explanation of symbols

１ 車両内装材用積層シート
２ 発泡ボード
３，４ 補強材
５，６ 接着層
７ 表皮側接着層
２１ タンデム押出機
２２ ダイス
２３ 冷却サイザー
２４ 引取機
２５ 積層装置 DESCRIPTION OF SYMBOLS 1 Laminated sheet | seat for vehicle interior materials 2 Foam board 3, 4 Reinforcement material 5, 6 Adhesive layer 7 Skin side adhesive layer 21 Tandem extruder 22 Die 23 Cooling sizer 24 Take-out machine 25 Laminating apparatus

Claims (8)

ポリプロピレン系樹脂発泡ボードを備えた車両内装材用積層シートであって、
前記ポリプロピレン系樹脂発泡ボードは、板状に押出成形されてなり、連続気泡率が５０％以上で、発泡倍率が１０倍〜５０倍であることを特徴とする車両内装材用積層シート。 A laminated sheet for vehicle interior material provided with a polypropylene resin foam board,
The polypropylene resin foam board is extruded into a plate shape, has an open cell ratio of 50% or more, and has a foaming ratio of 10 to 50 times. 前記発泡倍率が、３０倍〜３５倍であることを特徴とする請求項１に記載の車両内装材用積層シート。   The laminated sheet for vehicle interior materials according to claim 1, wherein the expansion ratio is 30 to 35 times. 前記ポリプロピレン系樹脂発泡ボードは、両面にスキン層が形成されていることを特徴とする請求項１に記載の車両内装材用積層シート。   The laminated sheet for a vehicle interior material according to claim 1, wherein the polypropylene resin foam board has skin layers formed on both sides thereof. 前記ポリプロピレン系樹脂発泡ボードの両面にシート状の補強材を備えることを特徴とする請求項１に記載の車両内装材用積層シート。   The laminated sheet for vehicle interior materials according to claim 1, comprising sheet-like reinforcing materials on both surfaces of the polypropylene resin foam board. 請求項１〜４いずれか記載の車両内装材用積層シートの表面に表皮材が積層一体化されたものを熱成形してなることを特徴とする車両用内装材。   An interior material for a vehicle, which is formed by thermoforming a laminated material for a surface of the laminated sheet for vehicle interior material according to any one of claims 1 to 4. ポリプロピレン系樹脂発泡ボードを備えた車両内装材用積層シートの製造方法であって、
ポリプロピレン系樹脂，核形成剤及び揮発性ガス発泡剤を押出機に供給し、該押出機内で溶融した樹脂混合物を高圧高温下で混練する混練工程と、
前記樹脂混合物を、前記押出機出口に設けられた断面略矩形のスリットを有するダイスより低圧下に押出し、略板状に押出発泡させる押出工程と、
押出発泡された前記樹脂混合物を、前記ダイスに連結され、断面が前記ダイスの前記スリットより大きい略矩形に形成されたスリットを有する冷却サイザーに接触させ、引取りながら冷却固化させて、略板状の前記発泡ボードを得る冷却工程と、
前記発泡ボードにシート状の補強材を積層して車両内装材用積層シートを得る積層工程と、を備えたことを特徴とする車両内装材用積層シートの製造方法。 A method for producing a laminated sheet for a vehicle interior material provided with a polypropylene resin foam board,
A kneading step of supplying a polypropylene resin, a nucleating agent and a volatile gas blowing agent to an extruder, and kneading the molten resin mixture in the extruder under high pressure and high temperature;
An extrusion step of extruding the resin mixture under a low pressure from a die having a slit having a substantially rectangular cross section provided at the extruder outlet, and extruding and foaming into a substantially plate shape;
The extruded and foamed resin mixture is connected to the die and brought into contact with a cooling sizer having a slit formed in a substantially rectangular shape that is larger than the slit of the die. Cooling step to obtain the foam board
And a lamination step of obtaining a laminated sheet for vehicle interior materials by laminating a sheet-like reinforcing material on the foam board. A method for producing a laminated sheet for vehicle interior materials. 前記混練工程は、前記押出機出口付近の前記樹脂混合物の温度を１５４℃〜１５７℃に維持して行い、
前記押出工程は、前記ダイスの前記スリット内の温度を１５４℃〜１５７℃，前記ダイスの前記スリット内の圧力を８０ｋｇ／ｃｍ２以上に維持して行うことを特徴とする請求項６に記載の車両内装材用積層シートの製造方法。 The kneading step is performed while maintaining the temperature of the resin mixture near the exit of the extruder at 154 ° C to 157 ° C,
The extrusion process is performed while maintaining the temperature in the slit of the die at 154 to 157 ° C and the pressure in the slit of the die at 80 kg / cm 2 or more. A method for producing a laminated sheet for vehicle interior materials. ポリプロピレン系樹脂発泡ボードを備えた車両内装材用積層シートの製造装置であって、
溶融したポリプロピレン系樹脂混合物を高圧高温下で混練する押出機と、該押出機出口に連結され、前記溶融した樹脂混合物を低圧下に送出し発泡させるダイスと、該ダイスに連結され発泡した前記樹脂混合物を冷却させて前記発泡ボードを得る冷却サイザーと、を備え、
前記ダイス及び前記冷却サイザーは、それぞれ断面略矩形のスリットを備え、それぞれの該スリットは、互いに連結して、前記ダイスから前記冷却サイザーに至る前記発泡ボードの通路を形成し、
前記冷却サイザーの前記スリットは、前記ダイスの前記スリットよりも断面が大きく形成されていることを特徴とする車両内装材用積層シートの製造装置。 An apparatus for producing a laminated sheet for a vehicle interior material provided with a polypropylene resin foam board,
An extruder for kneading a molten polypropylene-based resin mixture under high pressure and high temperature, a die connected to the outlet of the extruder, for blowing the molten resin mixture under low pressure, and the resin connected to the die and foamed A cooling sizer for cooling the mixture to obtain the foam board,
The dice and the cooling sizer are each provided with a slit having a substantially rectangular cross section, and the slits are connected to each other to form a passage of the foam board from the die to the cooling sizer,
The apparatus for manufacturing a laminated sheet for vehicle interior materials, wherein the slit of the cooling sizer is formed to have a larger cross section than the slit of the die.
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