Interior material for vehicle and production method of the same, and emboss roll for the production method

Abstract

To provide an interior material for a vehicle having air permeability without providing open holes on the entire thickness of a composite sheet material, that is, having air permeability derived from a fiber cloth layer on a concavity of an uneven pattern, a production method of an interior material for a vehicle, and an emboss roll for emboss roll processing capable of forming the uneven pattern.SOLUTION: An interior material 1 for a vehicle has a concaved part 3 on a side of a fiber cloth layer 2-1 in a composite sheet material 2 in which the fiber cloth layer 2-1 is integrally laminated on a cushion layer 2-2, wherein the concaved part 3 is formed by processing the cushion layer 2-2 in a thickness direction of the composite sheet 2, and the concaved part 3 has air permeability derived from the fiber cloth layer 2-1 without providing open holes.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention mainly relates to an interior material for a vehicle in which an embossed pattern is formed on a composite sheet material used mainly for seats and doors, a method for manufacturing the interior material for a vehicle, and an embossing roll for the manufacturing method. In the specification of the present application, the embossed pattern and the uneven pattern are used in the same meaning.

Background Art

[0002] Conventionally, an interior material for a vehicle in which an embossed pattern is formed on a composite sheet is known. For example, a method for manufacturing a seat skin material is disclosed in which a surface material of a fibrous fabric such as a woven fabric, a knitted fabric, or a non-woven fabric and a soft polyurethane foam material are laminated and integrated, and an uneven pattern is formed on the laminated sheet by an embossing roll and a heat roll. Further, a method for manufacturing a seat skin material is known in which a fibrous base material such as a woven fabric, a knitted fabric, or a non-woven fabric is laminated and integrated on a surface material made of synthetic leather, and an uneven pattern is formed on the laminated sheet by an embossing roll (Patent Document 1).

[0003] On the other hand, when synthetic leather, natural leather, etc. are used particularly for the seat surface as an interior material for a vehicle, sweating causes stuffiness and stickiness. Therefore, there have been attempts to solve the stuffiness and stickiness by forming openings in the leather and improving the moisture permeability. For example, a sheet-like material including a fibrous base material, an inner layer and an outermost layer made of a polyurethane resin laminated on one side of the fibrous base material, having a plurality of openings on the surface, wherein the outermost layer is non-porous, the heat melting temperature of the outermost layer is higher than the softening temperature of the inner layer, and the opening includes an opening peripheral portion in which the outermost layer is inclined toward the opening center, is known (Patent Document 2).

[0004] In addition, perforation processing is performed to impart moisture permeability, breathability, and / or design properties. For example, an epidermis material including at least an epidermis layer is known, wherein the epidermis material has a plurality of through holes penetrating in the thickness direction, and at least one surface of the epidermis layer has a recess with a depth of 0.2 mm or more (Patent Document 3).

[0005] However, in the manufacturing method described in Patent Document 1, although the concavo-convex pattern can be deeply and clearly formed on the laminated sheet, since a soft polyurethane foam is usually laminated on the back side of the laminated sheet, even if the surface material is breathable, the air permeability of the laminated sheet is inferior to that of the surface material. This is because the soft polyurethane foam melts due to the flame during lamination to form a film, and this molten film adheres to the surface material, which is a factor inhibiting the air permeability of the laminated sheet.

[0006] Also, even if the sheet-like material described in Patent Document 2 has openings, for example, although it has sufficient abrasion resistance for use as a vehicle interior material, even if openings are provided only in the resin layer, it is difficult to handle and manufacture an exposed needle embossing roll, and there is also a problem that it is even more difficult to manufacture needle embossing rolls with various designs.

[0007] Moreover, the manufacturing method described in Patent Document 3 is to perform existing embossing in a separate process after opening through holes with existing technology. Since the surface temperature reaches 90°C or higher during embossing, the sheet-like skin material shrinks slightly thermally. Therefore, it is difficult for designs that require aligning the positions of the through holes and the concavo-convex pattern in a separate process, which may cause the occurrence of defective products such as pattern misalignment, and there is also a possibility that the pattern in the concave part becomes monotonous.

Prior Art Documents

Patent Documents

[0008]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0009] Thus, the air permeability of the composite sheet using the soft polyurethane foam is inferior to that of the surface material. Even if a fiber cushion material is used instead of the soft polyurethane foam, an adhesive layer such as a hot melt agent or binder fiber, or a fused surface of a low melting point fiber is formed. Therefore, even if a breathable fiber fabric is used for the skin layer, the sheet material including the soft polyurethane foam or fiber cushion layer cannot obtain sufficient air permeability. Even if there are openings or through holes in the skin layer, sufficient air permeability cannot be obtained for the same reason. In addition, when the skin layer is a fiber fabric layer, it is difficult to penetrate, so there is a risk of single fiber breakage in the fiber fabric layer, resulting in poor appearance.

[0010] In addition, from the perspective of improving comfort, the adoption of an air-conditioned seat that blows warm air or cold air from an air conditioner through a duct provided in a pad on the back side of the seat seating surface is increasing, and high air permeability is also required in the fiber fabric layer.

[0011] On the other hand, when embossing is performed to enhance the design and an uneven pattern is formed, since the skin layer and the cushion layer are heated and compressed, the air permeability of the heated and compressed concave portions is further impaired.

[0012] The present invention has been made in view of such a technical background, and provides an interior material for a vehicle having air permeability without providing through holes throughout the thickness of the composite sheet material, that is, having air permeability derived from the fiber fabric layer in the concave portions of the uneven pattern, a manufacturing method of the interior material for a vehicle, and an embossing roll for embossing that can form the uneven pattern.

Means for Solving the Problems

[0013] To achieve the above object, the present invention provides the following means.

[0014] [1] In a composite sheet material in which a fiber fabric layer is laminated and integrated with a cushion layer, having a concave portion on the side of the fiber fabric layer, The concave portion is formed by shaping the cushion layer in the thickness direction of the composite sheet material, The vehicle interior material is characterized in that the concave portion has air permeability derived from the fiber fabric layer without providing a through hole.

[0015] [2] A method for manufacturing a vehicle interior material in which an embossed pattern is formed on a composite sheet material in which a fiber fabric layer and a cushion layer are laminated and integrated by an embossing roll, including a heating and pressing step of heating and pressing the fiber fabric layer side, a plurality of die pressing portions project from the surface of the embossing roll, the top surface of the die pressing portion has a plurality of needle-like protrusions, A method for manufacturing a vehicle interior material, characterized in that the top surface of the protrusion is substantially flat.

[0016] [3] The method for manufacturing a vehicle interior material according to item 2 above, wherein the height of the protrusion from the top surface of the die pressing portion is in the range of 500 μm to 1,000 μm.

[0017] [4] An embossing roll for forming an embossed pattern on a composite sheet material in which a fiber fabric layer and a cushion layer are laminated and integrated, a plurality of die pressing portions project from the surface of the embossing roll, the top surface of the die pressing portion has a plurality of needle-like protrusions, An embossing roll, characterized in that the top surface of the protrusion is substantially flat. [Advantages of the Invention]

[0018] In the invention of [1], on the side of the fiber fabric layer of the composite sheet material, a concave portion is also formed in the cushion layer exceeding the fiber fabric layer in the thickness direction, and the concave portion has air permeability derived from the fiber fabric layer without providing a through hole, so that a vehicle interior material can be provided.

[0019] In the invention of [2], it is possible to provide a method for manufacturing an interior material for a vehicle including a heating and compression step using the embossing roll, which has air permeability without providing through-holes throughout the thickness of the composite sheet material, that is, it is possible to form an uneven pattern while suppressing a decrease in air permeability derived from the fiber fabric layer. In particular, in the conventional embossing process, it is possible to suppress a decrease in air permeability derived from the fiber fabric layer in the heated and compressed concave portions where air permeability decreases. More specifically, since a pattern of through-hole air is formed in the concave portion by a plurality of needle-like protrusions on the top surface of the embossing portion in the same step as the formation of the uneven pattern, the patterns of the uneven pattern and the through-hole air pattern can be matched, and a defect such as pattern misalignment does not occur. Note that in the present specification, "through-hole air" means that it does not penetrate through the composite sheet material.

[0020] In the invention of [3], since the molten film of the soft polyurethane foam between the fiber fabric layer and the cushion layer of the composite sheet material is sufficiently broken, a decrease in air permeability can be further suppressed. At this time, there is no risk of opening through-holes in the concave portions of the embossed pattern.

[0021] In the invention of [4], in the composite sheet material in which the fiber fabric layer and the cushion layer are laminated and integrated, air permeability is provided without providing through holes throughout the thickness of the composite sheet material, that is, while suppressing a decrease in air permeability derived from the fiber fabric layer, an embossing roll for embossing can be provided that can impart the uneven pattern. More specifically, the plurality of needle-like protrusions on the top surface of the mold pressing portion on the surface of the embossing roll cause repulsion between the thickness of the composite sheet material and the cushion layer during embossing by the embossing roll, so that the molten film of the soft polyurethane foam between the fiber fabric layer and the cushion layer is broken without penetrating the composite sheet material. Therefore, it becomes an embossing roll that can impart an uneven pattern while suppressing a decrease in air permeability derived from the fiber fabric layer. In addition, a pattern similar to a through hole can be imparted to the concave portion of the embossed pattern, and since the tip of the protrusion is substantially flat on the top surface, the composite sheet material is not penetrated, so there is no possibility of a defect due to breakage of a single fiber of the fiber fabric layer. Further, since the area for heating and compressing the fiber fabric layer is reduced, a decrease in air permeability can also be suppressed.

Brief Description of the Drawings

[0022]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Embodiments for Carrying Out the Invention

[0023] Next, an embodiment of an interior material for a vehicle, a method for manufacturing the interior material for a vehicle, and an embossing roll according to the present invention will be described with reference to the drawings.

[0024] As shown in FIG. 1, an interior material 1 for a vehicle according to the present invention is a composite sheet material 2 in which a fiber fabric layer 2-1 is laminated and integrated with a cushion layer 2-2. The fiber fabric layer 2-1 has a concave portion 3 on its side. The concave portion 3 is formed by shaping the cushion layer 2-2 in the thickness direction of the composite sheet material 2. The concave portion 3 is characterized by having air permeability derived from the fiber fabric layer 2-1 without providing a through-hole. Note that the concave portion 3 and the convex portion 4 are included in an uneven pattern. More specifically, the convex portion 4 is a non-embossed portion. Also, the state of air permeability is not shown in the drawings.

[0025] By adopting this configuration, a concave portion 3 is also formed in the cushion layer 2-2 beyond the fiber fabric layer 2-1 in the thickness direction on the side of the fiber fabric layer 2-1 of the composite sheet material 2. The concave portion 3 can provide an interior material 1 for a vehicle having air permeability derived from the fiber fabric layer 2-1. The state of having air permeability derived from the fiber fabric layer 2-1 is preferably such that the fiber and / or the material of the cushion layer 2-2 is not formed into a film at the portion of the concave portion 3, and although it does not penetrate through, it preferably has holes in the form of through-hole air. (See FIG. 7)

[0026] The fiber fabric layer 2-1 is not particularly limited, and examples thereof include woven fabrics, knitted fabrics, and non-woven fabrics. The fibers constituting the fiber fabric layer 2-1 include synthetic fibers such as polyester fibers, polyamide fibers, and polyacrylonitrile fibers, cotton, rayon fibers, and the like. These may be appropriately combined. The thickness of the fiber fabric 2-1 is not particularly limited, but for the use as an interior material for vehicles, a range of 0.6 mm to 0.9 mm is generally preferable.

[0027] Since the fiber fabric layer 2-1 is literally made of fibers, for example, unlike a typical resin film, there are gaps between the fibers, so it has air permeability. In this specification, the air permeability derived from the fiber fabric layer 2-1 refers to the air permeability caused by the gaps between the fibers, and is used to distinguish it from the air permeability of through-holes by punching or the like in the prior art.

[0028] The cushion layer 2-2 can select the density, hardness, and thickness within a range where the cushioning property is good, so a soft urethane foam is preferable. Specifically, the density is in the range of 15 Kg / m 3 ~45 Kg / m 3 The hardness is in the range of 60 N / cm 2 ~180 N / cm 2 The thickness is preferably in the range of 1 mm to 10 mm. In addition, a material in which a knitted fabric (= backing fabric) is laminated on the back surface of the soft urethane foam is preferable because it has excellent processability in the manufacturing process of the vehicle interior material 1 and the workability when cutting the vehicle interior material 1 is improved. As the backing fabric, a normally coarse circular knitted fabric or warp knitted fabric is used, so it does not have an adverse effect on air permeability.

[0029] As shown in Fig. 2, the composite sheet material 2 is formed by laminating and integrating a fiber fabric layer 2-1 and a cushion layer 2-2. The method of laminating and integrating the fiber fabric layer 2-1 and the cushion layer 2-2 is not particularly limited, and examples include methods using an adhesive and methods using a frame lamination method. Among them, from the viewpoints of the strength of delamination between layers, productivity, etc., the frame lamination method is more preferable, and the integration strength of the fiber fabric layer 2-1 and the cushion layer 2-2 in a state where an embossed pattern is formed can be further improved. In any method, a molten film 2-3 is formed between the fiber fabric layer 2-1 and the cushion layer 2-2. In the former case, the adhesive is solidified by drying or heating to form a layer or film. In the latter case, the urethane of the soft urethane foam is melted by the frame lamination method and then becomes a layer or film. In the present specification, both the adhesive layer and the layer or film after melting of the soft urethane foam are all referred to as molten films.

[0030] Next, a method for manufacturing the vehicle interior material 1 according to the present invention will be described. The method for manufacturing the vehicle interior material 1 is a method for manufacturing a vehicle interior material in which an embossed pattern is formed on a composite sheet material 2 in which a fiber fabric layer 2-1 and a cushion layer 2-2 are laminated and integrated by an embossing roll 5, and includes a heating and pressing step of heating and pressing the fiber fabric layer 2-1 side. A plurality of die pressing portions 6 project from the surface of the embossing roll 5, the top surface 7 of the die pressing portion 6 has a plurality of needle-like protrusions 8, and the top surface 9 of the protrusion 8 is substantially flat.

[0031] According to this method, it is possible to provide a method for manufacturing the vehicle interior material 1 including a heating and compression step by the embossing roll 5 that can form an uneven pattern while suppressing a decrease in air permeability without providing through holes throughout the thickness of the composite sheet material 2, that is, while suppressing a decrease in air permeability derived from the fiber fabric layer 2-1. Note that the uneven pattern includes a concave portion 3 and a convex portion 4. The convex portion 4 is a non-embossed portion. That is, it is a portion that is not heated and pressed by the die pressing portion 6 of the embossing roll 5 and does not contact the surface of the embossing roll 5.

[0032] In particular, in the conventional embossing process, it is possible to suppress a decrease in air permeability derived from the fiber fabric layer 2-1 of the heated and compressed recess 5 where air permeability decreases. More specifically, due to the thickness of the composite sheet material 2 and the resilience of the cushion layer 2-2 during heating and compression, the molten film 2-3 of the soft polyurethane foam between the fiber fabric layer 2-1 and the cushion layer 2-2 is destroyed even before penetrating the composite sheet material 2. Therefore, it is possible to manufacture the vehicle interior material 1 in which a decrease in air permeability derived from the fiber fabric layer 2-1 is suppressed.

[0033] Furthermore, since the plurality of needle-shaped protrusions 8 have the top surface 9 and thus do not press beyond the thickness of the composite sheet material 2, no through holes (for example, FIG. 8) are formed in the composite sheet material 2, no single fiber breakage (for example, FIG. 9) occurs in the fiber fabric layer 2-1, and there is no strength reduction. On the contrary, if the plurality of needle-shaped protrusions 8 have no top surface 9 and are, for example, protrusions with sharp tips, when hitting the backup roll 10 during the embossing process, the surface of the backup roll 10 will be damaged.

[0034] In addition, since the pattern of through holes in the recess 3 is formed at the same time as the shaping of the uneven pattern by the plurality of needle-shaped protrusions 8 on the top surface 7 of the die pressing portion 6, the pattern of the uneven pattern and the pattern of the through hole pattern can be aligned, and no defect such as pattern misalignment occurs.

[0035] The interior material 1 for a vehicle according to the present invention is formed, for example, by using an embossing roll 5 having a mold pressing portion 6 shown in FIGS. 4 and / or 5 by an embossing device shown in FIG. 3 to impart an embossed pattern to a composite sheet material 2. Between a rotatably provided embossing roll 5 and a backup roll 10 rotatably provided facing the embossing roll 5, the composite sheet material 2 is supplied, and the fiber fabric layer 2-1 is passed with the embossing roll 5 side facing, and the supplied composite sheet material 2 is heated and pressed between the embossing roll 5 and the backup roll 10, thereby forming an embossed pattern, that is, forming a concave portion 3 on the side of the fiber fabric layer 2-1. Although not shown in FIG. 3, the mold pressing portion 6 and the like protruding from the surface of the embossing roll 5 that sandwiches the composite sheet material 2 in the embossing device are schematically shown in the enlarged view of the surface of the embossing roll 5, together with the protrusions 8.

[0036] Although not shown in FIG. 3, the embossing roll 5 and the backup roll 10 each include a heating means. In the heating and pressing step, the temperature range of the embossing roll 5 is preferably from 160°C to 210°C, and the temperature range of the backup roll 10 is preferably from 160°C to 235°C. If the temperature of the embossing roll 5 is lower than 160°C, the formation of the embossed pattern may be weak. If the temperature of the embossing roll 5 is higher than 210°C, sharp concave portions 3 may be generated in the fiber fabric layer 2-1, which is not preferable. If the temperature of the backup roll 10 is lower than 160°C, it may be difficult to sufficiently form the cushion layer 2-2. If the temperature of the backup roll 10 is higher than 235°C, the knitted fabric laminated on the back surface of the cushion layer 2-2 may melt and adhere to the backup roll 10, which is not preferable.

[0037] The surfaces of the embossing roll 5 and the backup roll 10 are made of metal and have good thermal conductivity, so the material is preferably carbon steel, S25C or S45C. If the surface of the backup roll 10 is made of rubber, which is an elastic body for example, although air permeability can be imparted, it is difficult to form an embossed pattern, and this is particularly prominent in the case of the composite sheet 2 having the cushion layer 2-2 laminated on the back surface, which is not preferable.

[0038] Also, the pressure between the embossing roll 5 and the backup roll 10 is in the range of 2 to 60 kg / cm 2 Under the condition range, the passing speed of the composite sheet material 2 is preferably in the range of 0.1 m / min to 5 m / min. By setting it within this range, it is preferable because the pattern matching of the concavo-convex pattern and the through-hole ventilation pattern becomes more stable. As a result, the vehicle interior material 1 with further suppressed reduction in air permeability derived from the fiber fabric layer 2-1 can be obtained. That is, it is easy to ensure air permeability.

[0039] The height d from the top surface 4 of the embossing portion 3 of the protrusion 5 is preferably in the range of 500 μm to 1,000 μm.

[0040] By adopting this configuration, since the molten film 2-3 of the soft polyurethane foam between the fiber fabric layer 2-1 and the cushion layer 2-2 of the composite sheet material 2 is sufficiently broken, it is possible to further suppress the reduction in air permeability without opening through-holes in the composite sheet material 2. When the height d is less than 500 μm, the entire fiber fabric layer 2-1 will be heated and compressed, resulting in poor air permeability derived from the fiber fabric layer 2-1, so it is not preferable. When it exceeds 1,000 μm, the protrusion 8 may be damaged during heating and compression, which is not preferable in terms of the production time of the embossing roll and the workability during production. Also, since the thickness of the fiber fabric layer 2-1 used for the vehicle interior material 1 is often about 0.6 mm to 0.9 mm, it is more preferably in the range of 600 μm to 900 μm.

[0041] An embossing roll 5 for imparting an embossed pattern to a composite sheet material 2 in which a fiber fabric layer 2-1 and a cushion layer 2-2 according to the present invention are laminated and integrated, wherein a plurality of embossing portions 6 project from the surface of the embossing roll 5, the top surface 7 of the embossing portion 6 has a plurality of needle-like protrusions 8, and the top surface 9 of the protrusion 8 is substantially flat.

[0042] By adopting this configuration, it is possible to provide an embossing roll for embossing that has air permeability without providing through-holes throughout the thickness of the composite sheet material, that is, it is possible to emboss the concavo-convex pattern while suppressing a decrease in air permeability derived from the fiber fabric layer.

[0043] For example, as shown in FIG. 3, by passing the composite sheet material 2 between the embossing roll 5 and the backup roll 10 facing the embossing roll 5, an embossing pattern is formed from the fiber fabric layer 2-1 side of the composite sheet material 2. A plurality of mold pressing portions 6 project from the surface of the embossing roll 5, and a pattern according to the contour shape of the top surface 7 of the mold pressing portion 6 is formed as a concave portion 3 of the embossing pattern on the fiber fabric layer 2-1 side of the composite sheet material 2. More specifically, as shown in FIG. 3, the top surface 7 of the mold pressing portion 6 has a plurality of needle-like protrusions 8. Since there is a reaction between the thickness of the composite sheet material 2 and the cushion layer 2-2 during embossing, the molten film 2-3 of the soft polyurethane foam between the fiber fabric layer 2-1 and the cushion layer 2-2 is broken without even penetrating the composite sheet material 2. Thus, it becomes an embossing roll 5 that can emboss the concavo-convex pattern while suppressing a decrease in air permeability derived from the fiber fabric layer 2-1. Also, since there are a plurality of needle-like protrusions 8 on the top surface 7 of the mold pressing portion 6, the area for heating and compressing the fiber fabric layer 2-1 by the top surface 7 of the mold pressing portion 6 is reduced, so a decrease in air permeability can also be suppressed.

[0044] In addition, a pattern like a through-hole wind can be imparted to the concave portion 3 of the embossing pattern, and since the tip of the protrusion 8 is substantially flat on the top surface 9, the composite sheet material 2 is not penetrated, so there is no risk of problems due to breakage of single fibers in the fiber fabric layer 2-1. In particular, the fiber fabric layer 2-1 used as the vehicle interior material 1 is mainly made by weaving and knitting polyester long fibers at a relatively high density. If filament breakage (single fiber breakage) occurs in the polyester long fibers, fuzzing occurs, which may deteriorate the appearance and have an adverse effect on the strength of the fabric.

[0045] The top surface 7 is the outer surface of the embossing portion 6 protruding from the surface of the embossing roll 5, and presses the composite sheet material 2 from the side of the fiber fabric layer 2-1. The contour shape of the top surface 7 is not particularly limited and may be appropriately determined according to the design of the concavo-convex pattern formed on the composite sheet material 2. For example, polygons such as triangles, quadrilaterals, rhombuses, pentagons, and circles can be mentioned.

[0046] The protrusion 8 is provided on the top surface 7 of the embossing portion 6, is needle-shaped, and has a narrow tip and a substantially flat top surface 9. The area of the top surface 9 is 2,500 μm 2 ~1,000,000 μm 2 within a preferable range. By setting it within this range, the cross-sectional shape of the protrusion 8 in the longitudinal direction is not particularly limited, and for example, those having the cross-sectional shapes shown in FIGS. 4 and 5 can be mentioned. That is, FIG. 4 shows the embossing portion 6 having the protrusion 8 with a trapezoidal cross-sectional shape on the top surface 7.

[0047] In addition, the protrusion 8 preferably has a stepped difference up to the tip. By having the stepped difference, the molten film 2-3 can be more reliably broken, so that a further decrease in air permeability can be suppressed. Even if the fiber fabric layer 2-1 has a hairy or bristly state due to this step, the fibers can surely open the holes for through-hole ventilation without being covered by wear, so that a decrease in air permeability can be suppressed and a pattern of through-hole ventilation can be imparted. On the other hand, if there is no such step, the holes for through-hole ventilation once opened in the concave portion 3 of the fiber fabric layer 2-1 may be closed and become smaller, which is not preferable.

[0048] Figure 5 shows an embossing portion 6 having projections 8 on the top surface 7 with a cross-sectional shape in the longitudinal direction being a quadrangle stacked in three layers, and the size of the quadrangle gradually decreasing in order from the top surface 7. Note that the number of steps is preferably in the range of two to five steps. By setting it within this range, it is easier to ensure air permeability without excessively compressing the material of the fiber fabric layer 2-1. Also, the height (= distance) of the step is preferably in the range of 50 μm to 100 μm. By setting it within this range, without heating and compressing the fiber fabric layer 2-1 more than necessary, the pattern of through-hole ventilation by the projections 8 and the concave portions 3 of the embossed pattern of the composite sheet material 2 can be formed together. Also, the plurality of steps may be concentric with the projections 8 or may be offset. Note that a bank may be provided at the edge of the top surface 7 of the embossing portion 6, and the bank is preferably about the same height as the height of the needle-like projections 8. The bank is a line having a top surface in plan view, and may be provided at all or a part of the edge of the top surface 7. Thus, the boundary of the concave portion 3 corresponding to the bank can form a more emphasized and embossed concavo-convex pattern.

[0049] In FIG. 5, an example of a quadrangle stacked in three layers is shown as the cross-sectional shape in the longitudinal direction of the projection 8, but stacking in two to five layers is preferable. In addition to the quadrangle, trapezoids may be stacked in the same manner. Also, the area of the top surface 9 is preferably in the range of 10,000 μm 2 to 500,000 μm 2 . By setting it within this range, a concave portion 3 having air permeability can be formed to form a pattern of through-hole ventilation. If it is less than 10,000 μm 2 , although it has air permeability, the formation of the concave portion 3 becomes weak, and if it exceeds 500,000 μm 2 , the concave portion 3 can be formed but the air permeability cannot be maintained.

[0050] In the present specification, the distance from the center of the protrusion 8 to the center of another adjacent protrusion 8 is represented as the mutual distance L, and L preferably ranges from 500 μm to 1,000 μm. FIG. 6(1) shows an example where the shape of the cross-section parallel to the top surface 7 of the protrusion 8 is a quadrilateral, and FIG. 6(2) shows an example of a circular shape. In FIGS. 6(1) and 6(2), for example, 20 needle-shaped protrusions 8 are neatly arranged on the top surface 7 of the embossing portion 6 of FIG. 4, and the mutual distances L from the other protrusions 8 arranged around the protrusion 8 are of three types, L1, L2, and L3, showing an embodiment of the embossing portion 6, and all the mutual distances L are within the above-mentioned range. When the mutual distance L is less than 500 μm, although the concavo-convex pattern can be formed, there is a risk that sufficient air permeability cannot be ensured and the strength of the vehicle interior material 1 may be adversely affected. Conversely, when it exceeds 1,000 μm, sufficient air permeability can be obtained, but there is a risk that a sufficient concavo-convex pattern cannot be formed.

[0051] In FIG. 6, an example is shown where the needle-shaped protrusions 8 are neatly arranged in 5 rows and 4 columns, but they may be arranged in a plurality of concentric circles or the like. Further, the cross-sectional shape of the protrusion 8 parallel to the top surface 7 is not particularly limited, and examples include polygons such as triangles, quadrilaterals, rhombuses, pentagons, and circles.

[0052] Also, the heights of the plurality of embossing portions 6 of the embossing roll 5 are preferably the same height of 1 mm or more. By setting it within this range, similar recesses 3 are easily formed. When the height of the embossing portion 6 is less than 1 mm, it is too small compared to the thickness of the composite sheet material 2, so it is difficult to say that a sufficient embossed pattern can be formed. Further, since there is a possibility that the surface portion of the embossing roll 5 other than the embossing portion 6 may come into contact with the fiber fabric layer 2-1 during heating and pressing, it may have an adverse effect such as hardening or discoloration of the fiber fabric layer 2-1, which is not preferable. The height of the embossing portion 6 is more preferably in the range of 3.0 mm to 12.0 mm.

Example

[0053] Next, specific embodiments of the present invention will be described, but the present invention is not particularly limited to these embodiments. Table 1 shows the specifications of the embossing roll and the like used in each example and comparative example, as well as the set temperature conditions and the like, and Table 2 shows each test result and comprehensive evaluation.

[0054] <Materials Used> Fiber fabric layer A: A woven fabric made of polyester fibers (thickness 1.0 mm) Fiber fabric layer B: A knitted fabric made of polyester fibers (thickness 0.8 mm) Cushion layer: Soft urethane foam (density 20 Kg / m 3 , thickness 5 mm, manufactured by Inoac Corporation, product name EL67) Backing fabric of the cushion layer: Circular knitted fabric (made of polyester fibers, basis weight 40 g / m 2 ) Composite sheet material A: A composite sheet material using fiber fabric layer A (total thickness 6.0 mm) Composite sheet material B: A composite sheet material using fiber fabric layer B (total thickness 5.8 mm)

[0055] <Rolls of the Embossing Apparatus> Embossing roll: Shows each specification regarding the protrusions of the embossing part (the top surface of the protrusions: substantially flat). (See Table 1) Backup roll: Two types, a steel roll (smooth surface) and a roll surface made of an elastomer (elastic roll with hardness A70)

[0056] <Example 1> Using an embossing apparatus equipped with a heating means, the composite sheet material A using fiber fabric layer A was heated and pressed by the embossing roll described in Table 1 to form an embossed pattern. That is, the passing speed of the composite sheet material A was set to 2 m / min so that the surface of the fiber fabric layer A of the composite sheet material faced the embossing roll side, and the composite sheet material was heated and pressed at a pressure of 50 Kg / cm 2 between the embossing roll (surface temperature: 190 °C) and the steel backup roll (surface temperature: 230 °C). Thus, an interior material for a vehicle with an embossed pattern formed on the composite sheet material A was obtained.

[0057] <Example 2> In Example 1, instead of the fiber fabric layer A, a fiber fabric layer B of a knitted fabric for a highly breathable air supply sheet was used, the embossing roll described in Table 1 was used, the surface temperature of the embossing roll was changed from 190°C to 200°C, and the surface temperature of the steel backup roll was changed from 230°C to 210°C. Then, heating and pressing were performed in the same manner as in Example 1. Thus, an interior material for a vehicle with an embossed pattern formed on the composite sheet material B was obtained.

[0058] <Example 3> In Example 1, heating and pressing were performed in the same manner as in Example 1, except that the embossing roll described in Table 1 was used. Thus, an interior material for a vehicle with an embossed pattern formed on the composite sheet material A was obtained.

[0059] <Example 4> In Example 1, heating and pressing were performed in the same manner as in Example 1, except that the embossing roll described in Table 1 was used. Thus, an interior material for a vehicle with an embossed pattern formed on the composite sheet material A was obtained.

[0060] <Example 5> In Example 1, except that two embankments with the same height as the height of the protrusions were provided at the edges of the embossing part of the embossing roll used in Example 1 (two sides perpendicular to the rotation direction of the roll, in the form of thin lines), heating and pressing were performed in the same manner as in Example 1. Thus, an interior material for a vehicle with an embossed pattern formed on the composite sheet material A was obtained. (See Figure 7) Note that Figure 7 shows a photograph in which the thin lines on the left and right of the through-hole ventilation pattern were formed by the above-mentioned embankments.

[0061] <Comparative Example 1> In Example 1, heating and pressing were performed in the same manner as in Example 1, except that an embossing roll with only an embossing part of the prior art without needle-like protrusions was used, and the surface temperature of the embossing roll was changed from 190°C to 200°C. Thus, an interior material for a vehicle with an embossed pattern formed on the composite sheet material A was obtained.

[0062] <Comparative Example 2> In Example 2, using only the embossing roll of the prior art type pressing part without needle-like projections on the type pressing part, the surface temperature of the embossing roll was changed from 200 °C to 190 °C, and the surface temperature of the backup roll made of steel was changed from 230 °C to 210 °C, and heating and pressing were performed in the same manner as in Example 2. Thus, an interior material for a vehicle with an embossed pattern formed on the composite sheet material B was obtained.

[0063] <Comparative Example 3> In Example 1, heating and pressing were performed in the same manner as in Example 1, except that an elastic body (elastic roll with a hardness of A70) was used for the roll surface instead of the steel roll (smooth surface), and the surface temperature of the elastic roll was changed from 230 °C to room temperature (18 °C). Thus, an interior material for a vehicle with an embossed pattern formed on the composite sheet material A was obtained.

[0064] <Comparative Example 4> In Example 1, heating and pressing were performed in the same manner as in Example 1, except that the embossing roll described in Table 1 was used and the surface temperature of the backup roll made of steel was changed from 230 °C to 210 °C. Thus, an interior material for a vehicle with an embossed pattern formed on the composite sheet material A was obtained.

[0065] <Comparative Example 5> In Example 1, heating and pressing were performed in the same manner as in Example 1, except that the embossing roll described in Table 1 was used. Thus, an interior material for a vehicle with an embossed pattern formed on the composite sheet material A was obtained.

[0066] <Comparative Example 6> In Example 1, heating and pressing were performed in the same manner as in Example 1, except that the embossing roll described in Table 1 was used and the surface temperature of the embossing roll was changed from 190 °C to 180 °C. Thus, an interior material for a vehicle with an embossed pattern formed on the composite sheet material A was obtained.

[0067] <Comparative Example 7> In Example 1, except that the embossing roll described in Table 1 was used and the surface temperature of the embossing roll was changed from 190°C to 200°C, heat pressing was performed in the same manner as in Example 1. Thus, an interior material for a vehicle with an embossed pattern formed on the composite sheet material A was obtained.

[0068]

Table 1

[0069] <Air permeability test> The air permeability was measured with a frigid tester conforming to JIS-L-1096 8.26.A method, and the percentage of air permeability was calculated by the following formula to evaluate the air permeability derived from the fiber fabric layer in the recess. Since the air permeability varies depending on the fiber fabric, focusing on the degree derived from the fiber fabric layer, a percentage of the air permeability of the fiber fabric layer in the recess of 40% or more was regarded as passing and indicated by "〇". Percentage of air permeability (%) = 100 × (Air permeability of embossed recess / Air permeability of embossed protrusion (non-embossed part))

[0070] <Thickness change test> The thickness of the composite sheet material before embossing and the thickness of the recess after embossing were measured using a microscope (HOZAN L-KIT581), respectively, and the thickness change rate (%) was calculated by the following formula. Regarding the recess formed on the surface by embossing, a thickness change rate of 30% or more that allows sufficient recognition of the large uneven pattern was regarded as passing and indicated by "〇". Thickness change rate (%) = 100 × ((Thickness before embossing - Thickness after embossing) / Thickness before embossing))

[0071] <Visual inspection> Observation was performed using a microscope (HOZAN L-KIT581), and the state of single fiber breakage in the recess of the embossed pattern on the surface was observed. The state of single fiber breakage was evaluated according to the following criteria. (Criteria for judgment) "None": No single fiber breakage is observed. "Yes": Single fiber breakage is observed.

[0072]

Table 2

[0073] The interior materials for vehicles of Examples 1 to 4 had large concave and convex patterns extending deeply to the cushion layer beyond the fiber fabric layer on the front side in the thickness direction. The concave portions also had breathability derived from the fiber fabric layer and had a through-hole ventilation pattern. Thus, they were excellent both in terms of design and function. That is, they could achieve both an excellent concave and convex pattern in terms of design and breathability. Furthermore, the interior material for a vehicle of Example 5 had a more effective wrinkling effect at the boundaries of the concave portions and also contributed to preventing damage to the protrusions of the embossing portion of the embossing roll.

[0074] On the other hand, in Comparative Examples 1 to 7, although deep concave and convex patterns extending to the cushion layer beyond the fiber fabric layer on the front side in the thickness direction could be formed, the breathability deteriorated, or conversely, even though there was breathability, the formation of the concave and convex patterns was insufficient. There were pros and cons, and they failed in the comprehensive evaluation. Furthermore, in Comparative Example 3, since the backup roll was an elastic roll, through-holes (see FIG. 8) penetrating to the back surface of the composite sheet were formed, so there was breathability, but since the cushion layer could not be heated, the formation of the concave and convex patterns was insufficient, and moreover, breakage of single fibers in the fiber fabric layer occurred. (See FIG. 9)

[0075] The interior material for a vehicle, its manufacturing method, and the embossing roll according to the present invention are suitable for interior materials for vehicles.

Explanation of Reference Numerals

[0076] 1 ··· Interior material for vehicle 2 ··· Composite sheet material 2-1 ··· Fiber fabric layer 2-2 ··· Cushion layer 2-3 ··· Melted film 3 ··· Concave portion 4 ··· Convex portion (non-embossed portion) 5 ··· Embossing roll 6 ··· Embossing portion 7 ··· Top surface 8 ··· Protrusion 9 ··· Top surface 10 ··· Backup roll d ··· Height L ··· Mutual distance

Claims

1. In a composite sheet material in which a fiber fabric layer is laminated and integrated with a cushion layer, it has a recess on the side of the fiber fabric layer, the recess is formed by shaping the cushion layer in the thickness direction of the composite sheet material, An interior material for a vehicle, characterized in that the recess has air permeability derived from the fiber fabric layer without providing a through hole.

2. A method for manufacturing an interior material for a vehicle in which an embossed pattern is formed on a composite sheet material in which a fiber fabric layer and a cushion layer are laminated and integrated by an embossing roll, including a heating and pressing step of heating and pressing the fiber fabric layer side, a plurality of die pressing portions project from the surface of the embossing roll, the top surface of the die pressing portion has a plurality of needle-like protrusions, A method for manufacturing an interior material for a vehicle, characterized in that the top surface of the protrusion is substantially flat.

3. The method for manufacturing an interior material for a vehicle according to claim 2, wherein the height of the protrusion from the top surface of the die pressing portion is in the range of 500 μm to 1,000 μm.

4. An embossing roll for forming an embossed pattern on a composite sheet material in which a fiber fabric layer and a cushion layer are laminated and integrated, a plurality of die pressing portions project from the surface of the embossing roll, the top surface of the die pressing portion has a plurality of needle-like protrusions, An embossing roll, characterized in that the top surface of the protrusion is substantially flat.

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