JP5341002B2 - 表皮材用基材、表皮材及び成形体 - Google Patents
表皮材用基材、表皮材及び成形体 Download PDFInfo
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Description
(1)繊維基材用繊維ウエブの製造;
表1に示すレーヨン繊維とポリエステル繊維とを、表1に示す質量比率で混合し、カード機により開繊して繊維基材用繊維ウエブを形成した。
#2:繊度1.7dtex、繊維長51mmのレーヨン繊維(Lenzing Fibers社製、品番:LENZING 9001 BK)
#3:繊度2.2dtex、繊維長51mmのポリエステル繊維(小山化学社製、オヤマエステルBL)
#4:繊度3.3dtex、繊維長60mmのレーヨン繊維(Lenzing Fibers社製、品番:LENZING 9001 BK)
(2)接着剤層用繊維ウエブの製造;
#2:繊度1.4dtex、繊維長38mmのポリエステル繊維(HUVIS社製、HUVIS ESTER クロ)IS ESTER クロ、融点:260℃)
#3:繊度1.7dtex、繊維長51mmのレーヨン繊維(Lenzing Fibers社製、品番:LENZING 9001 BK)
#4:ポリプロピレン樹脂製スパンボンド不織布(融点:160℃、目付:20g/m2、厚さ:0.2mm)
アクリル系樹脂バインダ又はポリエステル系樹脂バインダを、表3の固形分比率となるように配合した。
#2:アクリル樹脂エマルジョン(日本ゼオン社製 LX−851F2、Tg=15℃)
#3:アクリル樹脂エマルジョン(DIC社製 JT−80、Tg=30℃)
#4:メラミン樹脂(大日本インキ化学工業株式会社製、品番:ベッカミン J−103、=熱硬化性樹脂)
#5:ペンタブロモベンゼン(丸菱油化工業株式会社製、品番:ノンネンSMC−65、=難燃剤)
*5:リン酸アンモニウム(丸菱油化工業株式会社製、品番:ノンネンSMC−95、=難燃剤)
#6:アクリル樹脂と難燃剤との質量比率
#7:アクリル樹脂と熱硬化性樹脂との質量比率
繊維基材用繊維ウエブの片面のみに接着剤層用繊維ウエブを積層した後、繊維基材用繊維ウエブ側から、針密度170本/cm2又は90本/cm2(実施例2のみ)でニードルパンチし、表4に示すニードルパンチ積層不織布を製造した。
(5)−1 難燃性;
表皮材の難燃性を、米国自動車安全基準 FMVSS No.302に規定された燃焼試験に準拠して測定した。この燃焼試験を各表皮材5点について行い、次の基準により判定した。この結果は表5に示す通りであった。
×・・燃焼速度が100mm/min.を超える表皮材がある
基材マットとして、溶かしたガラスを遠心力によって吹き飛ばして形成した繊維を集積させた後に、フェノール樹脂によって結合させたグラスウールマット(目付:500g/m2)を用意した。
×・・表皮材表面の毛羽立ち及び繊維及び/又は樹脂の金型への付着が認められる
前記(5)−2(離型性)試験で成形体を製造した時に、表皮材が基材マットに追従しきれず、グラスウールマットと剥離した浮きや皺が発生したかどうかを確認した。つまり、次の基準で判断した。この結果は表5に示す通りであった。
×・・浮き及び/又は皺が認められる
前記(5)−2(離型性)試験で製造した成形体の周囲を、トリム刃を有する型枠で打ち抜き機によって打ち抜いた。その際に、表皮材が引っ張られ、引っ張られた表皮材の基材マットへの貼り付き度合いによって、トリミング性の良し悪しを判断した。つまり、次の基準により判断した。この結果は表5に示す通りであった。
×・・成形体端部において、グラスウール方向に引張られ、付着した繊維が目立つ
前記(5)−4 トリミング性試験で製造した成形体について、その表面意匠性を表皮材の透け度合いによって、意匠性の良し悪しを判断した。つまり、次の基準により判断した。この結果は表5に示す通りであった。
×・・成形体表面意匠部において、透けが目立つ
前記(5)−4 トリミング性試験で製造した成形体について、表皮材と基材マットとの接着性を、表皮材の基材マットからの剥離度合いによって、接着性の良し悪しを判断した。つまり、次の基準により判断した。この結果は表5に示す通りであった。
×・・成形体において、表皮材の基材マットからの剥離がある
1.実施例1と比較例5との比較から、繊維基材を構成する繊維の繊度が2.2dtex以下であれば、表皮材の透けが生じず、意匠性に優れていること。
2.実施例1と比較例6との比較から、アクリル系樹脂バインダを使用することによって、熱成形時の追従性に優れていること。
3.実施例6と比較例7との比較、及び実施例7と比較例8との比較から、アクリル系樹脂と熱硬化性樹脂との質量比率が80:20〜65:35であれば、離型性及び追従性に優れていること。
4.実施例1と実施例5から、難燃剤の種類に影響を受けず、難燃性に優れていること。
5.実施例1と実施例2から、接着剤層の形態に影響を受けず、表皮材と基材マットとが強固に接着一体化できること。
Claims (3)
- セルロース系繊維を含む繊維基材の片表面が、難燃剤と熱硬化性樹脂を含むアクリル系樹脂バインダによって接着されている表皮材用基材であり、繊維基材を構成する繊維の繊度が2.2dtex以下であり、かつアクリル系樹脂と熱硬化性樹脂との質量比率が80:20〜65:35であることを特徴とする表皮材用基材。
- 請求項1に記載の表皮材用基材における繊維基材の、アクリル系樹脂バインダによって接着された表装面と反対面に、200℃以下の融点をもつ樹脂を含む接着剤層を備えていることを特徴とする表皮材。
- 目付が30〜80g/m2であることを特徴とする、請求項2記載の表皮材。
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JP2010055766A JP5341002B2 (ja) | 2010-03-12 | 2010-03-12 | 表皮材用基材、表皮材及び成形体 |
CN201110061640.XA CN102199845B (zh) | 2010-03-12 | 2011-03-11 | 表皮材料用基材、表皮材料以及成型体 |
US13/045,720 US8663809B2 (en) | 2010-03-12 | 2011-03-11 | Surface material substrate, surface material and molded body |
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EP3012155A1 (en) * | 2014-10-20 | 2016-04-27 | Autoneum Management AG | Main floor part for a small utility vehicle |
JP7021884B2 (ja) * | 2017-09-06 | 2022-02-17 | 日本バイリーン株式会社 | 表皮材 |
JP2020041241A (ja) * | 2018-09-12 | 2020-03-19 | 日本バイリーン株式会社 | 内装用表面材 |
JP7313137B2 (ja) * | 2018-12-06 | 2023-07-24 | 日本バイリーン株式会社 | 内装用表面材 |
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JPH03212853A (ja) | 1990-01-17 | 1991-09-18 | Nec Corp | フレキシブルディスク用両面型磁気ヘッド |
JP3321271B2 (ja) | 1993-03-11 | 2002-09-03 | オリンパス光学工業株式会社 | 手術用顕微鏡 |
JP3196415B2 (ja) | 1993-03-29 | 2001-08-06 | 豊田工機株式会社 | 動力舵取装置用流量制御装置 |
JPH06278260A (ja) | 1993-03-29 | 1994-10-04 | Japan Vilene Co Ltd | 自動車内装用表皮材ならびに自動車内装材およびその製造法 |
JP2781947B2 (ja) | 1993-06-24 | 1998-07-30 | シャープ株式会社 | 直接拡散スペクトル拡散通信装置 |
CN1156101A (zh) * | 1995-11-27 | 1997-08-06 | 靖江贝斯特汽车成型覆盖件实业公司 | 无纺基汽车内装饰件的制造工艺方法 |
US6534145B1 (en) * | 1998-10-28 | 2003-03-18 | Lear Corporation | Pleated nonwoven products and methods of constructing such products |
JP2002067826A (ja) * | 2000-08-25 | 2002-03-08 | Nissan Motor Co Ltd | 車両用吸遮音構造体 |
JP4133553B2 (ja) * | 2002-04-30 | 2008-08-13 | 日本バイリーン株式会社 | 自動車内装材用表皮材及び自動車内装材 |
JP4043343B2 (ja) * | 2002-10-28 | 2008-02-06 | 帝人ファイバー株式会社 | 吸音構造体 |
CA2570368C (en) * | 2004-06-17 | 2011-06-21 | Philippe Pierre Marie Joseph Doneux | Acoustic laminate |
EP2628837B1 (en) * | 2005-04-01 | 2017-01-04 | Buckeye Technologies Inc. | Nonwoven material for acoustic insulation, and process for manufacture |
US7837009B2 (en) * | 2005-04-01 | 2010-11-23 | Buckeye Technologies Inc. | Nonwoven material for acoustic insulation, and process for manufacture |
US20070295659A1 (en) * | 2005-09-29 | 2007-12-27 | Sellars Absorbent Materials, Inc. | Filters and methods of manufacturing the same |
JP4908084B2 (ja) * | 2006-07-06 | 2012-04-04 | 名古屋油化株式会社 | 吸音性表面材料およびそれを使用した成形物 |
JP5080185B2 (ja) * | 2007-09-25 | 2012-11-21 | 日本バイリーン株式会社 | 表皮材用基材、表皮材及び成形体 |
JP4924945B2 (ja) * | 2007-09-26 | 2012-04-25 | クラレクラフレックス株式会社 | 積層不織布ならびにその製造方法、およびこれを用いる難燃吸音シートの製造方法 |
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