JPH06114958A - Manufacture of interior material of automobile - Google Patents

Abstract

PURPOSE:To provide a method for manufacturing an interior material for an automobile which can manufacture foam in a mold from preliminarily foamed particles, simultaneously integrate a laminate of extruded foamed sheet having no permeability and a fibrous skin with the foam in the mold, no fusion-bonding malfunction, soft skin touch due to the fibrous skin and flexible touch upon pressing. CONSTITUTION:A method for manufacturing an interior material for an automobile comprises the steps of so providing a laminate 11 of fibrous skin 10 and an extruded foamed sheet 9 that the skin 10 is brought into contact with an inner surface of the mold A1, providing a shape holding material 12 on an inner surface of a mold B2, then clamping the mold A1 and a mold B2 to constitute molds, charging polypropylene series resin preliminarily foamed particles in the molds, thereafter, preliminarily heating the particles preliminarily heated, evaporating it by steam, and earnestly heating it from the mold B2. The method further comprises the steps of manufacturing a foamed molded form in the mold without providing the shape holding material on the inner surface of the mold B2, and then providing the holding material on a surface of the foamed molded form in the mold.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an automobile interior material. More specifically, it has a high-class feeling and soft touch peculiar to the fibrous skin, and is, for example, an automobile door material, an instrument panel, a sun visor, a ceiling material,
Door trim, rear package, knee bolster, airbag door, headrest, armrest, various pillars,
Quarter trim, front side trim, front seat back, crash pad, console box,
The present invention relates to a method for producing an automobile interior material that can be suitably used as a console lid, a luggage floor cover, a partition board, a center console, a console box lid, and the like.

[0002]

2. Description of the Related Art Conventionally, interior materials for automobiles are manufactured by a method in which the in-mold foam is prepared in advance, an adhesive is applied to the foam, and then a skin material is applied. However, according to such a method, three steps, that is, a step of producing an in-mold foam, a step of applying an adhesive, and a step of attaching a skin material to the in-mold foam are required, and thus the manufacturing process is complicated. However, there was a drawback that production efficiency was not good.

As a method capable of eliminating the drawbacks of the above method,
A porous sheet having air permeability is provided on at least the steam hole surface of a pair of molds having a plurality of steam holes, and thermoplastic resin foam particles are filled, and then steam is introduced from the steam holes to form a porous sheet and foam. A method is known in which particles are heat-fused and integrated to each other (Japanese Patent Laid-Open No. 3-190723).

The above-mentioned method is effective when the skin material is a porous sheet, but when the skin material is a sheet having no air permeability, the steam introduced from the steam holes is Since the foamed particles are blocked by the sheet and do not reach the expanded particles, the expanded particles are not sufficiently heated, causing defective fusion, and the mechanical properties of the obtained automobile interior material are such that the in-mold foam has a skin material. There is a problem that it is inferior to that fused with an adhesive.

Further, in recent years, the conventional interior materials for automobiles having a fibrous skin have a high-class feeling and soft touch peculiar to the fibrous skin, but since the feeling when pressed is hard, it is further pressed. There is a long-awaited need for the development of interior materials for automobiles that give a supple feel when they do.

[0006]

Accordingly, the inventors of the present invention have conducted extensive studies in view of the above-mentioned prior art, and as a result, have made a laminate of a fibrous skin and a polypropylene resin extruded foam sheet into a polypropylene resin in-mold foam. It has been found that the laminate laminated on the body has a high-class feel and soft touch peculiar to the fibrous skin, and gives a supple feel when pressed, and can be suitably used as an interior material for automobiles. ing.

However, although the fibrous skin of the laminate has air permeability, the polypropylene-based resin extruded foam sheet does not have air permeability, and as described above, the fibrous skin and the polypropylene-based resin extruded sheet in the molding die. When a method of integrating the laminated body of the foamed sheet with the molding of the polypropylene-based resin in-mold foam is adopted, there is a problem that defective fusion occurs in the in-mold foamed molded body. It has been necessary to take a complicated means of pre-molding each of the foamed molded bodies and adhering and integrating them with, for example, an adhesive.

The present invention has been made in view of the above circumstances, and a breathable fibrous skin is used, and a polypropylene resin extruded foam sheet having no breathability is laminated on the fibrous skin. Even if it is, the in-mold foam can be manufactured from the pre-expanded particles, and at the same time, the fibrous skin and the laminate of the extruded foam sheet can be integrated, and the in-mold foam does not melt. It is an object of the present invention to provide a method for producing an interior material for an automobile, which does not have poor wearing.

[0009]

That is, according to the present invention, a laminate of a breathable fibrous skin and a polypropylene resin extruded foam sheet is provided so that the fibrous skin is in contact with the inner surface of the mold A, and the shape is A holding material is provided on the inner surface of the mold B, and the mold A and the mold B are clamped together to form a molding die.
The polypropylene resin pre-expanded particles are filled in the molding die, steam is supplied from the steam holes of the mold B, and the pre-expanded particles are preheated at a temperature lower than the temperature at which the pre-expanded particles fuse with each other. And steaming the pre-expanded particles with steam,
Then, the pre-expanded particles are main-heated from the mold B at a temperature higher than the temperature at which the pre-expanded particles are fused with each other, and a method for producing an automobile interior material, and a fibrous skin having air permeability. A polypropylene resin extruded foam sheet laminate is provided so that the fibrous skin contacts the inner surface of the mold A, and the mold A and the mold B are clamped to form a molding die, and then the polypropylene resin is used. The pre-expanded particles are filled in the mold, steam is supplied from the steam holes of the mold B, and the pre-expanded particles are pre-heated at a temperature lower than the temperature at which the pre-expanded particles fuse with each other. The pre-expanded particles are steamed with steam, and then the pre-expanded particles are main-heated from the mold B at a temperature equal to or higher than the temperature at which the pre-expanded particles are fused with each other, and the in-mold foaming obtained by opening the mold is obtained. Characterized by providing a shape-retaining material on the body surface That relates to a process for the production of automotive interior materials.

[0010]

OPERATION AND EXAMPLES In the method for producing an automobile interior material of the present invention, the pre-expanded particles must be heated from both sides in a molding die with steam or the like in order to eliminate defective fusion between the pre-expanded particles. It is a completely new method of manufacturing interior materials for automobiles that breaks the conventional wisdom that was said to be impossible.

Further, according to the method for producing an automobile interior material of the present invention, it is not clear why an in-mold foamed molded article without defective fusion of particles can be produced, but it is merely conventional. In addition to heating with steam, a step of performing preheating under specific conditions and then steaming is used, so pre-expanded particles on the side where the steam of the mold is introduced and the side of the laminated body It can be presumed that this is because the temperature difference of the foamed particles is reduced and the fusion property by the main heating is improved.

An embodiment of a method for manufacturing an automobile interior material of the present invention will be described below with reference to the drawings.

FIG. 1 is a schematic explanatory view showing one embodiment of a molding die used in the manufacturing method of the present invention.

In FIG. 1, the mold A1 is clamped to the mold B2. In FIG. 1, the mold A1 has no steam holes, but in the present invention, the steam holes may be provided because there is no particular problem. The mold A1 is, for example, a cylinder 3
And the like, and is configured to be able to clamp and open the mold A1 and the mold B2 by moving the mold A1. A plurality of steam holes 4 are provided on the inner surface of the mold B2, and the steam introduced from the steam inlet 5 passes through the steam holes 4 through the inside 6 of the mold B2 into the molding chamber 7. be introduced. A feeder 8 is provided in the mold B2, and the polypropylene resin pre-expanded particles as a raw material are introduced into the molding chamber 7 by the feeder 8.

On the inner surface of the mold A, first, a laminated body 11 of air-permeable fibrous skin 10 and polypropylene resin extruded foam sheet 9 is provided.

Examples of the breathable fibrous skin 10 include woven cloth, non-woven cloth and knitted cloth.
The present invention is not limited to only these examples. In the present invention, the type of the fibrous skin 10 may be appropriately selected and used according to the type of the intended automobile interior material. As an example thereof, for example, when the interior material for an automobile having a soft texture of raised fabric is used, a needle-punched nonwoven fabric may be used as the fibrous skin 10, and a car having a so-called backskin-like high-class feeling. When the interior material is used, as the fibrous surface skin 10, for example, suede-like artificial leather manufactured by Toray Industries, Inc. or Excene (trade name) can be used.

The type of fiber used for the fibrous skin 10 is not particularly limited, and examples thereof include polyester fiber, polyethylene fiber, polypropylene fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, polyamide fiber, and ethylene-vinyl acetate copolymer. Synthetic fibers such as united fibers; semi-synthetic fibers such as rayon fibers and acetate fibers; natural fibers such as cotton and wool. Among these fibers, polyester fibers are preferable in terms of heat resistance, light resistance, abrasion resistance, and the like, and polypropylene fibers and polyethylene fibers, especially polypropylene fibers are preferable in terms of adhesiveness with the polypropylene resin extruded foam sheet 9. It is also preferable in terms of recyclability.

The thickness of the fibrous skin 10 is such that
It may be appropriately adjusted according to the 10 types, the desired surface condition of the obtained automobile interior material, and the like.

The polypropylene-based resin extruded foam sheet 9 is a sheet formed by extrusion-foaming a polypropylene-based resin and has no air permeability. The extruded foam sheet 9 is used as an intermediate layer between the fibrous skin 10 and the in-mold foam, and gives the obtained automobile interior material a supple feel when pressed. If the expansion ratio of the extruded foam sheet 9 is too small, the obtained automobile interior material tends to be too hard to feel, and if it is too large, the obtained automobile interior material has a large expansion ratio. Since the touch tends to be too soft, it is preferably about 10 to 30 times, especially about 15 to 25 times.

If the thickness of the extruded foam sheet 9 is too small, the obtained automobile interior material tends to have a hard tactile sensation and the cushioning property tends to be small. If it is too large, the obtained automobile interior material tends to be too soft to touch, so that it is preferably 1 to 4 mm, especially 1.5 to 3.5 mm.

The fibrous skin 10 and the extruded foam sheet 9 can be integrated by, for example, a method in which the fibrous skin 10 and the extruded foam sheet 9 are integrated by an adhesive, and the fibrous skin 10 is composed of a thermoplastic resin fiber, particularly a polyolefin resin fiber. In some cases, it can be performed by a method of heating and melting and integrating both, and the present invention is not limited to such an integrating method.

In the present invention, the fibrous skin is
It is possible to prepare a laminate in which 10 and the extruded foam sheet 9 are integrated in advance, and to integrate this with the in-mold foam.

The laminated body 11 of the fibrous skin 10 and the extruded foam sheet 9 is previously formed into a desired shape by, for example, vacuum forming so as to be adapted to the shape of the inner surface of the mold A1. However, the laminated body 11
If it has flexibility, it is mounted in a molding die, molded into a desired shape by, for example, a vacuum molding method, and then the pre-expanded particles are filled in the molding die and molded. Good.

In order to improve the adhesion between the extruded foam sheet 9 and the pre-expanded particles, an adhesive may be provided in advance on the surface of the extruded foam sheet 9 that comes into contact with the pre-expanded particles. Examples of such an adhesive include a resin dissolved in an organic solvent, a resin emulsion, and a resin powder. Examples of the resin include ethylene-vinyl acetate resin, polypropylene, polyethylene, ethylene-propylene copolymer, chlorinated polypropylene, chlorinated polyethylene, ethylene-propylene-
Examples include polyolefin resins such as butene terpolymers and mixtures thereof, but the present invention is not limited to these examples. The amount of the adhesive used is
There is no particular limitation, and it may be appropriately adjusted according to the type of adhesive, the desired adhesive strength, and the like.

In the present invention, the in-mold foam contracts immediately after being taken out from the molding die.
While the polypropylene resin extruded foam sheet 9 suppresses the shrinkage of the in-mold foam on the surface where is provided, the shrinkage proceeds on the surface where the laminate 11 is not provided,
As a result, the automobile interior material is deformed.

In order to prevent such deformation of the automobile interior material, that is, to impart a deformation preventing function, the surface of the automobile interior material on which the laminated body 11 is not provided, that is, the surface of the in-mold foam is shaped. The shape-retaining material is provided by pasting the retaining material or embedding the shape-retaining material in the in-mold foam.

The automobile interior material used in the present invention can have a reinforcing function, an assembly material attaching function and the like in addition to the deformation preventing function.

As a method of providing the shape-retaining material, for example, a shape-retaining material is provided in advance on the inner surface of the mold B, and the shape-retaining material and the in-mold foam are integrated during the in-mold foam molding of the pre-expanded particles. Method, the laminate of the fibrous skin and the polypropylene resin extruded foam sheet and the in-mold foam are integrated in the molding die and taken out from the molding die, and then the shape retaining material is provided on the in-mold foam surface. The method etc. are given.

The shape of the shape-retaining material may be adjusted according to the shape of the interior material for automobiles and the like. Examples of the material for the shape-retaining material include paper, metal, wire mesh, wood, thermoplastic resins such as polyethylene, polypropylene and ABS resin, thermosetting resins such as phenol resin and formaldehyde resin, and FRP. The present invention is not limited to only these examples. Among such materials, polypropylene and the like are particularly preferable in consideration of the recyclability of the obtained automobile interior material.

In the former method, when the shape-retaining material is integrated with the in-mold foam at the time of molding the in-mold foam, the shape-retaining material may be softened and melted by heating during molding. Since the deformation preventing function of the material is not sufficiently exhibited, it is preferable to use a material that can withstand heating during molding as the shape retaining material.

When the shape-retaining material is attached to the surface where the laminated body 11 of the automobile interior material is not provided, after the shape-retaining material is provided on the inner surface of the mold B, the molding die is closed, The pre-expanded particles may be filled in a molding die and then molded. In this case, in order to firmly bond the in-mold foam and the shape-retaining material during the in-mold foam molding of the pre-expanded particles, the shape The adhesive or the like may be attached in advance to the surface of the holding material that is in contact with the pre-expanded particles.

In the case of imparting only the above-mentioned deformation preventing function to an automobile interior material, in order to reduce the weight, as the material of the shape-retaining material, a material such as paper, which itself is lightweight, is used. It is preferable to use.

When a shape-retaining material having a high hardness is used, not only the deformation preventing function but also the strength of the automobile interior material itself, that is, the reinforcing function can be enhanced.

In the case of embedding a shape-retaining material in an in-mold foam of an automobile interior material, for example, as shown in FIG. 1, a shape-retaining material 12 is provided on the inner surface of a mold B2 and then the molding die is formed. The mold may be closed, filled with pre-expanded particles in a molding die, and then molded. In this case, in order to embed the shape-retaining material 12 into the in-mold foam, for example, a groove is provided in a part of the mold B2. Then, for example, a mounting portion 13 for connecting to another member is inserted into the groove, and a shape-retaining material is formed in the in-mold foam during molding.
12 may be embedded. The shape of the mounting portion 13 is not particularly limited, and the mounting portion 13
If not required, it may not be provided.

The surface of the shape-retaining material 12 may be preliminarily adhered with, for example, the above-mentioned adhesive or the like in order to improve the adhesiveness with the pre-expanded particles.

When the latter method of providing the shape-retaining material, that is, the method of providing the shape-retaining material on the surface of the in-mold foam obtained by opening the mold, for example, the adhesive is used. The shape-retaining material and the in-mold foam body surface may be bonded together.

In the two methods of providing the shape-retaining material on the surface of the in-mold foam, generally the contraction of the in-mold foam starts immediately after the mold is opened, and the contraction is sufficiently prevented. In the present invention, the former method is particularly preferable.

After the mold A1 and the mold B2 are clamped, the polypropylene resin pre-expanded particles are filled into the mold through the feeder 8.

Examples of the polypropylene resin used for the polypropylene resin pre-expanded particles include propylene homopolymer, ethylene-propylene random copolymer, ethylene-propylene block copolymer, ethylene-propylene-butene random terpolymer, and propylene-vinyl chloride copolymer. , Propylene-
Resins having a propylene content of 50% by weight or more, such as butene copolymers and propylene-maleic anhydride copolymers, may be used alone or in admixture of two or more.

The above polypropylene-based resin is preferably in a non-crosslinked state, but may be one crosslinked with peroxide or radiation.

Further, as the polypropylene resin,
You may use what mixed the other thermoplastic resin which can be mixed with this polypropylene resin. Specific examples of such other thermoplastic resins include, for example, low density polyethylene,
Examples include linear low-density polyethylene, polystyrene, polybutene, and ionomers. The amount of the thermoplastic resin compounded is usually 20 parts or less per 100 parts of the polypropylene resin (parts by weight, the same applies below), especially 5
It is preferably from 10 to 10 parts.

The polypropylene-based resin is usually melted in advance by using, for example, an extruder, a kneader, a Banbury mixer, a roll, etc. so as to be easily pre-foamed, and is made into a columnar shape, an elliptic cylinder shape, a spherical shape, a cubic shape, a rectangular parallelepiped shape or the like. The desired particle shape, with an average particle size of 0.1-10 m
It is desirable to carry out molding so that the thickness is m, preferably 0.7 to 5 mm.

As a method for producing the polypropylene resin pre-expanded particles, for example, the polypropylene resin particles are made to contain a volatile foaming agent in a pressure vessel, dispersed in water with stirring, and a predetermined foaming temperature is applied under pressure. Examples of the method include a method in which the water dispersion is discharged to a low pressure region after being heated to the low temperature, but the present invention is not limited to such a method.

If the expansion ratio of the polypropylene resin pre-expanded particles is too large, the obtained in-mold expansion molded article tends to have large shrinkage or too softness, and is too small. In this case, since the buffering property tends to decrease, it is usually 3 to 60.
Times, preferably 5 to 50 times, more preferably 8 to 45 times,
Particularly preferably, it is 10 to 35 times.

When the polypropylene resin pre-expanded particles are filled into the mold through the feeder 8,
The pre-expanded particles may be preliminarily pressurized with a pressurizing gas, and the pre-expanded particles may be filled into the molding die in a state where the pre-expanded particles are sufficiently permeated into the pre-expanded particles and internal pressure is applied. The particles may be packed in a mold in a state of being compressed by using a pressurized gas. Alternatively, the pre-expanded particles may be filled in the mold as they are without being compressed or compressed. However, the present invention is not limited to such a filling method.

After the polypropylene resin pre-expanded particles are filled in a molding die, steam is supplied from the steam holes 4 of the mold B2, and the pre-expanded particles are preheated at a temperature lower than the temperature at which the pre-expanded particles are fused to each other. Preheat the expanded beads.

The present invention is also characterized in that the pre-expanded particles are pre-heated at a temperature lower than the temperature at which the pre-expanded particles are fused together. The pre-expanded particles are pre-heated in this manner. In this case, the pre-expanded particles are in a sufficiently heated state without being fused before the main heating is performed, and the uniform heating can be performed evenly by the main heating. In the present invention, during preheating, when the pre-expanded particles are heated to a temperature equal to or higher than the fusion temperature, the pre-expanded particles are preferentially fused from the water vapor hole side, and as a result, Since water vapor does not easily permeate to the pre-expanded particles on the surface material side and defective fusion occurs, preheating is performed at a temperature lower than the fusion temperature of the pre-expanded particles. Since the fusion temperature of the pre-expanded particles cannot be unconditionally determined because it varies depending on the type of resin used in the pre-expanded particles, after examining the fusion temperature of the pre-expanded particles in advance, Mold B
It is preferable to set the temperature of the water vapor introduced from the second vapor hole 4.

The fusion temperature means the pre-expanded particles are filled in a mold having a depth of about 50 mm, and steam at a predetermined temperature (predetermined pressure) is introduced into the mold for 10 to 20 seconds. It is the lowest temperature at which the pre-foamed particles are fused to each other and the shape of the in-mold foam molded article can be maintained.

If the temperature of the steam during the preheating is too low, the effect of the preheating tends not to be sufficiently exhibited. Therefore, the temperature of the steam is not higher than the fusion temperature of the pre-expanded particles to The temperature is 35 ° C lower than the fusing temperature, preferably 3 ° C lower than the fusing temperature to 30 ° C lower than the fusing temperature, more preferably 5 ° C lower than the fusing temperature to fusing It is desirable that the temperature is 25 ° C lower than the deposition temperature or higher.

The pressure of the steam during the preheating may be appropriately adjusted so that the temperature of the steam is within the above range.

Another feature of the present invention is that steam is supplied from the steam holes 4 of the mold B2 for preheating and then the pre-expanded particles are steamed with steam. When the pre-expanded particles are steamed with steam, the pre-heated particles may be steamed, or the steam supply may be stopped and the drain valve may be opened. When the pre-expanded particles are steamed in this way, the latent heat of the steam introduced between the pre-expanded particles in the molding die can be effectively utilized, and an in-mold foam having a particularly large thickness is produced. Bad,
There is an advantage that the pre-expanded particles can be heated uniformly. When steaming the pre-expanded particles in this way, the time required for such steaming depends on the thickness of the pre-expanded particle layer in the molding die, the size of the pre-expanded particles, the shape, the expansion ratio, etc. Although it cannot be unconditionally determined because the transmission speed is different, it is usually about 3 seconds or more, preferably about 5 seconds or more, more preferably 10 seconds or more when the thickness of the pre-expanded particle layer is about 50 mm. Is desirable.

After the steaming, there is a drain (water content) between the pre-expanded particles, and if main heating is performed in that state, defective fusion between the pre-expanded particles may occur. It is preferable to remove the generated drain. As a method of removing such a drain, for example, the steam chamber 4 provided in the mold B2 is used to form the molding chamber 7
The inside of the mold A is evacuated, and dry air at a temperature high enough to prevent the pre-expanded particles from being fused is aerated through the vapor holes 4 and the mold A
1 and the mold B2, a method of providing a space and removing the drain from the space may be mentioned, but the present invention is not limited to such a method.

Next, the pre-expanded particles are main-heated at a temperature equal to or higher than the temperature at which the pre-expanded particles are fused with each other.

The main heating is performed by the steam introduction port 5 of the mold B2.
This can be performed by heating the pre-expanded particles through the steam holes 4 through the steam holes and simultaneously introducing steam from the steam introduction port 14 of the mold A1 to steam heat the mold A1. As a method of heating the mold A1, for example, a method of heating using a heater or the like can be adopted in addition to a method of heating by steam.

The pressure of the steam may be adjusted so that the temperature of the steam falls within the temperature range described later.

The temperature of the water vapor may be higher than the temperature at which the pre-expanded particles are fused with each other. However, if the temperature of the water vapor is too high, shrinkage of the obtained in-mold foamed molded product may occur. Since it tends to become too large, it is desirable that the temperature is 30 ° C. or higher than the temperature at which the pre-expanded particles are fused, and preferably 25 ° C. or higher than the temperature at which the pre-expanded particles are fused.

After the pre-expanded particles are subjected to the main heating, it is preferable that the pre-expanded particles are kept in that state in order to sufficiently transfer the heat generated by the steam. The time required for such holding varies depending on the thickness of the pre-expanded particle layer, etc., and therefore cannot be unconditionally determined. It is desirable that the time is 3 seconds or more, preferably about 5 seconds or more, but if the time is too long, the obtained in-mold foam molded article shrinks, so that no shrinkage occurs during molding. It is preferable to set it appropriately within the range.

Then, the molding die is opened to obtain an automobile interior material.

In the present invention, the obtained automobile interior material may be cooled in advance before the mold is opened.

Further, since the obtained automobile interior material is contracted immediately after it is released from the molding die, it is, for example, 50%.
It is preferable to carry out curing under normal pressure of -80 ° C for about 3-24 hours.

According to the method for producing an automobile interior material of the present invention, the extruded foam sheet does not have air permeability, but at the same time when the in-mold foam is produced from the pre-expanded particles, the skin material and the in-mold foam are produced. It is possible to manufacture an interior material for automobiles which can be integrated and which does not cause defective fusion of pre-expanded particles in the in-mold foam.

In the production method of the present invention, even when the in-mold foam having a large wall thickness and the laminate are integrally molded,
Since it is possible to provide a good interior material for automobiles without causing the fusion failure of the pre-expanded particles on the surface of the in-mold foam contacting with the laminate, the in-mold foam has a relatively large wall thickness, for example, An automobile interior material comprising an in-mold foam having an extremely large wall thickness of about 100 mm and the above laminated body can be suitably manufactured.

Next, the method for producing an automobile interior material of the present invention will be described in more detail based on examples, but the present invention is not limited to these examples.

Example 1 A needle punched nonwoven fabric (thickness: 2 mm) made of polypropylene fiber and a polypropylene resin extruded foam sheet (foaming ratio: 20 times, thickness: 3 mm) were heated and melted on their respective adhesive surfaces, and then laminated. The combined and integrated laminate was attached so that the non-woven fabric surface was in contact with the flat plate-shaped mold surface having no steam holes.

Further, a die having a steam hole (vertical 300 mm,
An iron frame (diameter: 1 mm, surface coating: iron hook) (surface coating: ethylene-vinyl acetate resin) for fixing a set screw as a mounting part in a groove provided on the inner surface of the horizontal 800 mm, depth 20 mm) Rectangular shape retention material (vertical 250 mm, horizontal) made of ethylene-vinyl acetate resin
750 mm) was inserted and fixed.

As polypropylene resin pre-expanded particles, Eperan PP (manufactured by Kanegafuchi Chemical Industry Co., Ltd., trade name, expansion ratio 15 times) was placed in a pressure resistant container in advance and the internal pressure was 2 kg / cm.
² · G was given by air, and the mold was filled with the mold.

Next, steam (steam pressure 0.6 kg / cm ² · G, temperature 112 to 115 ° C.) was introduced into the mold from a mold having steam holes and preheated to prepare pre-expanded particles for about 10 seconds. After steaming, the drain and water vapor were removed by suction using a vacuum pump so that the internal pressure in the mold was 500 mmHg or less.

After that, steam (steam pressure 3.5 kg / cm ² · G, temperature 146 to 148 ° C.) was introduced into the mold from a mold having steam holes, kept for 25 seconds, cooled, and then molded. The mold was opened to obtain an automobile interior material.

As the physical properties of the obtained automobile interior material, the fusion rate, the adhesiveness with the laminate, the feel, the cushioning property and the recyclability were examined according to the following methods. The results are shown in Table 1.
Shown in.

(A) Fusing rate A thin cut was made on the surface of the in-mold foam molded article of the obtained automobile interior material with a knife, and then it was bent and broken, and the broken surface was observed, and the foamed particles were broken. The area ratio was expressed as a percentage and evaluated based on the following evaluation criteria.

(Evaluation Criteria) A: The fusion rate is 60% or more B: The fusion rate is 40 to 59% C: The fusion rate is 20 to 39% D: The fusion rate is 19% or less (b) Adhesiveness of the obtained laminated body and the in-mold foam molded article were peeled off, and the state of the interface was observed and evaluated based on the following evaluation criteria.

(Evaluation Criteria) A: Only material breakage is observed in the foam layer. B: Both material breakage of the foam layer and interfacial peeling between the foam layer and the laminate are observed. C: Interfacial peeling between the laminate and the foam layer is observed. D: The laminate and the foam layer are not adhered.

(C) Feeling As conventional interior materials for automobiles, needle punched non-woven fabric made of polypropylene fiber (thickness 2 mm), flexible polyurethane foam sheet (foaming ratio 8 times, thickness 8 mm) and AB
An S resin plate (thickness 2 to 3 mm) was sequentially laminated to obtain a product (hereinafter referred to as a conventional product A).

Next, the tactile sensation of the obtained automobile interior material was examined by pressing it with a finger, and compared with the conventional product A, evaluation was made based on the following evaluation criteria.

(Evaluation Criteria) A: The obtained automobile interior material is obviously softer and more supple than the conventional product A. B: The obtained automobile interior material is slightly softer and more supple than the conventional product A. C: There is almost no difference in touch between the obtained automobile interior material and the conventional product A. D: The conventional product A has a better tactile feel than the obtained automobile interior material.

(D) Buffering property A steel ball weighing 100 g was dropped from a position of 50 cm in height on the surface portion of the obtained automobile interior material and the conventional product A on the skin side, and based on the following evaluation criteria. And evaluated.

(Evaluation Criteria) A: The height of the steel ball when the steel ball is dropped and rebounded is higher in the conventional product A. B: The height of the steel ball when dropped and rebounded is almost the same in both the conventional product A and the obtained automobile interior material. C: The height of the steel ball when the steel ball was dropped and rebounded was higher in the interior material for automobiles.

(E) Recyclability The recyclability of the obtained automobile interior material was evaluated based on the following evaluation criteria.

(Evaluation Criteria) A: The obtained automobile interior material can be directly used for recycling without disassembling each constituent material. B: If the obtained interior materials for automobiles are decomposed into each constituent material, any of them can be used for recycling. C: The obtained automobile interior materials include materials that cannot be recycled.

Example 2 Instead of the laminate used in Example 1, suede-like synthetic leather made of polyester fiber (manufactured by Toray Industries, Inc., Excene: trade name) and a polypropylene resin extruded foam sheet (expansion ratio 20) 2 times, thickness 2.5 mm), and the synthetic leather surface of the laminated sheet is attached to the inner surface side of a flat plate-shaped mold, and the other mold is made of a polypropylene frame (diameter 1.5 mm) Rectangular shape retention material (vertical 25
An automobile interior material was obtained in the same manner as in Example 1 except that 0 mm and width 750 mm) were used.

The physical properties of the obtained automobile interior material are shown in Example 1.
I examined it in the same way. The results are shown in Table 1.

Example 3 A pile ground sheet (thickness 2
mm) and a polypropylene-based resin extruded foam sheet (foaming ratio: 20 times, thickness: 3.5 mm) were used, and the pile ground sheet surface of the laminate was attached to the inner surface of a flat die.

Further, a mold B having a steam hole (vertical 300 mm
, Width 800 mm, depth 60 mm) in the groove provided on the inner surface,
The same shape-retaining material as that used in Example 1 was inserted and fixed except that it had a polyolefin resin hook (surface coating: chlorinated polypropylene) for fixing a set screw as an attachment portion.

As pre-expanded polypropylene resin particles, Eperan PP (manufactured by Kanegafuchi Chemical Industry Co., Ltd., trade name, foaming ratio 30 times) was filled into the molding die through a feeder.

Next, steam (vapor pressure of 0.
5 kg / cm ² · G, temperature 109-113 ℃) is introduced into the mold to preheat, depressurize and steam the pre-expanded particles for 10 seconds, and then the internal pressure in the mold is 260 mmHg or less. The drain and water vapor were removed by suction using a vacuum pump.

After that, steam (vapor pressure: 3.2 kg / cm ² · G, temperature: 144 to 146 ° C.) was introduced from the molds A and B into the mold, and the mixture was kept for 20 seconds and cooled, and then the mold was formed. The mold was opened to obtain an automobile interior material.

The physical properties of the obtained automobile interior material are shown in Example 1.
I examined it in the same way. The results are shown in Table 1.

Example 4 In Example 3, as the polypropylene resin pre-expanded particles, Eperan PP (trade name, manufactured by Kanegafuchi Chemical Industry Co., Ltd.,
Except that a foaming ratio of 15) was used,
From the filling of the pre-expanded particles to the suction removal of the drain and water vapor.

Next, steam (vapor pressure 3.
5 kg / cm ² · G and a temperature of 146 to 148 ° C.) were introduced into the mold, held for 20 seconds, cooled, and then the mold was opened to obtain an automobile interior material.

The physical properties of the obtained automobile interior material are shown in Example 1.
I examined it in the same way. The results are shown in Table 1.

Example 5 Polypropylene was prepared in the same manner as in Example 1 except that a flat plate-shaped mold was used as the mold having steam holes and no shape-retaining material was provided on the inner surface of the mold. An in-mold resin foam molding was obtained.

Next, the in-mold foamed product surface of the obtained in-mold foamed molded product and a polypropylene frame (diameter: 1.5 mm
Shape retention material (vertical 250 mm, horizontal 7)
50 mm) and the respective adhesive surfaces were melted by heating and bonded to obtain an automobile interior material.

The physical properties of the obtained automobile interior material are shown in Example 1.
I examined it in the same way. The results are shown in Table 1.

Comparative Example 1 A polypropylene resin in-mold foam molded article was obtained in the same manner as in Example 1 except that after the preheating, the drain and water vapor were removed by suction without steaming.

The physical properties of the obtained in-mold foamed molded product are shown in Example 1.
I examined it in the same way. The results are shown in Table 1.

Comparative Example 2 A polypropylene resin in-mold foam molded article was obtained in the same manner as in Example 3, except that steaming was not performed after preheating.

The physical properties of the obtained in-mold foamed molded product are shown in Example 1.
I examined it in the same way. The results are shown in Table 1.

Comparative Example 3 In Comparative Example 2, except that preheating was not performed,
A polypropylene resin in-mold foam molded article was obtained in the same manner as in Comparative Example 2.

The physical properties of the obtained in-mold foam molded article are shown in Example 1.
I examined it in the same way. The results are shown in Table 1.

[0100]

[Table 1]

As is clear from the results shown in Table 1, when the extruded foam sheet having no air permeability is used according to the method for manufacturing automobile interior materials of Examples 1 to 5 of the present invention. Even in the case of producing an in-mold foam from the pre-expanded particles, the laminate and the in-mold foam can be integrated in a short time with good adhesiveness, and the obtained in-mold foam molded article is It can be seen that the pre-expanded particles have excellent fusion bonding properties.

Further, it can be seen that the automobile interior materials obtained in Examples 1 to 5 simultaneously have excellent feel, excellent cushioning properties, and excellent recyclability.

Further, since the automobile interior materials obtained in Examples 1 to 5 are all lightweight, they can sufficiently meet the demand for weight reduction of the parts constituting the automobile. there were.

[0104]

According to the method for producing an automobile interior material of the present invention, although an extruded foam sheet having no air permeability is used, an in-mold foam is produced from pre-expanded particles at the same time. The skin material and the in-mold foam can be firmly integrated, and the interior material for an automobile thus obtained has a fusion-bonding failure even if the in-mold foam layer has a large thickness. It has an excellent effect that it does not occur.

The automobile interior material obtained by the production method of the present invention has a high-quality feeling and a soft touch unique to the fibrous skin, and imparts a soft and supple feel when pressed. It has many excellent effects such as excellent cushioning property, light weight, and easy recycling.

[Brief description of drawings]

FIG. 1 is a schematic explanatory view showing one embodiment of a molding die used in the production method of the present invention.

[Explanation of symbols]

 1 Mold A 2 Mold B 4 Steam Hole 9 Polypropylene Resin Extrusion Foam Sheet 10 Fibrous Skin 11 Laminate 12 Shape Retaining Material

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Internal reference number FI technical display location B29L 31:58 4F

Claims (8)

[Claims] 1. A laminate of an air-permeable fibrous skin and a polypropylene resin extruded foam sheet is provided so that the fibrous skin contacts the inner surface of a mold A, and a shape-retaining material is provided on the inner surface of a mold B. After the mold A and the mold B are clamped to form a mold, polypropylene-based resin pre-expanded particles are filled into the mold, and steam is supplied from the steam holes of the mold B, The pre-expanded particles are pre-heated at a temperature lower than the temperature at which the pre-expanded particles fuse with each other, steam the pre-expanded particles with steam, and then at a temperature equal to or higher than the temperature at which the pre-expanded particles fuse with each other. A method for producing an interior material for an automobile, which comprises heating the pre-expanded particles from a mold B. 2. A laminate of an air-permeable fibrous skin and a polypropylene-based resin extruded foam sheet is provided so that the fibrous skin contacts the inner surface of the mold A, and the mold A and the mold B are molded. After forming the mold by tightening, the polypropylene resin pre-expanded particles are filled in the mold, steam is supplied from the steam holes of the mold B, and the temperature is higher than the temperature at which the pre-expanded particles are fused to each other. Preheating the pre-expanded particles at a low temperature,
The pre-expanded particles are steamed with steam, and then the pre-expanded particles are main-heated from the mold B at a temperature equal to or higher than the temperature at which the pre-expanded particles are fused to each other, and the molding die is opened. A method of manufacturing an interior material for an automobile, comprising providing a shape-retaining material on a foam surface. 3. The method for producing an interior material for an automobile according to claim 1, wherein the main heating is performed from the mold A when the main heating is performed from the mold B. 4. The method for producing an automobile interior material according to claim 1, 2 or 3, wherein the pre-expanded particles are steamed, the drain is removed, and then main heating is performed. 5. The method for manufacturing an automobile interior material according to claim 1, 2, 3 or 4, wherein a preformed laminate is used. 6. The method for producing an automobile interior material according to claim 1, 2, 3 or 4, wherein after molding the laminate in a molding die, polypropylene resin pre-expanded particles are filled in the molding die. 7. The fibrous skin comprises a polyolefin resin fiber, 1, 2, 3, 4, 5 or 6.
A method for producing the interior material for an automobile according to the description. 8. The method for producing an automobile interior material according to claim 1, wherein the fibrous skin is made of a polyester resin fiber.