JP7311949B2 - タイ層を有するフィルムを備える複合材製品 - Google Patents
タイ層を有するフィルムを備える複合材製品 Download PDFInfo
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- JP7311949B2 JP7311949B2 JP2017542790A JP2017542790A JP7311949B2 JP 7311949 B2 JP7311949 B2 JP 7311949B2 JP 2017542790 A JP2017542790 A JP 2017542790A JP 2017542790 A JP2017542790 A JP 2017542790A JP 7311949 B2 JP7311949 B2 JP 7311949B2
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Description
この出願は、2014年10月29日に出願された米国特許仮出願第62/072,261号及び2015年6月1日に出願された米国特許仮出願第62/169,412号に基づく優先権とその利益を主張し、それらの各々における全ての開示はこの参照により本明細書に援用される。
添付の図面を参照し、いくつの実施形態を説明する。
フィルムのいくつかの物理的な特性を評価する分析試験を実行した。以下を含む三つのフィルムを試験した。すなわち、(1)コポリアミド(CoPA)層とポリプロピレン(PP)層を有する二層フィルム(フィルム1)、(2)Xiro 45.311の60グラム/平方メートルのフィルム(フィルム2)、及び(3)Xiro 45.311の80グラム/平方メートルのフィルム(フィルム3)、である。試験毎に五つの試料について、直径約99ミリメートルの円盤を用いてフィルム1の坪量を測定した。サンプルは、華氏72度及び相対湿度50%において、24時間調製した。各パックの重量はフィルムを追加する前後において計量した。
熱可塑性コアと実施例1の三つのフィルムを含む複合材製品の剥離強度を、粘着性能を評価するために測定した。ポリウレタンフォーム層が、熱可塑性コア/フィルム複合材に積層されていた。
製品の厚み及び加工条件を変化させることにより、フィルムの粘着性能を更に試験した。異なる試験条件は表2に掲載されている。
個別の部品を小型のヘッドライナに成形した。成形温度は190℃及び210℃に設定した。試験製品(ST-8378)及び基準製品(ST-8379)を同じ方法で処理した。成形プロセスの間に有意な差は観察されなかった。パネル1の間隙が成形の間に制御された。図17の表3は、異なる成形条件の下での試料の実際の基材の成形厚みをまとめている。この実施例においては処理温度の間に色の変化は観察されなかった。図18及び図19は、縦方向及び横方向にモールド成形された全ての部品のピーク粘着性を示している。棒グラフの各グループにおいて、左から右への棒は、ST-8378(環境条件)、ST-8379(環境条件)、ST-8378(湿潤条件)及びST-8739(湿潤条件)を表している。2つの異なる処理温度において、有意な性能の差異は観察されなかった。基準及び試験の両方のサンプルにおいて、モールド厚みが増加するにつれて粘着性能は全般的に減少した。
実施例2に記載されているものと同様のコア層にフィルムを積層することによりフィルム1を更に評価した。ポリウレタン層をフィルムに積層してヘッドライナを形成した。加熱(90℃で24時間の後、環境温度で1時間)及び湿潤(50℃及び湿度90%で24時間の後、環境温度で1時間)の条件を用いつつ、ヘッドライナ片を環境条件(約25℃)の下で評価した。フィルム1を有する試料はST-8634と呼び、フィルム2を用いて製造されたヘッドライナ(基準1と呼び、800グラム/平方メートルの坪量のコアを有していた)と比較された。180度剥離試験の結果が図20に示されている。各棒グループにおいて、左から右に、棒はST-8634MD、基準1MD、ST-8634CD、基準1CDを表す。偏差量(deviation run)(実施例1で述べたフィルム1)及び生産量(production run)(実施例1で述べたフィルム2)について類似の試験を実行した。偏差量及び生産量の剥離試験の結果は図21に示されている。各棒グループにおいて、左から右に、それらの棒は偏差MD、生産MD、偏差CD及び生産CDを表している。
基準2のサンプルの成形されたヘッドライナから切り取った飾り板を用いて、実施例5の評価と類似の評価を実行した。このサンプルは、実施例1に記載のフィルム2を用いる、4パレット偏差量(deviation run)及び2パレット偏差量の両方について評価を行った。図22は、実施例5に記載される方法論に従って成形されたヘッドライナから切り取った4パレット偏差量試料の剥離強度を示している(コア材料は約700グラム/平方メートルの坪量を有しており、かつ偏差量は実施例1で述べたフィルム1を用いた)。図23は、実施例5に記載された方法論に従って成形されたヘッドライナから切り取った2パレット偏差量資料の剥離強度を示している。各棒グループにおいて、左から右に、それらの棒は基準2のMD、偏差MD、基準2のCD、及び偏差CDを表している。
音響性能について基準2及び偏差材料の追加の評価を実行した。ヘッドライナから切り取ったフラットパネルを測定した。フィルムの切れ込みがパネルに存在していた。4パレット偏差についての結果が図24に示され、かつ2パレット偏差の結果が図25に示されている。
図26A及び図26Bは三つの構造物の剥離強度を示している(図26Aは縦方向、図26Bは横方向)。棒グループのそれぞれにおいて、左から右に、それらの棒は環境、湿度、環境2、熱及び環境3を表す。図31の表に示すように、ST-9288A構造物は、高粘度タイ層のない80グラム/平方メートルフィルム、30グラム/平方メートルの接着剤、及び50グラム/平方メートルポリプロピレン(PP)を含んでいた。ST-9288C構造物は、高粘度タイ層を有する70グラム/平方メートルのフィルム、30グラム/平方メートルの接着剤、及び40グラム/平方メートルのPPを含んでいた。ST-9288D構造物は、高粘度タイ層を有する80グラム/平方メートルのフィルム、30グラム/平方メートルの接着剤、及び50グラム/平方メートルのPPを含んでいた。各構造物のコアの厚みは3.5ミリメートルであった。この実施例におけるフィルムの坪量は、先の実施例において、試験したフィルム1より高い。シートは、研究室で発泡タイプのカバー材料と組み立てられ、かつ150ミリメートル×25ミリメートルで測定した。負荷速度は300ミリメートル/分であった。
用いるコアの厚みが3.5ミリメートルの代わりに3.0ミリメートルであること以外は実施例8の試料と同様な追加の試料を試験した。結果は図27A及び図28Bに示されている。各棒グループにおいて、左から右に、それらの棒は環境、湿度、環境2、熱、及び環境3を表している。
図29は様々なヘッドライナ飾り板構造物についての剥離強度の測定の結果を示している。図30は実施例10において、用いた試験条件を示している。「冷間」とは-30℃を指し、「熱間」とは85℃を指し、かつ異なる環境の棒は環境条件における異なる測定値を表している。各棒グループにおいて、左から右に、それらの棒は、上記の実施例において、注目した環境及び湿度条件での環境1、湿度1、熱間1、冷間1、環境2、湿度2、熱間2、及び冷間2を表している。
実施例12~14においては、ある種の他のフィルムを性能について試験した。これらの実施例において、以下の省略が用いられる。
試験したフィルムの面密度は表5に掲載されている。その結果は、フィルム供給元から受け入れられた仕様情報を確認するものである。表4は、DSC測定の第2加熱サイクル(ステップ3)において、観察されたピークをまとめている。110℃あたりの吸熱ピークは接着成分の溶融ピークであり、より高い温度のものはポリオレフィン成分に関連している。55℃あたりの発熱ピークは、タイプ1の接着剤を有するフィルムにおいて観察されるだけであり、それは接着剤の再結晶ピークである。DSC測定は、試験したフィルムの間の差異を確認するために用いる。
図33は、2つの基準試料、フィルムX1とフィルムX2の間の環境条件下での比較を示している。フィルムX1及びフィルムX2は、同じ製品ファミリに属していて同一材料組成を共有している。フィルムX1とフィルムX2の間に差異を拡大するために、この特定の試験に用いるLWRTコア基材は典型的な用途よりも厚い基板厚さ6ミリメートルに成型した。これは、粘着性を達成するためにはより困難な状況を示している。試験試料はまた、スクリーニング研究室成形手順により調製された。ここで観察されることは、2つのフィルムが同じタイプの接着成分及び同じ量の接着成分を共有しているのに、フィルムX2がフィルムX1より著しく良好な剥離強度を示すことである。この性能の差異はLWRTの多孔性に起因している。成形の間、接着フィルムは溶融段階にあり、かつLWRTの多孔性はフィルムが基材にしみ込むことを可能にする。追加の高融点性ポリオレフィンがフィルムX2に存在してフィルムX1に存在しないことは、より粘着性の成分を接着界面に維持することを助ける。
フィルム構造の変更がなされ、かつ高粘度タイ層が導入された。追加のポリオレフィン成分を用いて界面にやける接着剤の浸透を防止することに代えて、この新しい構造はポリオレフィンの浸透の防止または緩徐化を助け得て、それは界面により多くの接着剤を維持し得る。図34は、フィルムX1と、高粘度タイ層を含むフィルムC1の間の比較を示している。各棒グループにおいて、左から右へと、それらの棒はMD環境、CD環境、MD加熱後、CD加熱後、MD湿潤後、及びCD湿潤後を表している。この比較において試験した試料は、ヘッドライナ製造業者から受け入れた成形ヘッドライナから切り取ったものであり、かつ基板の厚みは約5ミリメートルである。剥離粘着性試験は、1)環境条件下で、2)90℃での24時間の熱エージングの後、及び、3)50℃かつ湿度90%で24時間の湿潤エージングの後に実行した。いくつかの小さい改良により、フィルムC1は、フィルムX1に概ね匹敵する性能を示す。
Claims (13)
- ポリオレフィン材料及び複数の強化繊維を含む透過性のコア層であって、前記ポリオレフィン材料及び前記複数の強化繊維は複数の空所を含むウェブを形成し、前記透過性のコア層は前記透過性のコア層の全体的な体積に基づき5%を超える多孔率を有する、前記コア層と、
前記透過性のコア層の上に配置される5層フィルムであって、前記5層フィルムは、
前記透過性のコア層に隣接する第1層であって、前記第1層は第1ポリプロピレン層である、前記第1層と、
前記第1層の上に配置される第2層であって、前記第2層は高粘度のタイ層である、前記第2層と、
前記第2層の上に配置される第3層であって、前記第3層は追加のポリプロピレン層である、前記第3層と、
前記第3層の上に配置される第4層であって、前記第4層は追加のタイ層である、前記第4層と、
前記第4層の上に配置される第5層であって、前記第5層はポリアミドまたはコポリアミドを含む接着層である、前記第5層と、を含む前記5層フィルムであって、
2008年版のASTM D1084を用いて測定したときに、前記高粘度のタイ層の少なくとも1つの材料の粘度は、前記5層フィルムの他の層で用いられる材料の粘度よりも大きい、前記5層フィルムと、
前記5層フィルムの前記第5層の上に配置されるカバー層であって、前記5層フィルムの前記高粘度のタイ層は、前記高粘度のタイ層を欠いているフィルムに比較して、前記カバー層と前記5層フィルムの間の粘着性を高めるのに効果的である、前記カバー層と、
を備える複合材料。 - 前記第1ポリプロピレン層は第1のポリプロピレンを含み、
前記追加のポリプロピレン層は第2のポリプロピレンを含み、
2008年版のASTM D1084を用いて測定したときに、前記追加のポリプロピレン層中の前記第2のポリプロピレンの粘度は、前記第1ポリプロピレン層中の前記第1のポリプロピレンの粘度よりも少なくとも50%高い、請求項1に記載の複合材料。 - 前記5層フィルムは、80グラム/平方メートル未満の坪量を有する、請求項1に記載の複合材料。
- 前記接着層のポリアミドまたはコポリアミドは如何なるカプロラクタムも含まない、請求項1に記載の複合材料。
- 前記5層フィルムの前記五つの層の各々は同じ厚みである、請求項1に記載の複合材料。
- 2013年版のASTM D1238を用いて測定したときに、前記高粘度層に存在する材料のメルトフローインデックスは、1グラム/10分未満である、請求項1に記載の複合材料。
- 2013年版のASTM D1238を用いて測定したときに、前記5層フィルムの他の層に存在する材料のメルトフローインデックスは、1グラム/10分より大きい、請求項6に記載の複合材料。
- 前記5層フィルムの前記高粘度のタイ層及び前記5層フィルムの前記追加のタイ層は少なくとも一つの同一の材料を含む、請求項1に記載の複合材料。
- 前記追加のタイ層はポリアミドまたはコポリアミドを含む、請求項1に記載の複合材料。
- 前記カバー層は、ポリウレタン、不織材料、織物材料、布、及びフィルムのうちの一つまたは複数を含む、請求項1に記載の複合材料。
- 前記5層フィルムと前記カバー層との間に配置される追加の層を更に含む、請求項1に記載の複合材料。
- 前記透過性のコア層は前記ポリオレフィン材料としてポリプロピレンと、前記強化繊維としてガラス繊維を含む、請求項1に記載の複合材料。
- 前記5層フィルムは、80グラム/平方メートル未満の坪量を有する、請求項12に記載の複合材料。
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