Interior surface material

Abstract

To provide an interior material for automobiles excellent in heat shielding property.SOLUTION: Even if it is a surface material for interiors that contains inorganic particles applied to a non-woven fabric sheet as in conventional technologies, it has been found that excellent heat insulation properties can be achieved in automotive interior materials by adjusting the range of the inorganic particles present within the non-woven fabric. The surface material for interiors according to the present invention is an interior surface material that includes near-infrared scattering or near-infrared absorbing inorganic particles in the non-woven fabric, characterized in that the inorganic particles are present only within a range of less than 21% of the thickness in the non-woven fabric from one principal surface to the other principal surface.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to an interior surface material having excellent heat insulation properties.

Background Art

[0002] Conventionally, interior surface materials such as ceiling materials are required to exhibit various performances in addition to their design properties and tactile sensations. For example, Japanese Patent Application Laid-Open No. 2009-119711 (Patent Document 1) discloses an interior material for automobiles provided with a heat insulation layer composed of inorganic particles having near-infrared scattering properties or near-infrared absorbing properties, and provides an interior material for automobiles having heat insulation properties by providing the heat insulation layer.

[0003] In addition, Patent Document 1 discloses · As the heat insulation layer, a non-woven fabric coated by impregnation, printing, coating, spray spraying, etc. using ceramic balloons, ceramic fine particles, or metal oxides such as titanium oxide as a heat insulation paint can be adopted, And · From the viewpoint of heat insulation properties, it is preferable to provide a heat insulation layer on one surface of a sheet such as a non-woven fabric, or to provide a heat insulation layer in which a heat insulation material is applied and contained in a sheet such as a non-woven fabric, which is disclosed as a finding.

[0004] Further, Japanese Patent No. 6368913 (Patent Document 2) discloses a finding that near-infrared rays contained in sunlight can be blocked by using inorganic particles having near-infrared scattering properties and / or near-infrared absorbing properties (for example, metal oxides such as titanium oxide). In Patent Document 2, a highly light-transmissive film material having heat insulation properties is provided by providing the inorganic particles.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

[0006] The applicant of the present application has studied an interior surface material provided with a nonwoven fabric to which inorganic particles having near-infrared scattering properties and / or near-infrared absorbing properties are imparted, with reference to the prior art. However, the interior surface material prepared based on the prior art did not always have sufficient heat insulation properties. Therefore, there has been a demand for providing an automotive interior material having excellent heat insulation properties. MEANS FOR SOLVING THE PROBLEMS

[0007] The present disclosure is “(Claim 1) An interior surface material comprising inorganic particles having near-infrared scattering properties or near-infrared absorbing properties in a nonwoven fabric, wherein, in the nonwoven fabric having the inorganic particles, the inorganic particles are present only in a range of less than 21% of the thickness from one main surface to the other main surface of the nonwoven fabric having the inorganic particles, Interior surface material. (Claim 2) The interior surface material according to claim 1, wherein the inorganic particles contain one or more particles selected from metals, metal oxides, boron nitride, talc, and ceramics.” That is. EFFECTS OF THE INVENTION

[0008] The interior surface material according to the present disclosure is an interior surface material comprising inorganic particles having near-infrared scattering properties or near-infrared absorbing properties (hereinafter sometimes abbreviated as inorganic particles) in a nonwoven fabric, and is characterized in that the inorganic particles are present only in a range of less than 21% of the thickness in the nonwoven fabric having the inorganic particles from one main surface to the other main surface.

[0009] When attempting to provide an automotive interior material with excellent heat shielding properties, in order to efficiently prevent the passage of sunlight, it is considered desirable for the automotive interior material to include a layer of inorganic particles, such as a layer of inorganic particles formed on the main surface of a non-porous film.

[0010] In comparison, an interior surface material formed by applying and containing inorganic particles to a sheet such as a non-woven fabric as disclosed in the prior art has inorganic particles within the non-woven fabric, so the constituent fibers of the non-woven fabric are present in the layer of inorganic particles. As a result, sunlight passes through the portion where the constituent fibers are present, making the layer of inorganic particles easily penetrable by sunlight, and it was considered difficult to provide an automotive interior material with excellent heat shielding properties.

[0011] However, as a result of continued research by the applicant of the present application, it has been found that even for an interior surface material formed by applying and containing inorganic particles to a sheet such as a non-woven fabric as in the prior art, by adjusting the range of existence of the inorganic particles present in the non-woven fabric, an automotive interior material with excellent heat shielding properties can be realized. Specifically, it has been found that when inorganic particles are present only in a range less than 21% of the thickness within the non-woven fabric provided with inorganic particles, as measured from one main surface to the other main surface of the non-woven fabric provided with inorganic particles, an automotive interior material that exhibits excellent heat shielding properties can be realized.

[0012] Also, by including one or more kinds of particles selected from metals or metal oxides, boron nitride, talc, and ceramics as inorganic particles having near-infrared scattering properties and / or near-infrared absorption properties, it is easy to realize an automotive interior material with excellent heat shielding properties.

Mode for Carrying Out the Invention

[0013] In the present invention, various configurations can be appropriately selected, such as the following configurations. Note that, unless otherwise specified, all various measurements described in the present invention are performed under atmospheric pressure. Also, the measurements are performed under the temperature condition of 25°C. And, unless otherwise specified, all various measurement results described in the present invention are measured up to a value one digit smaller than the required value, and the required value is calculated by rounding off the said value. As a specific example, when the value up to the first decimal place is the required value, the value up to the second decimal place is obtained by measurement, and the value up to the first decimal place is calculated by rounding off the obtained value of the second decimal place, and this value is taken as the required value. And, each upper limit value and each lower limit value exemplified in the present invention can be arbitrarily combined.

[0014] Since the interior surface material according to the present invention includes a non-woven fabric, it is flexible, has excellent touch feeling, and is rich in mold followability and excellent in formability.

[0015] As the constituent fibers of the nonwoven fabric, for example, inorganic fibers composed of inorganic components such as glass fibers, silica fibers, and alumina fibers, or organic resin fibers composed of resins can be adopted. The organic resin fibers are, for example, polyolefin resins (for example, polyethylene, polypropylene, polyolefin resins with a structure in which a part of hydrocarbons is substituted with a halogen such as a cyano group, fluorine, or chlorine), polymethylpentene, styrene resins, polyvinyl alcohol resins, polyether resins (for example, polyether ether ketone, polyacetal, modified polyphenylene ether, aromatic polyether ketone, etc.), polyester resins (for example, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polybutylene naphthalate, polycarbonate, polyarylate, wholly aromatic polyester resin, etc.), polyimide resins, polyamideimide resins, polyamide resins (for example, aromatic polyamide resins, aromatic polyether amide resins, nylon resins, etc.), resins having a nitrile group (for example, polyacrylonitrile, etc.), urethane resins, epoxy resins, polysulfone resins (for example, polysulfone, polyether sulfone, etc.), fluorine resins (for example, polytetrafluoroethylene, polyvinylidene fluoride, etc.), cellulose resins, polybenzimidazole resins, acrylic resins (for example, polyacrylonitrile resins copolymerized with acrylic acid esters or methacrylic acid esters, modacrylic resins copolymerized with acrylonitrile and vinyl chloride or vinylidene chloride, etc.), etc., and are fibers composed of known resins.

[0016] When flame retardancy is required for the interior surface material, it is preferable that the constituent fibers of the nonwoven fabric contain flame-retardant organic resin fibers. Examples of such flame-retardant organic resin fibers include modacrylic resins, vinylidene resins, polyvinyl chloride resins, polyvinylidene fluoride resins, novoloid resins, polyvinyl chloride resins, polyester resins copolymerized with phosphorus compounds, acrylic resins copolymerized with halogen-containing monomers, aramid resins, and resins kneaded with halogen-based, phosphorus-based, or metal compound-based flame retardants.

[0017] In addition, the constituent components of the inorganic fibers and the constituent resins of the organic fibers may be composed of either linear polymers or branched polymers, and may also be block copolymers or random copolymers, and the presence or absence of a three-dimensional structure or crystallinity is not particularly limited. Furthermore, the organic fibers may be fibers formed by mixing a plurality of types of the resin, or composite fibers formed by compositing a plurality of types of the resin. Also, the inorganic fibers may be fibers formed by mixing a plurality of types of the inorganic components, or composite fibers formed by compositing a plurality of types of the inorganic component resins.

[0018] The constituent fibers of the nonwoven fabric are fibers composed of a plurality of types of inorganic components and resins, and are generally referred to as composite fibers. For example, they can be fibers such as core-sheath type, sea-island type, side-by-side type, orange type, bimetal type, etc.

[0019] Because of being flexible, it can provide an interior surface material with better touch and excellent mold followability and formability. Therefore, it is preferable that the nonwoven fabric contains organic fibers as the constituent fibers, and it is more preferable that the constituent fibers of the nonwoven fabric are only organic fibers.

[0020] Also, the constituent fibers of the nonwoven fabric may include fibers with a cross-sectional shape other than substantially circular fibers and elliptical fibers. As the profiled cross-section fibers, they may have a fiber cross-section such as a hollow shape, a polygonal shape such as a triangular shape, an alphabetic character type shape such as a Y shape, an irregular shape, a multi-lobe shape, a symbol type shape such as an asterisk shape, or a shape formed by combining a plurality of these shapes.

[0021] When the nonwoven fabric contains heat-fusible fibers as constituent fibers, it is preferable to impart strength and form stability to the nonwoven fabric by heat-fusing the fibers together, which can suppress fuzzing and fiber scattering. Such heat-fusible fibers may be fully fused heat-fusible fibers or partially fused heat-fusible fibers in the form of the composite fibers described above. As components that exhibit heat-fusibility in heat-fusible fibers, for example, low-melting-point polyolefin resins, low-melting-point polyester resins, etc. can be appropriately selected and used.

[0022] When the nonwoven fabric contains crimped fibers, it is preferable because the stretchability is increased and the followability to the mold is excellent. As such crimped fibers, for example, crimped fibers in which the crimps of latent crimped fibers are developed, fibers having crimps, etc. can be used. Further, the nonwoven fabric may contain latent crimped fibers that develop crimps when heated.

[0023] The constituent fibers of the nonwoven fabric can be obtained by known methods such as, for example, the melt spinning method, dry spinning method, wet spinning method, direct spinning method (melt blow method, spunbond method, electrospinning method, etc.), a method of extracting fibers with a fine fiber diameter by removing one or more resin components from composite fibers, a method of obtaining fibers by beating and splitting fibers.

[0024] The nonwoven fabric can be prepared, for example, by a dry method of entangling fibers by supplying the above-mentioned fibers to a carding device, an air-laying device, etc., a wet method of dispersing fibers in a dispersion medium and forming a sheet to entangle the fibers, a direct spinning method (melt blow method, spunbond method, electrospinning method, a method of spinning by discharging a spinning dope and a gas stream in parallel (for example, the method disclosed in JP-A-2009-287138), etc.) to spin the fibers and entangle and collect the spun fibers.

[0025] Moreover, the constituent fibers of the nonwoven fabric may be integrated with each other. As a method for integrating the constituent fibers, for example, a method of entangling by needles or water flow, a method of fusing the constituent fibers with all melt-bonded fibers or partially melt-bonded composite fibers contained in the constituent fibers by subjecting them to heat treatment, a method of adhering the constituent fibers to each other using a binder, and the like can be mentioned.

[0026] When adopting the method of adhering the constituent fibers to each other using a binder, the type of binder that can be used is appropriately selected. For example, polyolefin (such as modified polyolefin), ethylene vinyl alcohol copolymer, ethylene-acrylate copolymer such as ethylene-ethyl acrylate copolymer, various rubbers and their derivatives (styrene-butadiene rubber (SBR), fluororubber, urethane rubber, ethylene-propylene-diene rubber (EPDM), etc.), cellulose derivatives (carboxymethyl cellulose (CMC), hydroxyethyl cellulose, hydroxypropyl cellulose, etc.), polyvinyl alcohol (PVA), polyvinyl butyral (PVB), polyvinyl pyrrolidone (PVP), epoxy resin, polyvinylidene fluoride (PVdF), vinylidene fluoride-hexafluoropropylene copolymer (PVdF-HFP), acrylic resins (acrylate resin, acrylonitrile styrene copolymer resin, etc.), polyurethane resin, etc. can be used.

[0027] When the binder contains an acrylic resin, it is preferably softened moderately during thermoforming such as heat pressing using a mold, so that an interior surface material excellent in followability to the mold can be provided.

[0028] In addition to the above-mentioned resins, the binder may also contain additives such as flame retardants, fragrances, pigments, antibacterial agents, antifungal agents, photocatalyst particles, emulsifiers, dispersants, surfactants, thickeners, and flame retardants.

[0029] The basis weight of the binder contained in the nonwoven fabric is appropriately selected. However, since it is easier to provide an interior surface material with a smoother main surface as the amount of the binder increases, the basis weight of the binder is 1 g / m 2It is preferably as described above. On the other hand, when the amount of the binder is excessively large, there is a risk that the interior surface material may be inferior in flexibility. Therefore, the basis weight of the binder is preferably 50 g / m 2 or less, more preferably 30 g / m 2 or less, still more preferably 20 g / m 2 or less.

[0030] When adopting a method of fusing constituent fibers with each other by all-fusion type fibers or partially-fusion type composite fibers contained in the constituent fibers by subjecting them to heat treatment, the method of heat treatment can be appropriately selected. For example, a method of heating or heating and pressing with a roll, a method of subjecting to a heating machine such as an oven dryer, an infrared heater, a hot air dryer, or a heat dryer and heating, a method of irradiating infrared rays under no pressure to heat the contained fusion component, etc. can be used.

[0031] The fineness and fiber length of the constituent fibers of the nonwoven fabric can be appropriately adjusted. The fineness can be 0.1 dtex or more, can be 0.5 dtex or more, and can be 1 dtex or more. On the other hand, in order to provide an interior surface material in which inorganic particles are present only in a range less than 21% of the thickness within the nonwoven fabric provided with inorganic particles, from one main surface to the other main surface of the nonwoven fabric provided with inorganic particles, it is preferable that the fineness of the constituent fibers of the nonwoven fabric is smaller. It is preferably 30 dtex or less, more preferably 10 dtex or less, still more preferably 5 dtex or less, and most preferably 3 dtex or less.

[0032] The constituent fibers may be short fibers cut to have a specific fiber length. The fiber length of the short fibers can be 5 to 120 mm, can be 10 to 100 mm, and can be 20 to 80 mm. Note that the "fiber length" of the short fibers cut to have a specific fiber length refers to the fiber length measured in accordance with JIS L1015 (2010), 8.4.1c direct method (Method C). Alternatively, the constituent fibers can be fibers (fibers having a continuous length) that are not cut to have a specific fiber length and have a fiber length longer than 120 mm, such as directly spun fibers (melt blown fibers, electrospun fibers, etc.). Further, a nonwoven fabric formed by mixing fibers having a specific fiber length and fibers having a continuous length may be used.

[0033] Various configurations of the nonwoven fabric, such as the basis weight and thickness, can be adjusted as appropriate. The basis weight can be 5 to 500 g / m 2 and can be 10 to 300 g / m 2 and can be 30 to 200 g / m 2 . Note that the basis weight refers to the mass per 1 m 2 of the surface (main surface) having the largest area of the measurement object. The thickness can be 0.1 to 50 mm, can be 0.3 to 10 mm, and can be 0.5 to 3 mm. Note that in the present invention, the basis weight refers to the mass per 1 m2 of the surface (main surface) having the largest area of the measurement object, and the thickness can be measured by the following method.

[0034] (Method for Measuring Thickness) (Step 1) Cut the measurement object such as a nonwoven fabric or an interior surface material in the thickness direction. The measurement object having a cut surface prepared in this way is used as a sample. Five samples are prepared. (Step 2) Photograph the cross section of the sample using a microscope (Keyence Corporation, VHX-500P). Adjust the magnification so that both main surfaces of the sample in the cross section are entirely shown in the photographed image thus obtained. (Step 3) Draw the longest line segment C1 that can pass through a randomly selected point on the sample shown in the captured image and is parallel to the aforementioned thickness direction and can be drawn on the sample. Similarly, at four other randomly selected points (points other than the already drawn line segment C1) on the sample, draw the longest line segments C2 to C5 that can pass through the randomly selected points, are parallel to the aforementioned thickness direction, and can be drawn on the sample, respectively. The average value of the lengths of the five line segments C1 to C5 drawn in this way is taken as the thickness (unit: μm).

[0035] The interior surface material according to the present invention includes inorganic particles having near-infrared scattering properties and / or near-infrared absorbing properties. Whether the inorganic particles referred to here have near-infrared scattering properties and / or near-infrared absorbing properties can be determined by the following measurement method.

[0036] (Method for confirming whether it has near-infrared scattering properties) (Step 1) Collect inorganic particles present in the non-woven fabric provided in the interior surface material from the interior surface material. Alternatively, if the manufacturing process of the interior surface material is known, prepare the inorganic particles used in the manufacturing process. (Step 2) Put the inorganic particles into a measurement cell and subject them to an ultraviolet-visible near-infrared spectrophotometer (V-670 manufactured by Nippon Denshoku Industries Co., Ltd.) to measure the spectral reflectance (unit: %) of the inorganic particles for wavelengths in the range of 780 to 2500 nm. As a result of the measurement, if the inorganic particles exhibit a spectral reflectance of 70% or more, it is determined that the inorganic particles have near-infrared scattering properties. On the other hand, as a result of the measurement, if the inorganic particles exhibit a spectral reflectance of less than 70%, it is determined that the inorganic particles do not have near-infrared scattering properties.

[0037] (Method for confirming whether it has near-infrared absorbing properties) (Step 1) As a result of subjecting to a method for confirming near-infrared scattering property, a surface material for interior decoration of a cloth provided with a nonwoven fabric including inorganic particles, which is determined not to have near-infrared scattering property, is prepared. Then, inorganic particles existing in the nonwoven fabric included in the interior decoration surface material are collected from the interior decoration surface material. Alternatively, when the manufacturing process of the interior decoration surface material is known, the inorganic particles used in the manufacturing process are prepared. (Step 2) Using a twin-screw extruder, 70 parts by mass of molten polyethylene resin is mixed with 30 parts by mass of inorganic particles, and then, using an inflation molding machine (temperature during extrusion: 160 °C), a film with a thickness of 0.05 mm is manufactured. (Step 3) By subjecting the manufactured film to an ultraviolet-visible near-infrared spectrophotometer (UH4150, manufactured by Hitachi High-Technologies Corporation, SCAN SPEED 300 nm / min, SLIT width 5 nm, measurement interval: every 1 nm), the transmittance (unit: %) with respect to wavelengths in the range of 780 to 2500 nm exhibited by the film is measured. (Step 4) A value obtained by adding up and averaging the measured transmittances is calculated, and the calculated value is taken as the average visible light transmittance (unit: %). When the average visible light transmittance of the film is 30% or less, it is determined that the inorganic particles used for the preparation of the film have near-infrared absorbency. On the other hand, when the average visible light transmittance of the film is greater than 30%, it is determined that the inorganic particles used for the preparation of the film do not have near-infrared absorbency.

[0038] As the above-described inorganic particles having near-infrared scattering property, metals such as titanium and aluminum, metal oxides such as titanium oxide and aluminum oxide, and in addition, boron nitride, talc, ceramics, etc. can be adopted. Further, as the above-described inorganic particles having near-infrared absorbency, metal oxides such as antimony-doped tin oxide and tin-doped indium oxide can be exemplified.

[0039] In particular, it is preferable to adopt titanium oxide, aluminum oxide or antimony-doped tin oxide as the inorganic particles so as to easily realize an interior decoration surface material with further improved heat insulation property.

[0040] The basis weight of the inorganic particles included in the interior surface material is appropriately selected. For example, it can be 3 to 30 g / m 2 and can be 5 to 20 g / m 2 and can be 7 to 15 g / m 2 and can be.

[0041] In the interior surface material according to the present invention, inorganic particles are present in the non-woven fabric included in the interior surface material from one main surface toward the other main surface.

[0042] In the present invention, the fact that the non-woven fabric includes inorganic particles means that the inorganic particles are present on the surface of the constituent fibers of the non-woven fabric and / or between the constituent fibers of the non-woven fabric. Note that the inorganic particles may be present without adhering to the constituent fibers of the non-woven fabric. However, since it is easy to provide an interior surface material with improved heat insulation efficiency by preventing the inorganic particles from falling off, it is preferable that the inorganic particles are fixed on the surface of the constituent fibers of the non-woven fabric and / or between the constituent fibers of the non-woven fabric. Specifically, it is preferable that the inorganic particles are fixed on the surface of the constituent fibers by melting the thermoplastic component contained on the surface of the constituent fibers of the non-woven fabric, or it is preferable that the inorganic particles are fixed on the surface of the constituent fibers of the non-woven fabric and / or between the constituent fibers of the non-woven fabric by being adhered with a resin.

[0043] The type of resin used for adhering and fixing the inorganic particles can be appropriately adjusted, but it can be selected and used from the resins mentioned as the above-described binder. Note that the resin may contain additives other than inorganic particles having near-infrared scattering properties and / or near-infrared absorption properties, such as a flame retardant, a fragrance, a pigment, an antibacterial agent, an antifungal agent, photocatalyst particles, and a flame retardant.

[0044] The basis weight of the resin included in the interior surface material is appropriately selected. For example, it can be 1 to 50 g / m 2 and can be 3 to 30 g / m 2 and can be 5 to 20 g / m 2It can be so. Further, the mass percentage of the inorganic particles in the mass of the resin that adheres the inorganic particles can be adjusted as appropriate. For example, it can be 10 to 75%, it can be 25 to 65%, and it can be 45 to 55%.

[0045] In the interior surface material according to the present invention, in the nonwoven fabric provided with inorganic particles, the inorganic particles exist only in a range less than 21% of the thickness within the nonwoven fabric from one main surface toward the other main surface.

[0046] Whether the interior surface material has inorganic particles only in the existence range defined in the present invention can be determined by the following measurement method.

[0047] (Method for confirming the existence range of inorganic particles) (Step 1) Remove unnecessary layers such as a base material described later from the interior surface material, and collect a nonwoven fabric provided with inorganic particles inside. (Step 2) Cut the collected nonwoven fabric in the thickness direction. The nonwoven fabric having a cut surface thus prepared is used as a sample. Note that 5 samples are prepared. (Step 3) Photograph the cross section of the sample using a microscope (Keyence Corporation, VHX-500P). Adjust the magnification so that both main surfaces of the sample in the cross section are all shown in the photographed image thus obtained. (Step 4) Among the samples shown in the photographed image, check the portion excluding the layer of inorganic particles that does not contain fibers (hereinafter sometimes referred to as the nonwoven fabric portion). Then, draw the longest line segment A1 that can be drawn on the nonwoven fabric portion parallel to the above-mentioned thickness direction through a randomly selected point on the nonwoven fabric portion. Similarly, at the other 4 randomly selected points (points other than the line segment A1 that has already been drawn) on the nonwoven fabric portion, draw the longest line segments A2 to A5 that can be drawn on the nonwoven fabric portion parallel to the above-mentioned thickness direction through the randomly selected points. The average value of the lengths of the 5 line segments A1 to A5 thus drawn is defined as the thickness (unit: μm) of the nonwoven fabric provided with inorganic particles. (Step 5) Check for the presence of a layer composed of a mixture of the constituent fibers of the nonwoven fabric and inorganic particles, which exists from one main surface to the other main surface in the nonwoven fabric portion shown in the captured image. When the layer exists, draw the longest line segment B1 that can be drawn on the layer parallel to the aforementioned thickness direction through a randomly selected point on the layer. Similarly, at four other randomly selected points (points other than the already drawn line segment B1) on the layer, draw the longest line segments B2 to B5 that can be drawn on the layer parallel to the aforementioned thickness direction through the randomly selected points. The average value of the lengths of the five line segments B1 to B5 thus drawn is defined as the length of the range where inorganic particles are present (unit: μm). (Step 6) Calculate the percentage (unit: %) of the length of the range where inorganic particles are present in the thickness of the nonwoven fabric provided with inorganic particles. (Step 7) Also perform the above-described steps (Step 3) to (Step 6) for the other four samples, and calculate the percentage for each. (Step 8) Calculate the average value of the calculated percentages. The calculated average value is defined as the range (unit: %, hereinafter may be referred to as the existing range) where inorganic particles are present from one main surface to the other main surface in the thickness of the nonwoven fabric.

[0048] In addition, in (Step 5), when inorganic particles are present throughout the nonwoven fabric portion, inorganic particles are present in a range of 100% of the thickness of the nonwoven fabric from one main surface to the other main surface.

[0049] Also, in (Step 5), when inorganic particles are present without contacting either of the two main surfaces of the nonwoven fabric portion, that is, when inorganic particles are present only in the central portion in the thickness direction of the nonwoven fabric portion, the interior surface material subjected to the measurement does not include the nonwoven fabric defined in the present invention.

[0050] In order to realize an interior surface material with improved heat insulation properties, it is preferable that the inorganic particles exist only in the range of 20% or less of the thickness of the nonwoven fabric provided with inorganic particles, preferably only in the range of 16% or less, and more preferably only in the range of 13% or less, from one main surface to the other main surface of the nonwoven fabric provided with inorganic particles.

[0051] In the nonwoven fabric provided with inorganic particles according to the present invention, the inorganic particles also exist in a range greater than 0% of the thickness of the nonwoven fabric from one main surface to the other main surface of the nonwoven fabric. In order to realize an interior surface material with improved heat insulation properties, it is preferable that the inorganic particles also exist in a range of 1% or more of the thickness of the nonwoven fabric, preferably in a range of 5% or more, and more preferably in a range of 6% or more, from one main surface to the other main surface of the nonwoven fabric.

[0052] In addition, the interior surface material according to the present invention may have an inorganic particle layer mainly composed of inorganic particles (or mainly composed of resin and inorganic particles) on one main surface of the nonwoven fabric. The form of the inorganic particle layer present on the main surface of the nonwoven fabric can be adjusted as appropriate, and it can be a form that covers the entire one main surface of the nonwoven fabric, or a form that covers a part of the one main surface of the nonwoven fabric so as to form a pattern such as a lattice pattern, a pattern such as a linear shape, a dot shape, or an irregular shape.

[0053] The thickness of the interior surface material can be appropriately selected, but it can be 2.5 mm or less, and can be 2 mm or less. On the other hand, although the lower limit value of the thickness can be adjusted as appropriate, it is realistic that it is 0.5 mm or more. The basis weight of the interior surface material can be appropriately selected, but it can be 300 g / m 2 or less. On the other hand, although the lower limit value of the basis weight can be adjusted as appropriate, it is realistic that it is 100 g / m 2 or more.

[0054] Next, a manufacturing method of the interior surface material of the present invention will be described with specific examples. Note that the description will be omitted for the items and configurations that are the same as those described for the above-mentioned interior surface material.

[0055] The manufacturing method of the interior surface material according to the present invention can be appropriately selected. As an example, (Step 1) A step of preparing a non-woven fabric, (Step 2) A step of preparing a coating liquid in which a resin and inorganic particles are mixed in a solvent or a dispersion medium, (Step 3) A step of applying the coating liquid onto one main surface of the non-woven fabric, (Step 4) A step of removing the solvent or the dispersion medium by heating the non-woven fabric to which the coating liquid has been applied, A manufacturing method of the interior surface material including the above steps can be mentioned.

[0056] (Step 1) will be described.

[0057] Regarding the non-woven fabric to be used, the fineness and fiber length of the constituent fibers, the thickness and basis weight of the non-woven fabric can adopt the above-mentioned numerical values.

[0058] At this time, by adopting a non-woven fabric with adjusted density, the existence range of inorganic particles can be adjusted. Specifically, by adopting a non-woven fabric with a high density, it becomes easier to provide an interior surface material in which the inorganic particles exist only in a shallow range of the thickness of the non-woven fabric from one main surface to the other main surface of the non-woven fabric.

[0059] The method for preparing a non-woven fabric with a high density can be appropriately selected, and examples include a method of crushing the non-woven fabric in the thickness direction by subjecting it to calender treatment, a method of preparing a non-woven fabric by strengthening the entanglement of constituent fibers by needle punching treatment or water jet entanglement treatment, and a method of preparing a non-woven fabric composed of fibers with a small fineness.

[0060] Alternatively, the existence range of inorganic particles can be adjusted by adopting a non-woven fabric with reduced voids on one main surface side.

[0061] Specifically, by applying the coating liquid to the main surface side where the voids in the non-woven fabric are reduced, it becomes easier to provide an interior surface material in which the inorganic particles are present only in a shallow range of the thickness of the non-woven fabric, from one main surface toward the other main surface.

[0062] A method for preparing a non-woven fabric with reduced voids on one main surface side can be appropriately selected, and examples include a method of applying a binder only to one main surface of the non-woven fabric (more preferably, applying it multiple times).

[0063] The description of (Step 2) will be given.

[0064] The type of solvent or dispersion medium can be appropriately selected. However, in order to preferably apply the coating liquid onto one main surface of the non-woven fabric, a solvent in which the resin used to adhere and fix the inorganic particles to the non-woven fabric dissolves and the particles do not dissolve but can be dispersed is adopted, or a dispersion medium in which the resin and the inorganic particles do not dissolve but can be dispersed is preferably adopted. In addition to the inorganic particles, the coating liquid may also contain additives other than the inorganic particles, such as flame retardants, fragrances, pigments, antibacterial agents, antifungal agents, photocatalyst particles, emulsifiers, dispersants, surfactants, thickeners, and flame retardants, which have near-infrared scattering properties and / or near-infrared absorption properties.

[0065] The description of (Step 3) will be given.

[0066] A method for applying the coating liquid onto one main surface of the non-woven fabric can be appropriately selected. Examples include a method of spraying or applying the coating liquid as it is or in a foamed state onto one main surface of the non-woven fabric using a spray or an impregnation roll, or a method of immersing only one main surface of the non-woven fabric in the coating liquid. The form of the coating liquid applied onto one main surface of the non-woven fabric can be appropriately selected, and examples include a method of applying it so as to cover the entire main surface, or a method of printing or dyeing it so as to form a pattern on the main surface.

[0067] The description of (Step 4) will be given.

[0068] The method for removing the solvent or dispersion medium can be appropriately selected. For example, it can be subjected to heating using a heating device such as an oven dryer, far-infrared heater, dry heat dryer, hot air dryer, etc., or allowed to stand in a room temperature atmosphere or under reduced pressure to evaporate and remove the solvent or dispersion medium. The heating temperature when removing the solvent or dispersion medium is a temperature at which the solvent or dispersion medium can volatilize, and the upper limit of the heating temperature is selected so that the shape and function of constituent members such as fabrics do not decrease unintentionally.

[0069] In addition, in this step, inorganic particles can be fixed on the surface of the constituent fibers of the non-woven fabric and / or between the constituent fibers of the non-woven fabric by the resin contained in the dispersion medium. At this time, the constituent fibers of the non-woven fabric may be adhered to each other by the resin contained in the dispersion medium.

[0070] After removing the solvent or dispersion medium, it is preferable to cool the non-woven fabric or allow it to cool in the air.

[0071] The non-woven fabric provided with inorganic particles prepared as described above may be used as an interior surface material as it is, or may be an interior surface material formed by laminating a base material such as a woven fabric, knitted fabric, separately prepared non-woven fabric, film (porous film or non-porous film), foam, etc.

[0072] In addition, it may be subjected to various secondary processes such as a process of processing by punching out a shape according to the use and usage mode, and a pressure treatment process for adjusting the thickness or smoothing the surface such as a resilient press treatment.

[0073] In addition, although the usage mode of the interior surface material according to the present invention can be appropriately adjusted, the interior surface material can be used in a state where the main surface on the side where the inorganic particles are present in the non-woven fabric faces the direction in which sunlight or radiant heat generated when sunlight hits an object enters.

Examples

[0074] Hereinafter, the present invention will be specifically described by way of examples, but these do not limit the scope of the present invention.

[0075] (Reference Example) A non-porous film made of polyester (thickness: 0.02 mm) was prepared. Then, the coating liquid described below was applied to the entire one main surface of the non-porous film using a cylinder. Coating liquid: An aqueous dispersion containing titanium oxide particles and an acrylic resin (solid content concentration of titanium oxide particles: 5.0% by mass, solid content concentration of acrylic resin: 5.0% by mass). Then, by drying with a dryer at a temperature of 140 °C, a non-porous film in which a layer of inorganic particles composed of the solid content derived from the coating liquid covered the entire one main surface was prepared. Note that the inorganic particles formed a layer and adhered only on the main surface of the non-porous film by the acrylic resin. The non-porous film provided with inorganic particles prepared in this way (solid content derived from the coating liquid: 5 g / m 2 ) was used as an interior surface material.

[0076] (Comparative Example 1) Using 100% of virgin polyester fibers (fineness: 2.2 dtex, fiber length: 38 mm), after opening the fibers with a carding machine to form a fiber web, from one main surface side, the needle density was 400 needles / m 2 and needle punching treatment was performed. Then, by feeding it between hot rolls (gap interval: 0.6 mm, roll heating temperature: 165 °C), a needle punched nonwoven fabric was prepared. Next, the binder liquid described below was applied in a foamed state to the entire main surface on the side opposite to the surface where the needling of the needle punched nonwoven fabric was performed. Binder liquid: An aqueous dispersion containing an acrylate resin (solid content concentration of acrylate resin: 1.2% by mass). Then, after feeding it between rolls (gap interval: 0.25 mm) and drying with a candler at a temperature of 160 °C, a binder-bonded nonwoven fabric A1 (basis weight: 194 g / m 2 , thickness: 1.5 mm, solid content derived from the binder liquid: 5 g / m 2 ) was prepared. On the entire main surface of the binder-bonded nonwoven fabric A1 on the side opposite to the needled surface, the coating liquid used in the reference example was applied using a cylinder. Then, by drying with a dryer at a temperature of 140°C, an interior surface material having inorganic particles only on the main surface side opposite to the needled surface (basis weight: 220 g / m 2 , thickness: 1.5 mm, of which inorganic particles: 12.4 g / m 2 ) was prepared.

[0077] (Comparative Example 2) The binder liquid used in Comparative Example 1 was applied in a foamed state to the entire main surface of the binder-bonded nonwoven fabric A1 on the needled side. Then, after passing it between rolls (gap interval: 0.25 mm) and drying with a can dryer at a temperature of 160°C, a binder-bonded nonwoven fabric A2 (basis weight: 199 g / m 2 , thickness: 1.5 mm, of which solid content derived from the binder liquid: 10 g / m 2 ) was prepared. The coating liquid used in the reference example was applied to the entire main surface of the binder-bonded nonwoven fabric A2 on the side opposite to the needled surface using a cylinder. Then, by drying with a dryer at a temperature of 140°C, an interior surface material having inorganic particles only on the main surface side opposite to the needled surface (basis weight: 225 g / m 2 , thickness: 1.1 mm, of which inorganic particles: 12.4 g / m 2 ) was prepared.

[0078] (Example 1) By subjecting the binder-bonded nonwoven fabric A1 to calendering, a further flattened binder-bonded nonwoven fabric A3 (basis weight: 194 g / m 2 , thickness: 1.0 mm, of which solid content derived from the binder liquid: 5 g / m 2 ) was prepared. An interior surface material having inorganic particles only on the main surface side opposite to the needled surface (basis weight: 220 g / m 2 , thickness: 1.5 mm, of which inorganic particles: 12.4 g / m 2) was prepared.

[0079] (Example 2) The binder liquid was applied again to the side of the binder-bonded nonwoven fabric A1 where the binder liquid had been applied, in a foamed state. Then, after passing it between rolls (gap interval: 0.25 mm), it was dried with a cand dryer at a temperature of 160°C to obtain a binder-bonded nonwoven fabric A4 (basis weight: 199 g / m 2 , thickness: 1.5 mm, solid content derived from the binder liquid: 10 g / m 2 ). Note that the binder-bonded nonwoven fabric A4 was a nonwoven fabric with further reduced voids on the side where the binder liquid was applied. An interior surface material having inorganic particles only on the main surface side opposite to the needled surface was prepared in the same manner as in Comparative Example 1, except that the binder-bonded nonwoven fabric A4 was used instead of the binder-bonded nonwoven fabric A1 (basis weight: 225 g / m 2 , thickness: 1.5 mm, inorganic particles: 12.4 g / m 2 ).

[0080] (Comparative Example 3) All of the binder-bonded nonwoven fabric A1 was immersed in the coating liquid. Then, it was dried with a dryer at a temperature of 140°C to obtain an interior surface material having inorganic particles throughout (basis weight: 220 g / m 2 , thickness: 1.5 mm, inorganic particles: 12.4 g / m 2 ).

[0081] Note that in the surface materials prepared in the examples and comparative examples, inorganic particles were adhered and fixed to the surface of the constituent fibers of the binder-bonded nonwoven fabric and between the constituent fibers by an acrylic resin.

[0082] For the interior surface materials prepared as described above, various physical properties were measured and evaluated and summarized in Table 1. For components that were not present, "-" was described in the table. Also, the heat insulation property of the interior surface material was evaluated using the measurement results of the rising temperature evaluated by the following method.

[0083] (Method for measuring the rising temperature) (Step 1) Prepare a cubic test box (inner dimension: a cube with a side length of 30 cm) with an outer dimension of 33 cm per side, which is composed of Achilles Board (registered trademark). Only one side of the test box has an opening (a square with a side length of 15 cm) at the central part of the side, and the opening is covered with a polyethylene terephthalate film with a thickness of 190 μm so as to be sealed. (Step 2) Install a temperature measuring device inside the test box. (Step 3) Set a halogen lamp (300 W) above the opening provided on one side of the test box. At this time, adjust so that the shortest distance between the opening and the halogen lamp is 5 cm. Also, adjust so that the light irradiated from the halogen lamp when the halogen lamp is energized illuminates all of the openings. (Step 4) Place the interior surface material to be measured on one side of the test box so as to cover the polyethylene terephthalate film installed at the opening of the test box. At this time, turn the side where the inorganic particles are present in the non-woven fabric provided in the interior surface material toward the side opposite to the opening of the test box. (Step 5) Measure the internal temperature A (unit: °C) of the test box using the temperature measuring device. (Step 6) Energize the halogen lamp and irradiate the interior surface material with the light from the halogen lamp for 30 minutes. (Step 7) Measure the internal temperature B (unit: °C) of the test box immediately after irradiating the interior surface material with the light from the halogen lamp for 30 minutes using the temperature measuring device. (Step 8) Subtract the internal temperature A from the internal temperature B, and use the calculated value as the rising temperature (unit: °C).

[0084] The interior surface material prepared in the reference example was subjected to the above-described method for measuring the rising temperature, and was based on the obtained rising temperature (19.3 °C). Then, the interior surface material that was subjected to the above-described method for measuring the rising temperature and had a rising temperature of 19.3°C or less was evaluated as an interior surface material with excellent heat insulation properties, and "〇" was described in the table. On the other hand, the interior surface material that was subjected to the above-described method for measuring the rising temperature and had a rising temperature higher than 19.3°C was evaluated as an interior surface material with poor heat insulation properties, and "×" was described in the table.

[0085]

Table 1

[0086] From the results of comparing the examples and the comparative examples, it was found that by having inorganic particles present only in a range of less than 21% of the thickness within the non-woven fabric provided with inorganic particles, from one main surface to the other main surface of the non-woven fabric provided with inorganic particles, it is possible to provide an interior surface material with excellent heat insulation properties.

[0087] (Example 3) Except for changing the fineness of the original polyester fiber used to 1.3 dtex and reducing the coating amount of the coating liquid, in the same manner as in Comparative Example 1, a binder-bonded non-woven fabric B1 (basis weight: 185 g / m 2 , thickness: 1.5 mm, solid content derived from the binder liquid: 5 g / m 2 ) was prepared. The coating liquid used in the reference example was applied to the entire main surface on the side opposite to the needled surface of the binder-bonded non-woven fabric B1 using a cylinder. Then, by drying with a dryer at a temperature of 140°C, an interior surface material provided with inorganic particles only on the main surface side opposite to the needled surface (basis weight: 200 g / m 2 , thickness: 1.5 mm, inorganic particles: 7.2 g / m 2 ) was prepared.

[0088] (Example 4) The binder-bonded non-woven fabric B1 was subjected to calendering to obtain a binder-bonded non-woven fabric B2 (basis weight: 185 g / m 2 , thickness: 1.1 mm, binder amount: 5 g / m 2 ) with its thickness reduced. An interior surface material having inorganic particles only on the main surface side opposite to the needled surface was prepared in the same manner as in Example 3, except that binder-bonded nonwoven fabric B2 was used instead of binder-bonded nonwoven fabric B1 (basis weight: 200 g / m 2 , thickness: 1.1 mm, of which inorganic particles: 7.2 g / m 2 ).

[0089] (Comparative Example 4) All of the binder-bonded nonwoven fabric B1 was immersed in the coating solution. Then, by drying with a dryer at a temperature of 140°C, an interior surface material having inorganic particles throughout (basis weight: 200 g / m 2 , thickness: 1.5 mm, of which inorganic particles: 7.2 g / m 2 ) was prepared. In addition, in the surface materials prepared in the examples and comparative examples, inorganic particles were adhered and fixed to the surface of the constituent fibers of the binder-bonded nonwoven fabric and between the constituent fibers by an acrylic resin.

[0090] For the interior surface materials prepared as described above, various physical properties were measured and evaluated together with the interior surface materials prepared in the reference examples and summarized in Table 2. For the configurations that were not present, "-" was described in the table.

[0091]

Table 2

[0092] As described above, it was found that even when different nonwoven fabrics are used, an interior surface material excellent in heat insulation can be provided because the inorganic particles are present only in a range of less than 21% of the thickness within the nonwoven fabric having inorganic particles, from one main surface to the other main surface of the nonwoven fabric having inorganic particles.

Industrial Applicability

[0093] The interior surface material of the present invention can be suitably used for automotive applications such as ceilings, door sides, pillar garnishes, and rear packages; for interior applications such as partitions; and for building materials such as wall coverings.

Claims

Claim 1 An interior surface material comprising inorganic particles having near-infrared scattering properties or near-infrared absorbing properties within a nonwoven fabric, wherein in the nonwoven fabric including the inorganic particles, the inorganic particles are present only in a range less than 21% of the thickness, from one main surface to the other main surface of the nonwoven fabric including the inorganic particles, the interior surface material. Claim 2 The interior surface material according to claim 1, wherein the inorganic particles contain one or more particles selected from metals, metal oxides, boron nitride, talc, and ceramics.

Images