Vehicle interior and exterior material

Abstract

This invention provides a vehicle interior and exterior material that can be manufactured through a simple process, is easy to recycle, and has controllable air permeability. The vehicle interior and exterior material (1) includes a first fiber material layer (10) and a second fiber material layer (20) located on one side of the first fiber material layer (10). The portion of the second fiber material layer (20) on the side of the first fiber material layer (10) further includes a resin-impregnated portion (22) formed by impregnating the fibers with a low-melting-point resin whose melting point is lower than that of the fibers of the first and second fiber material layers. Compared to the portion (21) of the second fiber material layer (20) that is not impregnated with the low-melting-point resin, the resin-impregnated portion (22) has a higher density and lower air permeability. The overall air permeability resistance of the vehicle interior and exterior material is 3000 Ns / m. 3 The above. Between the first fiber material layer (10) and the second fiber material layer (20), there may also be a nonwoven fabric layer made of a second resin with a melting point higher than that of a low-melting-point resin.

Description

Technical Field

[0001] This invention relates to interior and exterior materials for vehicles. Background Technology

[0002] Various vehicle components, including interior and exterior materials, are recycled to achieve resource reuse. For example, in Patent Document 1, a method for manufacturing a soundproof barrier for motor vehicles is described, comprising: a step of manufacturing a composite having a porous back layer mainly composed of fibers, an intermediate layer mainly composed of pulverized recycled materials, a porous surface layer, and a thermoplastic binder; a step of heating the composite to the melting point of the binder; a step of placing the heated composite in a thermoforming mold to manufacture a three-dimensional shell; a step of removing the shell from the mold after cooling; a step of placing the shell in a reaction injection molding mold defining a molding cavity, wherein a space is left between the back layer and the cavity wall; a step of injecting an elastically compressible foam precursor mixture into the space, and overmolding the back layer with the foam to form a sealed soundproof barrier; and a step of removing the obtained panel from the mold after the foam expands in the space and a spring layer is formed, wherein the binder is mixed into the surface layer, and the surface layer has a density of 500–2000 g / m³. 2 The surface quality, and the surface layer further includes a micro-compressed strong sound-absorbing region with a thickness of 4 to 10 mm, wherein the minimum total proportion of the strong sound-absorbing region is 40% of the surface area of ​​the surface layer.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2019-521039 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] Regarding Patent Document 1, the inventors of this application discovered through research that polyurethane foaming takes time, and because a polyurethane foam made of a different material than the main material of the panel is used, there is a problem that it is difficult to recycle.

[0008] In addition, in vehicle interior and exterior materials, the ventilation resistance can be changed by altering the density of the fiber material constituting the vehicle interior and exterior materials, thereby controlling the sound absorption performance. However, in the panel described in Patent Document 1, since polyurethane foam is used, there is a problem that it is difficult to control the overall ventilation of the panel.

[0009] In view of the above problems, the object of the present invention is to provide a vehicle interior and exterior material that can be manufactured with a simple process, is easy to recycle, and has controllable ventilation.

[0010] Methods for solving problems

[0011] To achieve the above objectives, as one aspect of the vehicle interior and exterior material of the present invention, the vehicle interior and exterior material includes: a first fiber material layer composed of a first fiber material containing resin; and a second fiber material layer located on one surface of the first fiber material layer and composed of a second fiber material containing resin. The second fiber material layer further includes a resin-impregnated portion in a portion adjacent to the first fiber material layer. The resin-impregnated portion is formed by impregnating the second fiber material with a low-melting-point resin whose melting point is lower than that of the resins of the first and second fiber materials. Compared with the portion of the second fiber material layer not impregnated with the low-melting-point resin, the resin-impregnated portion has a higher density and lower airflow resistance. The overall airflow resistance of the vehicle interior and exterior material is 3000 Ns / m. 3 above.

[0012] In another aspect, the vehicle interior and exterior material of the present invention includes: a first fiber material layer composed of a first fiber material containing resin; and a second fiber material layer located on one surface of the first fiber material layer and composed of a second fiber material containing resin, wherein the portion of the second fiber material layer on the side of the first fiber material layer further includes a resin-impregnated portion, the resin-impregnated portion being formed by impregnating the second fiber material with a low-melting-point resin having a melting point lower than that of the first fiber material and the resin of the second fiber material, the resin-impregnated portion having a higher density and lower air permeability compared to the portion of the second fiber material layer not impregnated with the low-melting-point resin, and a nonwoven fabric layer composed of a second resin having a melting point higher than that of the low-melting-point resin is further included between the first fiber material layer and the second fiber material layer, the overall air permeability of the vehicle interior and exterior material being 3000 Ns / m. 3 above.

[0013] The density of the second fiber material layer can be higher than that of the first fiber material layer.

[0014] The density of the resin-impregnated portion can be 500 kg / m³. 3 above.

[0015] The overall air resistance of the vehicle's interior and exterior materials can be 12500 Ns / m. 3 above.

[0016] The second fiber material of the second fiber material layer may include a regenerated fiber material containing resin.

[0017] The low-melting-point resin in the resin impregnation part can be polypropylene or polyethylene.

[0018] The first fiber material of the first fiber material layer and / or the second fiber material of the second fiber material layer may be materials containing polyethylene terephthalate.

[0019] The effects of the invention

[0020] Thus, according to the present invention, a resin impregnation layer is formed by impregnating a portion of the second fiber material layer with a low-melting-point resin whose melting point is lower than that of the first and second fiber materials, thereby providing a vehicle interior and exterior material that can be manufactured with a simple process, is easy to recycle, and has controllable air permeability. Attached Figure Description

[0021] Figure 1 This is a cross-sectional view schematically illustrating one embodiment of the vehicle interior and exterior materials of the present invention.

[0022] Figure 2 This is a flowchart illustrating an example of a method for manufacturing interior and exterior materials for vehicles according to the present invention.

[0023] Figure 3 This is a cross-sectional view schematically illustrating another embodiment of the vehicle interior and exterior materials of the present invention.

[0024] Figure 4 The image is obtained by observing a cross-section of the vehicle interior and exterior materials of the present invention using a microscope.

[0025] Figure 5 This is a graph showing the relationship between the unit area weight of nonwoven fabric used in vehicle interior and exterior materials and the air resistance of vehicle interior and exterior materials, which is the result of an experiment as an example. Detailed Implementation

[0026] In the following description, one embodiment of the vehicle interior and exterior materials of the present invention will be described with reference to the accompanying drawings.

[0027] like Figure 1As shown, the vehicle interior and exterior material 1 of this embodiment includes a first fiber material layer 10 and a second fiber material layer 20 located on one side of the first fiber material layer. The second fiber material layer 20 also includes a resin-impregnated portion 22 formed by impregnating a portion adjacent to the first fiber material layer 10 with a low-melting-point resin having a melting point lower than that of the resin constituting the first fiber material layer 10 and the second fiber material layer 20. Compared with the portion 21 of the second fiber material layer 20 that is not impregnated with low-melting-point resin, the resin-impregnated portion 22 has a higher density and lower air permeability. In addition, the overall air permeability of the vehicle interior and exterior material 1 is 3000 Ns / m. 3 above.

[0028] The first fiber material used for the first fiber material layer 10 can be any resin-based fiber material conventionally used in vehicle interior and exterior materials, without particular limitation. However, a resin with a high melting point is preferred. A single thermoplastic resin (such as polyethylene terephthalate (PET)) or a fiber material obtained by combining multiple thermoplastic resins can be used. From the perspectives of ease of processing, durability, and recyclability, PET is more preferred. The fiber material can be composed solely of PET, or it can contain PET as the main material. Furthermore, the fiber material may further contain commonly used additives such as colorants, antioxidants, and antistatic agents.

[0029] As the second fiber material used for the second fiber material layer 20, the same resin-based fiber material as the first fiber material layer 10 can be used. However, recycled fiber materials such as recycled PET fiber material can be used alone, or recycled fiber materials such as recycled PET fiber material can be used in combination with the aforementioned fiber materials. The first fiber material and the second fiber material can be fiber materials made of the same resin, or they can be fiber materials made of different resins.

[0030] The second fiber material layer 20 preferably has a higher density than the first fiber material layer 10. The specific density values ​​of the first fiber material layer 10 and the second fiber material layer 20 are not limited thereto; for example, the density of the first fiber material layer 10 is preferably a preform density of 20 kg / m³. 3 ~45 kg / m 3 Within the range, more preferably 25 kg / m 3 ~40 kg / m 3 Within the range. The density of the second fiber material layer 20 is preferably a preform density of 170 kg / m³. 3 ~260 kg / m 3 Within the range, more preferably 190 kg / m 3 ~240 kg / m 3Within this range. Thus, by making the density of the second fiber material layer 20 higher than that of the first fiber material layer 10, an advantage is gained in impregnating low-melting-point resins.

[0031] As the low-melting-point resin used for the resin impregnation portion 22 of the second fiber material layer 20, a resin having a melting point of 170°C or lower is preferred. Specifically, it is not limited to this, and thermoplastic resins such as polypropylene (PP) and polyethylene (PE) can be used, for example. Among these, PP and PE are more preferred from the perspective of melting point. The lower limit of the melting point of the low-melting-point resin is not particularly limited, for example, it can be 110°C or higher.

[0032] The resin-impregnated portion 22, by impregnating the second fiber material with the low-melting-point resin, has a higher density and lower air permeability compared to the portion 21 without low-melting-point resin impregnation. The density of the resin-impregnated portion 22 is not limited to this; for example, a density of 450 kg / m³ is preferred. 3 The above, more preferably 470 kg / m 3 The above is further preferred to be 500 kg / m 3 That's all. There is no particular upper limit to the density of the resin-impregnated portion 22; for example, it could be 800 kg / m³. 3 the following.

[0033] By changing the amount of low-melting-point resin impregnated in the resin impregnation section 22, the overall ventilation resistance of the vehicle interior and exterior trim 1 can be controlled. The overall ventilation resistance of the vehicle interior and exterior trim 1 is preferably 3000 Ns / m during ventilation. 3 Above and below 10000 Ns / m 3 On the other hand, when the indication is almost non-ventilated, 12500 Ns / m is more preferable. 3 That's all. There's no specific upper limit to the ventilation resistance at this point; it can also be 19990 Ns / m. 3 The method for impregnating the second fiber material with low-melting-point resin and the amount of low-melting-point resin are described in detail in the section on manufacturing methods of interior and exterior materials for vehicles.

[0034] In addition, by disposing the resin impregnation portion 22 on the side of the first fiber material layer 10, the first fiber material layer 10 and the second fiber material layer 20 can be firmly bonded together.

[0035] The vehicle interior and exterior material 1 with such a structure can be used, for example, as a dashboard sound insulation pad or a luggage insulator. When the vehicle interior and exterior material 1 is used as a dashboard sound insulation pad, the second fiber material layer 20 is installed on the interior side (i.e., the dashboard side). The first fiber material layer 10 is installed on the dashboard panel. Thus, by placing the second fiber material layer 20 on the interior side, for example, sound absorption of the interior can be achieved, eliminating reverberation within the vehicle and making sounds easier to hear.

[0036] Next, refer to Figure 2 An example of a method for manufacturing the vehicle interior and exterior materials of the present invention will be described. First, as... Figure 2 As shown in (a), a second sheet 21a made of a second fiber material and a nonwoven fabric 22a made of a low-melting-point resin are fed into a press 30 having a fixed lower heating plate 31 and an upper heating plate 32 that can move up and down, in an overlapping state. Furthermore, an anti-adhesion sheet 13 may be clamped between the nonwoven fabric 22a and the upper heating plate 32 to prevent the nonwoven fabric 22a from adhering to the upper heating plate 32. Teflon (registered trademark) sheets can be used as the anti-adhesion sheet 13.

[0037] Then, as Figure 2 As shown in (b), the second sheet 21a and the nonwoven fabric 22a are pressed and heated by an upper heating plate 32 and a lower heating plate 31 heated to a predetermined temperature, thereby melting the low-melting-point resin of the nonwoven fabric 22a and impregnating it with the second fiber material of the second sheet 21a. This yields a second fiber material sheet 20a having a resin-impregnated portion 22 obtained by impregnating the second fiber material with the low-melting-point resin and a portion 21 composed of the unimpregnated second fiber material.

[0038] Thus, the amount of low-melting-point resin in the resin impregnation section 22 is equivalent to the area weight per unit area of ​​the nonwoven fabric 22a composed of low-melting-point resin. The area weight per unit area of ​​the nonwoven fabric 22a is preferably less than 80 g / m² when it is breathable. 2 When set to non-ventilated, the preferred value is 80 g / m³. 2 The above is not the upper limit for the unit area weight of nonwoven fabric 22a; it can also be 120 g / m². 2 the following.

[0039] The temperature of the lower heating plate 31 and the upper heating plate 32 of the press 30 can be above the melting point of the low melting point resin and below the melting point of the second fiber material. The temperature will vary depending on the low melting point resin and the resin used for the second fiber material. For example, it can be set in the range of 190°C to 230°C.

[0040] On the other hand, such as Figure 2 As shown in (c), a first sheet 10a made of a first fibrous material is placed in a heating furnace 40 heated to a predetermined atmosphere temperature, or placed on a heating plate (such as the lower heating plate 31 of a press 30) heated to a predetermined temperature for heating. Furthermore, the atmosphere temperature of the heating furnace 40 is lower than the melting point of the resin of the first fibrous material, and is a temperature at which the first fibrous material can be molded; this varies depending on the resin used in the first fibrous material, and for example, it can be set to 200°C. When using a heating plate, the temperature is also lower than the melting point of the resin of the first fibrous material, and is a temperature at which the first fibrous material can be molded; this also varies depending on the resin used in the first fibrous material, and for example, it can be set to 200°C.

[0041] Next, as Figure 2 As shown in (d), the second fiber material sheet 20a is taken out from the press 30, and the first sheet 10a is taken out from the heating furnace 40. The second fiber material sheet 20a and the first sheet 10a, which are still warm, are overlapped with the resin impregnation portion 22 located on the side of the first sheet 10a, and then fed into the press 50. The press 50 is equipped with a molding die 51, the lower die 51a is fixed, and the upper die 51b, which is at room temperature, can move up and down. The molding die 51 can be molded, for example, into the shape of the aforementioned front sound insulation pad. At this time, the die (lower die 51a or upper die 51b) on the side of the first sheet 10a can be heated, and the temperature can be set to, for example, 140°C.

[0042] Additionally, when Teflon (registered trademark) sheets are used as anti-sticking sheets 13 in the press 30, such as Figure 2 As shown in (d), the anti-stick sheet 13 is peeled off from the second fiber material sheet 20a and fed into the press 50.

[0043] Then, as Figure 2 As shown in (e), by pressing and molding the first sheet 10a and the second fiber material sheet 20a with the lower mold 51a and the upper mold 52b, the second fiber material layer 20 is bonded to the first fiber material layer 10 via the resin impregnation part 22, thereby obtaining a vehicle interior and exterior material 1 shaped into a predetermined shape.

[0044] Furthermore, in the press machine 30, although the nonwoven fabric 22a is overlapped on the second sheet 21a, the second sheet 21a can also be overlapped on the nonwoven fabric 22a. Similarly, in the press machine 50, although the second fiber material sheet 20a is overlapped on the first sheet 10a, if the resin impregnation portion 22 is located on the side of the first sheet 10a, the first sheet 10a can also be overlapped on the second fiber material sheet 20a.

[0045] Furthermore, although the use of Teflon (registered trademark) sheet as anti-sticking sheet 13 has been described, the present invention is not limited thereto. As anti-sticking sheet 13, a nonwoven sheet made of a second resin different from the low-melting-point resin of nonwoven fabric 22a can also be used. As the second resin, a resin having a melting point that does not melt at the heating temperatures of press 30 and press 50 (described later) can be used; PET is an example of such a resin. Additionally, the nonwoven sheet made of the second resin is preferably set to a unit area weight that maintains air permeability even after pressing by press 30 and press 50; for example, it can be set to 5 g / m². 2 ~50 g / m 2 The range can also be set to 12 g / m³. 2 ~15 g / m 2 The range is defined as follows. As for nonwoven fabrics, spunbond nonwoven fabrics are preferred.

[0046] When using a nonwoven fabric made of the second resin as the anti-adhesion sheet 13, when the low-melting-point resin of the nonwoven fabric 22a melts under the action of the press 30, although the low-melting-point resin is also impregnated in the nonwoven fabric sheet made of the second resin, the air permeability of the nonwoven fabric sheet made of the second resin is maintained. Then, the second fiber material sheet 20a, which maintains the attached state of the anti-adhesion sheet 13, is fed into the press 50. In the press 50, the second fiber material sheet 20a is overlapped with the first sheet 10a and pressed with the anti-adhesion sheet 13 located on the side of the first sheet 10a. The low-melting-point resin impregnates the nonwoven fabric sheet made of the second resin, which serves as the anti-adhesion sheet 13, thereby enabling the first fiber material layer 10 to be bonded to the second fiber material layer 20.

[0047] Furthermore, regarding the fabrication of the second sheet 21a made of the second fiber material, when using a recycled fiber material as the second fiber material, the second fiber material can be placed on a nonwoven fabric made of a third resin, which is a different material from the second fiber material, and then a nonwoven fabric 22a made of a low-melting-point resin can be placed on top. The second fiber material is then sandwiched between the two nonwoven fabric sheets, and the sheet is heated and pressurized at a temperature lower than the melting temperature of the low-melting-point resin to obtain the final product. In this state, it can also be processed as follows... Figure 2As shown in (a), it is fed into the press 30. Alternatively, the second fiber material can be placed on a nonwoven fabric made of a third resin, which is a material different from the second fiber material, and then the same nonwoven fabric can be placed on top. This is obtained by heating and pressing while the second fiber material is sandwiched between two pieces of nonwoven fabric made of the third resin. When the second sheet 21a is obtained in the above manner, one piece of nonwoven fabric made of the third resin can be peeled off, and a nonwoven fabric made of a low-melting-point resin can be placed there. While retaining the other piece of nonwoven fabric made of the third resin, it can be processed as follows: Figure 2 As shown in (a), it is fed into the press 30.

[0048] Alternatively, the second fiber material can be placed first on a nonwoven fabric made of a third resin, which is a material different from the second fiber material. Then, a nonwoven fabric 22a made of a low-melting-point resin can be placed on top, followed by a nonwoven fabric sheet made of the second resin as an anti-sticking sheet 13. The second fiber material is sandwiched between the nonwoven fabric made of the third resin and the two overlapping nonwoven fabric sheets, and then heated and pressurized at a temperature lower than the melting temperature of the low-melting-point resin. In this state, it can also be done as follows... Figure 2 The material is fed into the press 30 as shown in (a). Alternatively, the method of overlapping the materials can be the reverse of the above. That is, the nonwoven fabric 22a made of low-melting-point resin, the second fiber material, and the nonwoven fabric made of third resin can be overlapped on the nonwoven fabric sheet made of the second resin and then heated and pressed.

[0049] As the third resin, a resin with a melting point that does not melt at the heating temperatures of presses 30 and 50 can be used; PET is an example of such a resin. Furthermore, the nonwoven fabric made of the third resin is preferably set to retain air permeability after pressing by presses 30 and 50, for example, at a unit area weight of 20 g / m². 2 ~40 g / m 2 The range is defined as follows. As for nonwoven fabrics, spunlace nonwoven fabrics are preferred.

[0050] exist Figure 3 The diagram shows a vehicle interior and exterior material 1A made using a nonwoven fabric sheet composed of a second resin as an anti-sticking sheet 13, and a second sheet 21a made of a nonwoven fabric composed of a third resin. Figure 3As shown, the vehicle interior and exterior material 1A includes: a first fiber material layer 10, a nonwoven fabric layer 13a made of a second resin located on one side of the first fiber material layer, a second fiber material layer 20 located on the other side of the nonwoven fabric layer 13a, and a nonwoven fabric layer 23 made of a third resin located on the side of the second fiber material layer 20 opposite to the nonwoven fabric layer 13a. The second fiber material layer 20 further includes a resin impregnation portion 22 adjacent to the nonwoven fabric layer 13a made of the second resin. The resin impregnation portion 22 is formed by impregnating a resin with a lower melting point than the resins constituting the first fiber material layer 10 and the second fiber material layer 20, as well as the second and third resins. The overall air resistance of this vehicle interior and exterior material 1A can also be set to 3000 Ns / m. 3 above.

[0051] Example

[0052] The present invention will be described below with reference to embodiments thereof, but the present invention is not limited to these embodiments.

[0053] A first sheet (28 mm thick, 900 g / m²) was prepared using the same PET fiber as both the first and second fiber materials. 2 ) and the second sheet (thickness 10 mm, weight per unit area 2260 g / m²) 2 Furthermore, a nonwoven fabric formed using PE / PP sheath-core bicomponent fiber (core: PP, sheath: PE) as a low-melting-point resin through a hot-air process is overlapped onto one side of a second sheet and heated and pressed at 190°C. This melts the PE / PP resin in the nonwoven fabric, resulting in a second fiber material sheet with a resin-impregnated portion formed by PE / PP resin impregnating PET fibers. The thickness of the second fiber material sheet is 6 mm.

[0054] Then, the second fiber material sheet is stacked on the first sheet, which has been heated in a furnace at an ambient temperature of 200°C, via a resin impregnation section. The sheet is then pressed using a room-temperature molding die to obtain a sample of vehicle interior and exterior trim material having a first fiber material layer and a second fiber material layer, wherein the second fiber material layer has a resin impregnation section. The sample thickness is 15 mm.

[0055] The obtained vehicle interior and exterior trim material samples were cut, and the cross-sections of the samples were observed using a microscope (KEYENCE VHX-8000 digital microscope). Images of the cross-sections are shown below. Figure 4 .like Figure 4As shown, the second fiber material layer 20 has: a resin-impregnated portion 22, which is formed by impregnating PET fibers with PE / PP resin melted into nonwoven fabric; and a portion 21 composed of a second fiber material that is not impregnated with PE / PP resin. The first fiber material layer 10 and the second fiber material layer 20 are firmly bonded, but the first fiber material layer 10 is almost completely impregnated with PE / PP resin.

[0056] In addition, for the obtained vehicle interior and exterior material samples, the air resistance was measured, and the samples were cut open to measure the height of the resin-impregnated portion from their cross-section. Then, based on the size and weight of the nonwoven fabric used, the area weight per unit area was calculated, and the density of the resin-impregnated portion was calculated based on the area weight per unit area of ​​the nonwoven fabric and the height of the resin-impregnated portion. The results of the total area weight per unit area of ​​the samples, the density of the resin-impregnated portion, and the air resistance (AFR) are shown in Table 1.

[0057] In addition, ventilation resistance was measured using a ventilation resistance measuring instrument (Norsonic, Flow resistivity analyzer type AFM80) according to Method B (also known as the AC method) of "Method for measuring ventilation resistance of air conditioning equipment" in "Air flow measuring instruments for air conditioning" as specified in ISO 9053:1991. The sample was clamped between the measuring container and the cap of the ventilation resistance measuring instrument, and the cap was locked. The stroke of the pressure regulating piston was set to 2.8 mm. Then, the motor of the ventilation resistance measuring instrument was started, causing the pressure regulating piston to operate, and the average value of the 2Hz sound pressure level at 1 / 3 octave band over a 10-second period was taken as the measured value of ventilation resistance (AFR). The unit of measurement is Ns / m. 3 Furthermore, the measuring container of the ventilation resistance measuring device has a diameter of 100 mm, and the sample size has a diameter of 120 mm or more. In this embodiment, the ventilation resistance was measured using the aforementioned "Method B," but measurements obtained using "Method A" (direct current method) based on ISO 9053:1991 can also be used. Given the order of magnitude of the AFR values ​​measured in this embodiment, there is virtually no difference between Method A and Method B.

[0058] Table 1

[0059] The samples prepared using any of the above-mentioned nonwoven fabrics per unit area weight all show that by impregnating PE / PP resin into PET fiber material, thereby increasing the density of the resin-impregnated part, the overall air resistance of the vehicle interior and exterior materials increases significantly to the point of almost no air permeability.

[0060] In addition, except for using nonwoven fabrics with PP / PE core-sheath type bicomponent fibers having the area weight shown in Table 2 below, vehicle interior and exterior material samples were prepared according to the same procedure as in Experiment 1 above, and the air resistance of these samples was measured. The results are shown in Table 2 and... Figure 4 As shown. Furthermore, in Figure 5 The document also shows the above-mentioned samples 1, 2, and 3 (nonwoven fabric with a unit area weight of 80 g / m²). 2 120 g / m 2 120 g / m 2 The measurement results.

[0061] Table 2

[0062] like Figure 5 As shown, it can be seen that by changing the unit area weight of the nonwoven fabric impregnated with low-melting-point resin, the overall ventilation resistance of vehicle interior and exterior materials can be controlled. Furthermore, it is known that the ventilation resistance fluctuates with the resin content of the PET fiber material. The higher the resin content of the PET fiber material, the higher the ventilation resistance; conversely, the lower the resin content, the lower the ventilation resistance.

[0063] The embodiments or examples of the present invention have been described above, but the present invention is not limited to these embodiments or examples. Various modifications and changes can be made within the scope of the claims.

[0064] In addition, the manufacturing method of the vehicle interior and exterior materials of the present invention can be described as follows [1] to [8].

[0065] [1] A method for manufacturing interior and exterior materials for vehicles, comprising: The process of heating a first sheet made of a first fibrous material containing resin; A process for obtaining a second fiber material sheet, wherein the second fiber material sheet includes a resin-impregnated portion and a portion composed of an unimpregnated second fiber material, the resin-impregnated portion being obtained by overlapping a second sheet composed of a resin-containing second fiber material with a nonwoven fabric containing a low-melting-point resin (lower than the melting point of the first fiber material and the resin of the second fiber material), and heating and pressing the nonwoven fabric, wherein the low-melting-point resin melts and impregnates the second fiber material of the second sheet; and The process of obtaining interior and exterior materials for vehicles involves overlapping and pressing a second fiber material sheet and a first sheet such that the resin impregnation portion is located on the side of the first sheet, such that a second fiber material layer made of the second fiber material and a first fiber material layer made of the first fiber material are bonded together via the resin impregnation portion to form the interior and exterior materials for vehicles.

[0066] [2] According to the manufacturing method of vehicle interior and exterior materials described in [1], the overall air resistance of the vehicle interior and exterior materials is 3000 Ns / m. 3 above.

[0067] [3] The method for manufacturing interior and exterior materials for vehicles according to [1] or [2], wherein the density of the second fiber material layer is higher than the density of the first fiber material layer.

[0068] [4] The method for manufacturing interior and exterior materials for vehicles according to [1] or [2], wherein the density of the resin-impregnated portion is 500 kg / m³. 3 above.

[0069] [5] According to the manufacturing method of vehicle interior and exterior materials as described in [1] or [2], wherein the overall air resistance of the vehicle interior and exterior materials is 12500 Ns / m. 3 above.

[0070] [6] The method for manufacturing interior and exterior materials for vehicles according to [1] or [2], wherein the second fiber material of the second fiber material layer comprises a regenerated fiber material containing resin.

[0071] [7] The method for manufacturing interior and exterior materials for vehicles according to [1] or [2], wherein the low-melting-point resin of the resin impregnation portion is polypropylene or polyethylene.

[0072] [8] The method of manufacturing interior and exterior materials for vehicles according to [1] or [2], wherein the first fiber material of the first fiber material layer and / or the second fiber material of the second fiber material layer comprises polyethylene terephthalate.

[0073] [9] The method for manufacturing interior and exterior materials for vehicles according to [1] or [2], wherein, The process of obtaining the second fiber material sheet includes: further overlapping a nonwoven fabric made of a second resin onto the nonwoven fabric made of the low-melting-point resin, and performing heat pressing, wherein the low-melting-point resin melts onto the nonwoven fabric made of the second resin, to obtain a second fiber material sheet comprising a nonwoven fabric made of the second resin impregnated with the low-melting-point resin. The process of obtaining the vehicle interior and exterior materials includes: overlapping and pressing a nonwoven fabric made of a second resin impregnated with the low-melting-point resin on the side of the first sheet to obtain a vehicle interior and exterior material formed by bonding a first fiber material layer made of the first fiber material and the resin impregnated portion through a nonwoven fabric made of a second resin impregnated with the low-melting-point resin.

[0074] Explanation of reference numerals in the attached figures

[0075] 1.1A: Interior and exterior materials for vehicles; 10: First fiber material layer; 13: Anti-sticking sheet; 13a: A nonwoven fabric layer composed of a second resin; 20: Second fiber material layer; 22: Resin-impregnated section; 23: A nonwoven fabric layer composed of a third resin; 30, 50: Pressing machine; 40: Heating furnace.

Claims

1. A vehicle interior and exterior trim material, comprising: The first fiber material layer is composed of a first fiber material containing resin; as well as The second fiber material layer, located on one surface of the first fiber material layer, is composed of a second fiber material containing resin. The second fiber material layer also includes a resin-impregnated portion adjacent to the first fiber material layer. This resin-impregnated portion is formed by impregnating the second fiber material with a low-melting-point resin (which has a melting point lower than both the first and second fiber materials). Compared to the portions of the second fiber material layer not impregnated with the low-melting-point resin, this resin-impregnated portion has a higher density and lower air permeability. The overall air resistance of the vehicle's interior and exterior materials is 3000 Ns / m. 3 above.

2. The vehicle interior and exterior materials according to claim 1, wherein, The density of the second fiber material layer is higher than that of the first fiber material layer.

3. The vehicle interior and exterior materials according to claim 1 or 2, wherein, The density of the resin-impregnated portion is 500 kg / m³. 3 above.

4. The vehicle interior and exterior materials according to claim 1 or 2, wherein, The overall air resistance of the vehicle's interior and exterior materials is 12500 Ns / m. 3 above.

5. The vehicle interior and exterior materials according to claim 1 or 2, wherein, The second fiber material of the second fiber material layer comprises a regenerated fiber material containing resin.

6. The vehicle interior and exterior materials according to claim 1 or 2, wherein, The low-melting-point resin in the resin impregnation part is polypropylene or polyethylene.

7. The vehicle interior and exterior materials according to claim 1 or 2, wherein, The first fiber material of the first fiber material layer and / or the second fiber material of the second fiber material layer contain polyethylene terephthalate.

8. A vehicle interior and exterior trim material, comprising: The first fiber material layer is composed of a first fiber material containing resin; as well as The second fiber material layer, located on one surface of the first fiber material layer, is composed of a second fiber material containing resin. The portion of the second fiber material layer on the side of the first fiber material layer also includes a resin-impregnated portion. This resin-impregnated portion is formed by impregnating the second fiber material with a low-melting-point resin (a resin with a melting point lower than both the first and second fiber materials). Compared to the portion of the second fiber material layer not impregnated with the low-melting-point resin, this resin-impregnated portion has a higher density and lower air permeability. Between the first fiber material layer and the second fiber material layer, there is also a nonwoven fabric layer composed of a second resin with a melting point higher than that of the low-melting-point resin. The overall air resistance of the vehicle's interior and exterior materials is 3000 Ns / m. 3 above.

9. The vehicle interior and exterior materials according to claim 8, wherein, The density of the second fiber material layer is higher than that of the first fiber material layer.

10. The vehicle interior and exterior trim materials according to claim 8 or 9, wherein, The density of the resin-impregnated portion is 500 kg / m³. 3 above.

11. The vehicle interior and exterior trim materials according to claim 8 or 9, wherein, The overall air resistance of the vehicle's interior and exterior materials is 12500 Ns / m. 3 above.

12. The vehicle interior and exterior trim materials according to claim 8 or 9, wherein, The second fiber material of the second fiber material layer comprises a regenerated fiber material containing resin.

13. The vehicle interior and exterior trim materials according to claim 8 or 9, wherein, The low-melting-point resin in the resin impregnation part is polypropylene or polyethylene.

14. The vehicle interior and exterior trim materials according to claim 8 or 9, wherein, The first fiber material of the first fiber material layer and / or the second fiber material of the second fiber material layer contain polyethylene terephthalate.

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