Method for manufacturing interior material for vehicle, and ceiling material for vehicle

Abstract

To provide a technique capable of preventing exudation of a foam component onto a skin material surface, without impairing each performance capable of being exhibited as an interior material for a vehicle of a laminated structure, while including a simple manufacturing process.SOLUTION: A method for manufacturing an interior material for a vehicle having a laminated structure including a skin material and a foam includes the steps of: coating water onto the skin material; and integrally foaming the skin material to which the water is coated, with a foam raw material of the foam material.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present technology relates to a method for manufacturing a vehicle interior material, and more particularly to a method for manufacturing a vehicle interior material having a laminated structure, and a vehicle ceiling material. [Background technology]

[0002] Laminated structures with various characteristics have been developed as interior materials for vehicles. In these laminated structures, the layers are often bonded together by some method, but depending on the environment in which they are used, there is a problem that the components contained in the adhesive or each layer may seep out to the surface due to changes in the viscosity of the adhesive used for bonding or changes in the physical properties of each layer.

[0003] To address this problem, for example, Patent Document 1 discloses a technique for manufacturing a ceiling material in which a base sheet made of foamed resin and a skin sheet made of woven or nonwoven fabric are thermally compressed with a binder between them to bond the two sheets in a molded state. The technique involves applying moisture to the surface of the skin sheet before thermal compression molding, which heats the moisture and turns it into steam, and the pressure of this steam prevents the binder from penetrating into the skin sheet.

[0004] The laminated structures used for vehicle ceiling materials are mainly formed by hot pressing each layer with an adhesive (binder) between them, as in Patent Document 1, but for laminated structures used for vehicle interior materials other than ceiling materials, such as floor mats, a method of forming the laminated structure by integrally foaming a foam raw material with a skin material is also used.

[0005] For example, Patent Document 2 discloses a technology for manufacturing a vehicle floor spacer in which a skin material is placed on the cavity surface of a mold, and a foamable synthetic resin raw material is injected into the mold and foamed, thereby bonding the skin material to the surface of the foamable synthetic resin.

[0006] Furthermore, in recent years, a technique has been developed for forming a laminated structure by integrally foaming a foam raw material with a skin material, even in the case of a laminated structure used in a vehicle ceiling material. For example, Patent Document 3 discloses a method for manufacturing a vehicle ceiling interior material in which the skin of the vehicle ceiling interior material and, if necessary, wiring members are placed in a mold, and the injected polyurethane raw material is foamed, thereby forming a polyurethane foam integrally with the skin of the vehicle ceiling interior material in the mold.

[0007] In vehicle interior materials such as vehicle ceiling materials, appearance is particularly important, and even when foam raw materials are foamed integrally with the skin material, there is a problem that the design is deteriorated if the foam components seep out to the surface. In response to this problem, Patent Document 3 proposes a method of arranging a film to prevent liquid leakage inside the skin. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] Japanese Patent Application Laid-Open No. 2007-216536 [Patent Document 2] Japanese Patent Publication No. 2022-169823 [Patent Document 3] Japanese Patent Application Laid-Open No. 2015-229298 Summary of the Invention [Problem to be solved by the invention]

[0009] As mentioned above, the main methods for manufacturing a laminated structure include a method of adhesively molding each layer by hot pressing with an adhesive (binder) interposed therebetween, and a method of forming a laminated structure by integrally foaming a foam raw material with a skin material, but from the viewpoint of ease of manufacturing, etc., the method of forming a laminated structure by integrally foaming a foam raw material with a skin material is preferred. As mentioned above, the integral foaming method also has the problem of foam components seeping out to the surface of the skin material, and previous technologies have solved this problem by placing a film or the like between the foam raw material and the skin material, increasing the basis weight of the skin material, or impregnating the skin material with resin or metal.

[0010] However, methods such as placing a film between the foam raw material and the skin material, increasing the basis weight of the skin material, or impregnating the skin material with resin or metal may reduce the performance (sound absorption performance, etc.) originally expected of the laminated structure. Furthermore, these methods may also reduce the adhesion between the layers.

[0011] Therefore, the main objective of this technology is to provide a technology that can prevent the exudation of foam components onto the surface of a skin material, while simplifying the manufacturing process and without compromising the various performances that the laminated structure can exhibit as a vehicle interior material. [Means for solving the problem]

[0012] The present inventors have conducted extensive research to solve the above-mentioned problems and have succeeded in preventing the foam components from seeping out onto the surface of a skin material by forming a laminated structure by integrally foaming a foam raw material with a skin material to which water has been applied, thereby completing the present technology.

[0013] As in the aforementioned Patent Document 1, there was a technology in which, when a base sheet made of a foamed resin and a skin sheet are thermally compressed with a binder interposed therebetween, the moisture is applied to the surface of the skin sheet while the thermal compression molding is performed, whereby the moisture is heated to form steam, and the pressure of this steam prevents the binder from penetrating into the skin sheet. This technology requires that the moisture be converted to steam by thermal compression molding, so it is assumed that the thermal press is performed at 100°C or higher. For this reason, it was common technical knowledge that this technology could not be used to integrally foam a foam raw material with a skin without thermal pressing.

[0014] However, by forming a laminated structure by co-foaming a foam raw material with a skin material coated with water, we unexpectedly succeeded in preventing the exudation of foam components onto the surface of the skin material. Furthermore, we discovered that exudation of foam components onto the surface of the skin material can be prevented even when the basis weight of the skin material is reduced. While the mechanism by which this technology prevents exudation of foam components onto the surface of the skin material is unclear, the method of co-foaming a foam raw material with a skin material raises the temperature during molding only to about 60°C. Therefore, it is presumed that the exudation of foam components onto the surface of the skin material can be prevented by a mechanism different from that of the technology described in Patent Document 1 (which suppresses binder penetration into the skin material sheet by water vapor pressure). The mechanism by which this technology prevents exudation of foam components onto the surface of the skin material is thought to be that the hydrophobicity of the foam raw material increases as the foaming reaction of the foam raw material progresses, but the details are unknown.

[0015] In the present technology, first, there is provided a method for manufacturing a vehicle interior material having a laminated structure including a skin material and a foam, the method comprising: applying water to the skin material; and foaming the surface material to which water has been applied and the foam raw material of the foam material together. In the manufacturing method according to the present technology, the amount of water applied is 80 g / m 2 It can be more than that.

[0016] The present technology also provides a vehicle ceiling material having a laminated structure including a skin material and a foam, The vehicle ceiling material is provided, wherein the skin material is impregnated with the foam component of the foam from one side. In the vehicle ceiling material according to the present technology, the basis weight of the skin material is 150 g / m 2 More than 350g / m 2 It can be as follows: In the vehicle ceiling material according to the present technology, the skin material may be made of knit, and in this case, the skin material may be impregnated with the foam component to a thickness of 40% or less of the thickness of the skin material. In the vehicle ceiling material according to the present technology, the one surface of the skin material may not be subjected to a nap-raising process. [Brief explanation of the drawings]

[0017] [Figure 1] 1 is a conceptual cross-sectional view schematically illustrating a first embodiment of a laminated structure 1 constituting a vehicle interior material according to the present technology. [Figure 2] 1 is a conceptual diagram schematically illustrating an example of a method for manufacturing a vehicle interior material according to the present technology. [Figure 3] 3 is a conceptual diagram schematically illustrating an example different from that shown in FIG. 2 of the method for producing a vehicle interior material according to the present technology. [Figure 4] FIG. 1 is a conceptual diagram that schematically illustrates an example of a case where a fiber layer 13 is interposed between a skin material 11 and a foam raw material 121 in a manufacturing method for a vehicle interior material according to the present technology. [Figure 5] FIG. 1 is a conceptual diagram showing an example of a method for manufacturing a vehicle interior material according to the present technology, in which a back surface material 14 is provided on the side of a foam 12 opposite to a skin material 11, and a fiber layer 13 is interposed between the skin material 11 and a foam raw material 121 and between the back surface material 14 and a foam raw material 121. [Figure 6] 6 is a conceptual diagram schematically illustrating an example different from that of FIG. 5 of the method for manufacturing a vehicle interior material according to the present technology. [Figure 7] 7 is a conceptual diagram schematically illustrating an example of a method for manufacturing a vehicle interior material according to the present technology, which is different from the examples shown in FIGS. 5 and 6. FIG. [Figure 8] FIG. 1 is a conceptual cross-sectional view that schematically illustrates a second embodiment of a laminated structure 1 that constitutes a vehicle interior material according to the present technology. [Figure 9] FIG. 1 is a conceptual cross-sectional view that schematically illustrates a third embodiment of the laminated structure 1 that constitutes a vehicle interior material according to the present technology. [Figure 10] 3 is a photograph of the laminated structure 1 of Example 3, Example 4, and Comparative Example 3 taken from the skin side. DETAILED DESCRIPTION OF THE INVENTION

[0018] Hereinafter, preferred embodiments for carrying out the present technology will be described with reference to the drawings. The embodiments described below are examples of typical embodiments of the present technology, and any of the embodiments can be combined. Furthermore, the scope of the present technology is not to be interpreted as being narrow.

[0019] 1. Manufacturing method for vehicle interior materials FIG. 1 is a conceptual cross-sectional view schematically illustrating a first embodiment of a laminated structure 1 constituting a vehicle interior material according to the present technology. The manufacturing method for a vehicle interior material according to the present technology is a manufacturing method for a vehicle interior material having a laminated structure 1 including a skin material 11 and a foam 12. The manufacturing method for a vehicle interior material according to the present technology includes a step of applying water to the skin material 11 (hereinafter also referred to as the "water application step") and a step of foaming a foam raw material 121 together with the skin material 11 in a water-applied state (hereinafter also referred to as the "foaming step"). Furthermore, if necessary, other steps performed when manufacturing a general vehicle interior material may be freely combined. Below, each step and the materials used will be described in detail.

[0020] (1) Water application process The water application step is a step of applying water to the skin material 11. The water application needs to be performed on at least one surface of the skin material 11 on which the foam 12 is disposed, and water may be applied to only that one surface or to both surfaces.

[0021] The amount of water to be applied in the water application step can be freely set as long as it does not impair the action and effect of the present technology. In the present technology, the lower limit of the amount of water to be applied is, for example, 70 g / m 2 More than 80g / m 2 More preferably, 90 g / m 2 More preferably, 100 g / m 2 By setting the lower limit of the amount of water to be applied within this range, it is possible to more reliably prevent the foam components from seeping out onto the surface of skin 11, and even when the basis weight of skin 11 is reduced, it is possible to prevent the foam components from seeping out onto the surface of skin 11.

[0022] There is no particular upper limit to the amount of water to be applied, for example, 300 g / m 2 Below 250g / m 2 Below 200g / m 2 It can be set as follows:

[0023] Any combination of methods can be used to apply water to the skin material 11 as long as it does not impair the effects and advantages of the present technology. Examples include spraying, transferring, scattering, or printing water, applying water using an applicator such as a brush, and submerging the skin material 11 in water. Among these, the present technology preferably uses a method of spraying or scattering water from the viewpoints of uniform application, ease of controlling the amount of application, and ease of the manufacturing process.

[0024] The timing of applying water to skin material 11 is not particularly limited as long as it is before foam raw material 121 is laminated on skin material 11. For example, when mold foaming is used in the foaming step described below, skin material 11 may be placed in a mold described below after water is applied to skin material 11, or water may be applied to skin material 11 after placing it in the mold.

[0025] The materials constituting the skin material 11 can be one or a combination of two or more materials depending on the application and purpose of the vehicle interior material, as long as the action and effect of the present technology are not impaired. Specific examples include woven fabrics, knitted fabrics, nonwoven fabrics, etc., made of one or a combination of two or more fibers, such as polyethylene terephthalate (PET) fiber, polyester fiber, polypropylene fiber, polyamide fiber, acrylic fiber, vinylon fiber, polyurethane fiber (spandex), glass fiber, carbon fiber, and natural fibers (e.g., wool, cotton, cellulose nanofiber, etc.). Synthetic leather (e.g., PVC, urethane, etc.), genuine leather, etc. may also be used.

[0026] In this technology, a "woven fabric" is a fabric made by combining warp threads (fiber bundles) and weft threads (fiber bundles) at right angles. In this technology, a "knit" is a fabric made by intertwining a single thread (fiber bundle), and is a fabric with higher breathability and elasticity than the woven fabric. In this technology, a "nonwoven fabric" is a fabric made by irregularly intertwining fibers or by bonding or welding them with heat, adhesives, etc.

[0027] In this technology, even if a highly breathable and stretchable knit (knitted fabric) is used for the covering material 11, the water application step can prevent the foam components from seeping out onto the surface of the covering material 11.

[0028] The basis weight of the skin material 11 can be freely set as long as it does not impair the action and effect of the present technology. In the present technology, the lower limit of the basis weight of the skin material 11 is, for example, 150 g / m 2 or more, preferably 160 g / m 2 More preferably, 170 g / m 2 More preferably, 180 g / m 2 In the present technology, even if the lower limit of the basis weight of the skin material 11 is set within this range, it is possible to prevent the foam component from seeping out onto the surface of the skin material 11.

[0029] The upper limit of the basis weight of the skin material 11 is, for example, 400 g / m 2 or less, preferably 350 g / m2 In this technology, by performing the water application process, as mentioned above, the basis weight can be reduced compared to the surface material of general vehicle interior materials, for example, 300 g / m 2 Below 250g / m 2 Below 200g / m 2 Setting the upper limit of the basis weight of the skin material 11 within this range can contribute to reducing the weight and cost of vehicle interior materials.

[0030] In a typical laminated structure, raising the surface of the skin material improves peel strength and prevents adhesive and foam components from seeping out onto the surface of the skin material. However, in this technology, by performing the foaming process after the water application process, sufficient peel strength and the above-mentioned seepage prevention effect can be achieved without raising the surface of the skin material 11 facing the foam 12. Note that in this technology, sufficient effects can be obtained without raising the surface of the skin material 11 facing the foam 12, but raising the surface is also possible. Furthermore, the surface of the skin material 11 opposite the foam 12 side can be raised as desired depending on other purposes, such as design.

[0031] Here, in the present technology, "raising" refers to a process in which fibers on the surface of the upholstery material 11 are scraped with a needle or a protruding object to increase the thickness of the upholstery material 11. In the present technology, "non-raising" refers to a state in which intentional raising has not been performed, and also includes cases in which raising occurs due to contact with equipment, etc. during the manufacturing or storage process of the upholstery material 11 or during the manufacturing or storage process of the vehicle interior material. For example, the degree of raising required to improve peel strength and the exudation prevention effect generally requires a process in which 30% or more of the fibers constituting the surface to be raised are cut and / or pulled out. On the other hand, in the present technology, sufficient peel strength and the exudation prevention effect can be achieved even if the proportion of cut and / or pulled out fibers of the surface of the upholstery material 11 on which the foam 12 is placed is 20% or less.

[0032] The term "skin" is used for convenience because the skin material 11 is disposed on the outermost surface of the essential structures of the laminated structure 1 constituting the vehicle interior material according to the present technology, but in an actual product, it is not limited to being disposed on the outermost surface. For example, it is possible to further laminate a desired material on the surface of the skin material 11, to cover the skin material 11 with a desired material, or to cover the entire laminated structure 1 with a desired material.

[0033] When manufacturing the laminated structure 1 constituting the vehicle interior material according to the present technology, a fiber layer 13 or the like can be interposed between the skin material 11 and the foam raw material 121 depending on the purpose (see FIG. 4 described later). When the fiber layer 13 is interposed between the skin material 11 and the foam raw material 121, it is preferable to apply water to one side of the fiber layer 13 on which the foam 12 is disposed (see FIG. 4 described later). Applying water to the fiber layer 13 more reliably prevents the foam components from seeping out onto the surface of the skin material 11.

[0034] Furthermore, when manufacturing the laminated structure 1 constituting the vehicle interior material according to the present technology, a backing material 14 can be provided on the side of the foam 12 opposite to the skin material 11 (see FIG. 5 described later). When the backing material 14 is provided, water may also be applied to the surface of the backing material 14 on the side where the foam 12 is placed (not shown). Applying water to the backing material 14 can also prevent components of the foam from seeping out onto the surface of the backing material 14.

[0035] When the backing material 14 is provided, a fiber layer 13 or the like can be interposed between the backing material 14 and the foam raw material 121 depending on the purpose (see FIG. 5 described later). When the fiber layer 13 is interposed between the backing material 14 and the foam raw material 121, water can also be applied to one surface of the fiber layer 13 on the side where the foam 12 is placed (not shown). By applying water to the fiber layer 13, it is possible to more reliably prevent the foam components from seeping out onto the surface of the backing material 14.

[0036] The fiber layer 13 and the back surface material 14 will be described in detail later.

[0037] (2) Foaming process The foaming process is a process in which the foam raw material 121 is foamed together with the skin material 11 to which water has been applied. By foaming the foam raw material 121 together with the skin material 11, a laminated structure 1 is formed in which the skin material 11 and the foam 12 are integrated together in a state in which the skin material 11 is partially impregnated with the foam component. In this way, with this technology, the skin material 11 and the foam 12 are integrated together, and no binder or catalyst is required to bond the skin material 11 and the foam 12. This contributes to reducing the weight and cost of vehicle interior materials, as well as suppressing the generation of volatile organic compounds (VOCs), thereby contributing to preventing air pollution and the generation of unpleasant or irritating odors.

[0038] The foaming process can be carried out by either mold foaming or slab foaming. Mold foaming is a method in which foam raw material 121 is mixed and injected into the cavity of a mold M (forming die) and foamed to the shape of the cavity. On the other hand, slab foaming is a method in which foam raw material 121 is mixed and discharged onto a belt conveyer and foamed at atmospheric pressure and room temperature. In this technology, mold foaming is preferably selected from the viewpoint of improving the peel strength between the skin material 11 and the foam 12.

[0039] Fig. 2 is a conceptual diagram schematically illustrating an example of a method for manufacturing a vehicle interior material according to the present technology. The example shown in Fig. 2 is an example in which mold foaming is performed in the foaming step. After foam raw material 121 is poured into a molding die M as shown in Fig. 2A, a skin material 11 to which water W has been applied is placed in the molding die M as shown in Fig. 2B. In this state, the foam raw material 121 and the skin material 11 are foamed together, and then the resulting mixture is demolded as shown in Fig. 2C, thereby forming a laminated structure 1.

[0040] Fig. 3 is a conceptual diagram schematically illustrating an example different from Fig. 2 of the method for manufacturing a vehicle interior material according to the present technology. The example shown in Fig. 3 is also an example in which mold foaming is performed in the foaming step. As shown in Fig. 3A, a skin material 11 to which water W has been applied is placed in a molding die M, and then a foam raw material 121 is injected into the molding die M. As shown in Fig. 3B, the foam raw material 121 is foamed together with the skin material 11 in this state, and then the resulting mixture is demolded as shown in Fig. 3C, thereby forming a laminated structure 1.

[0041] Here, in the foaming step, the skin material 11 needs to be coated with water when the foam raw material 121 is laminated onto the skin material 11, and the timing of pouring the foam raw material 121 into the mold and placing the skin material 11 in the mold is not limited. For example, as shown in the example in Fig. 2, the foam raw material 121 may be poured into the mold M, and then the skin material 11 coated with water W may be placed in the mold M. Alternatively, as shown in the example in Fig. 3, the foam raw material 121 may be poured into the mold M after the skin material 11 coated with water W is placed in the mold M. Furthermore, the foam raw material 121 may be discharged onto the skin material 11 coated with water, and then the skin material 11 and the foam raw material 121 may be placed in the mold M at the same time.

[0042] In the example shown in FIG. 3, the application of water W to the skin material 11 may be performed after the skin material 11 is placed in the mold M, or the water W may be applied to the skin material 11 first, and then the skin material 11 with the water W applied thereto may be placed in the mold M.

[0043] FIG. 4 is a conceptual diagram schematically illustrating an example in which a fiber layer 13 is interposed between a skin material 11 and a foam raw material 121. The example shown in FIG. 4 also illustrates a case in which mold foaming is performed in the foaming process. First, as shown in FIG. 4A, a skin material 11 to which water W has been applied is placed in a molding die M, and a fiber layer 13 is further placed on top of the skin material 11 to which water W has been applied. Water W can also be applied to the fiber layer 13. In this state, a foam raw material 121 is poured into the molding die M, and the foam raw material 121 and the skin material 11 are foamed together as shown in FIG. 4B. The foam is then demolded as shown in FIG. 4C, thereby forming a laminated structure 1. In the example shown in FIG. 4, the skin material 11 is partially impregnated with the foam component, and the fiber layer 13 is impregnated with the foam component, and a laminated structure 1 is formed in which the skin material 11, the fiber layer 13, and the foam 12 are integrated.

[0044] In the example shown in FIG. 4 , the application of water W to the skin material 11 and / or fiber layer 13 may be carried out after the skin material 11 and / or fiber layer 13 are placed in the molding die M, or the water W may be applied to the skin material 11 and / or fiber layer 13 first, and then the skin material 11 and / or fiber layer 13 to which the water W has been applied may be placed in the molding die M.

[0045] FIG. 5 is a conceptual diagram illustrating an example of a method for manufacturing a vehicle interior material according to the present disclosure, in which a backing material 14 is provided on the side of a foam 12 opposite to the skin material 11, and a fiber layer 13 is interposed between the skin material 11 and the foam raw material 121 and between the backing material 14 and the foam raw material 121. The example shown in FIG. 5 also illustrates a case in which mold foaming is performed in the foaming process. First, as shown in FIG. 5A, the backing material 14 is placed in a mold M, and a fiber layer 13 is further placed on the backing material 14. At this time, although not shown, water W may be applied to the surface of the backing material 14 and / or the fiber layer 13 on which the foam 12 will be placed. In this state, the foam raw material for the foam 12 is poured into the mold M, and the fiber layer 13 is placed in the mold M as shown in FIG. 5B. At this time, water W may be applied to the surface of the fiber layer 13 on which the foam raw material 121 will be placed. Furthermore, the skin material 11 to which water W has been applied is placed on the fiber layer 13. In this state, as shown in Fig. 5C, the foam raw material 121 is foamed integrally with the skin material 11 and the back surface material 14, and then the foam is removed from the mold as shown in Fig. 5D, thereby forming the laminated structure 1.

[0046] In the example shown in FIG. 5, the skin material 11 and the back surface material 14 are partially impregnated with the foam component, and the fiber layer 13 is also impregnated with the foam component, thereby forming a laminated structure 1 in which the skin material 11, the fiber layer 13, the back surface material 14, and the foam 12 are integrated.

[0047] In the example shown in FIG. 5, the backing material 14 is first placed in the mold M, but this is not limiting. As in the examples shown in FIGS. 3 and 4, the skin material 11 to which water W has been applied may be first placed in the mold M, and the fiber layer 13, foam raw material 121, fiber layer 13, and backing material 14 may be layered on top of the skin material 11 in this order.

[0048] 2 to 5, the foam raw material 121 may be injected from one location, but it is preferable to inject it from multiple locations from the viewpoint of forming a uniform layer of foam 12 and preventing seepage. Injecting a large amount of foam raw material 121 from one specific location may raise concerns that seepage from that specific location is likely to occur, but injecting it from multiple locations can prevent seepage from that specific location.

[0049] FIG. 6 is a conceptual diagram schematically illustrating an example of a method for manufacturing a vehicle interior material according to the present technology, different from FIG. 5 . The example shown in FIG. 6 illustrates a case in which the layers of a laminated structure 1 are laminated on a conveyor, and then mold foaming is performed in the foaming process. The backing material 14 and the fiber layer 13 are pulled out from rolls wound around them and transported in a laminated state, and a molten foam raw material 121 is discharged onto them. The fiber layer 13, to which water W has been applied, is then laminated on the discharged foam raw material 121, and the skin material 11, to which water W has been applied, is then laminated on the fiber layer 13. This laminate is cut to a predetermined size and placed in a mold M. In this state, the foam raw material 121 is foamed together with the skin material 11 and the backing material 14 as shown in FIG. 6B, and then demolded as shown in FIG. 6C, thereby forming the laminated structure 1.

[0050] In the example shown in Fig. 6, slab foaming may be performed in the foaming step. In this case, for example, as shown in the example shown in Fig. 7, the laminated structure 1 can be formed by passing the laminated body between rollers arranged at a predetermined interval, for example, without cutting, and foaming the foam raw material 121 together with the skin material 11 and the back surface material 14.

[0051] As the foam 12 that can be used in the present technology, one or more types of foams that can be used in general vehicle interior materials can be freely selected and used, as long as the action and effect of the present technology are not impaired. Specific examples include polyurethane foam, polyethylene foam, polypropylene foam, vinyl chloride foam, polystyrene foam, etc. Among these, polyurethane foam is particularly preferred in the present technology.

[0052] The polyurethane foam that can be used in the present technology can be produced using a composition for producing polyurethane foam that contains a polyol, a blowing agent, a catalyst, a foam stabilizer, an isocyanate, and, as necessary, various additives, etc. Each raw material for polyurethane foam is described below.

[0053] <Polyol> The polyol used in the polyurethane foam-producing composition can be one or more polyols that can be used in polyurethane foam production, as long as the effects and advantages of the present technology are not impaired. Specific examples include polyether polyols obtained by adding alkylene oxides such as ethylene oxide (EO) and propylene oxide (PO) to polyhydric alcohols such as ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, butylene glycol, neopentyl glycol, glycerin, pentaerythritol, trimethylolpropane, sorbitol, and sucrose; polyester polyols obtained by polycondensation of aliphatic carboxylic acids such as malonic acid, succinic acid, and adipic acid, or aromatic carboxylic acids such as phthalic acid, with aliphatic glycols such as ethylene glycol, diethylene glycol, and propylene glycol; polyether ester polyols obtained by reacting the above polyether polyols with polybasic acids to form polyesters; and polyether ester polyols having both polyether and polyester segments in one molecule.

[0054] <Foaming agent> The blowing agent used in the polyurethane foam-producing composition can be one or more blowing agents that can be used in the production of polyurethane foam, as long as the action and effect of the present technology are not impaired. Specific examples include water, methylene chloride, carbon dioxide, and pentane. The amount of blowing agent used is not particularly limited as long as the action and effect of the present technology are not impaired. For example, it is preferable to use 1 to 8 parts by mass of blowing agent per 100 parts by mass of polyol.

[0055] <Catalyst> The catalyst used in the polyurethane foam-producing composition can be one or more catalysts that can be used in polyurethane foam production, as long as the action and effect of the present technology are not impaired. Specific examples include amine-based catalysts such as triethylamine, dimethylaminohexanol, triethylenediamine, and tetramethylguanidine; tin-based catalysts such as stannous octoate; and metal catalysts (also referred to as "organometallic catalysts") such as phenylmercury propionate and lead octenate. The amount of catalyst used is not particularly limited as long as the action and effect of the present technology are not impaired. For example, it is preferable to use 0.1 to 2 parts by mass of catalyst per 100 parts by mass of polyol.

[0056] <Foam stabilizer> The foam stabilizer used in the composition for producing polyurethane foam can be one or more foam stabilizers that can be freely selected from those that can be used in the production of polyurethane foam, as long as the action and effect of the present technology are not impaired. Specific examples include silicone-based foam stabilizers, fluorine-containing compound-based foam stabilizers, surfactants, etc. The amount of foam stabilizer used is not particularly limited as long as the action and effect of the present technology are not impaired. For example, it is preferable to use 0.5 to 3 parts by mass of foam stabilizer per 100 parts by mass of polyol.

[0057] <Isocyanate> The isocyanate used in the composition for producing polyurethane foam can be one or more isocyanates that can be used in the production of polyurethane foam, as long as the action and effect of the present technology are not impaired. Specific examples include aliphatic isocyanates such as hexamethylene diisocyanate, isophorone diisocyanate, and dicyclohexamethane diisocyanate; aromatic isocyanates such as toluene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), naphthalene diisocyanate, xylylene diisocyanate, and polymeric polyisocyanate (crude MDI); and modified polyisocyanates obtained by modifying these.

[0058] The isocyanate index of the polyurethane foam is not particularly limited as long as it does not impair the functions and effects of the present technology, but for example, it is possible to use a polyurethane foam with an isocyanate index of 90 to 120. In the present technology, the isocyanate index is a value calculated by [(isocyanate equivalent in the composition for producing polyurethane foam / active hydrogen equivalent in the composition for producing polyurethane foam) × 100].

[0059] <Other> The composition for producing polyurethane foam may contain one or more additives that can be used in the production of polyurethane foam, as needed, as long as they do not impair the functions and effects of the present technology. Specific examples include flame retardants, stabilizers, plasticizers, colorants, pigments, antioxidants, crosslinking agents, antibacterial agents, dispersants, and ultraviolet absorbers.

[0060] (3) Other processes The laminated structure 1 obtained in the foaming process can be molded into a desired shape by edge trimming, cutting, etc., as necessary, and then further processed to match the shape of the desired vehicle interior material.

[0061] 2. Vehicle interior materials The vehicle interior material according to the present technology has a laminated structure 1 including a skin material 11 and a foam 12. The skin material 11 is characterized in that one side of the skin material 11 is impregnated with a foam component of the foam 12.

[0062] The specific use of the vehicle interior material according to the present technology is not particularly limited, and it can be used for any vehicle interior material. Examples include vehicle ceiling materials, armrests, headrests, seats, pillar covers, rear trays, door trims, trunk trims, console boxes, airbag covers, instrument panels, meter covers, crash pads, etc. It is particularly preferable that the vehicle interior material according to the present technology be used as a vehicle ceiling material.

[0063] In general, vehicle ceiling materials are often constructed by bonding a skin material and a foam by heat pressing with a binder interposed therebetween, and in this case, the skin material of the vehicle ceiling material is not impregnated with a foam component. On the other hand, the vehicle ceiling material according to the present technology is characterized in that the foam raw material 121 is foamed integrally with the skin material 11, and therefore the foam component of the foam 12 is impregnated from one side of the skin material 11.

[0064] The degree of impregnation of the foam component in the skin material 11 can be freely set depending on the type of skin material 11, etc. For example, when the skin material 11 is made of knit, the foam component is preferably impregnated to a thickness of 80% or less of the skin material, more preferably to a thickness of 50% or less, even more preferably to a thickness of 45% or less, and particularly preferably to a thickness of 40% or less. By setting the upper limit of the degree of impregnation of the foam component in the knit skin material 11 within this range, it is possible to prevent the foam component from being visible through the surface of the skin material 11.

[0065] Furthermore, for example, when the skin material 11 is made of nonwoven fabric, the foam component is preferably impregnated to a thickness of 90% or less of the thickness of the skin material, more preferably to a thickness of 85% or less, and even more preferably to a thickness of 80% or less. By setting the upper limit of the degree of impregnation of the foam component in the nonwoven fabric skin material 11 within this range, it is possible to prevent the foam component from being visible through the surface of the skin material 11.

[0066] The lower limit of the degree of impregnation of the foam component in the skin material 11 is preferably 5% or more, more preferably 10% or more, and even more preferably 15% or more of the thickness of the skin material. By setting the lower limit of the degree of impregnation of the foam component in the skin material 11 within this range, the peel strength between the skin material 11 and the foam 12 can be further improved.

[0067] In the present technology, the impregnation thickness of the foam component relative to the thickness of the skin material 11 is the distance from the surface of the skin material 11 on the foam 12 side to the deepest impregnated part.

[0068] In the laminate structure 1 constituting the vehicle interior material according to the present technology, in addition to the skin material 11 and the foam 12, other layers such as a fiber layer 13 and a backing material 14 may be laminated depending on the purpose. For example, FIG. 8 is a conceptual cross-sectional view that schematically shows a second embodiment of the laminate structure 1 constituting the vehicle interior material according to the present technology. In the second embodiment shown in FIG. 8, the fiber layer 13 is provided between the skin material 11 and the foam 12. In the second embodiment, the foam component of the foam 12 is impregnated from the fiber layer 13 to a portion of the skin material 11.

[0069] As the fiber layer 13 used in the present technology, one or more types of fibers that can be used in a general laminate structure can be freely selected and used as long as the action and effect of the present technology are not impaired. Specific examples include layers using inorganic fibers such as glass fiber, carbon fiber, rock wool, and metal fiber. In the present technology, among these, a fiber layer 13 using glass fiber is particularly preferred.

[0070] 9 is a conceptual cross-sectional view schematically illustrating a third embodiment of a laminated structure 1 constituting a vehicle interior material according to the present technology. A back surface material 14 is provided on the side of a foam 12 opposite to a skin material 11, and a fiber layer 13 is provided between the skin material 11 and the foam 12 and between the back surface material 14 and the foam 12. In the third embodiment, the foam component of the foam 12 is impregnated from the fiber layer 13 to a portion of the skin material 11 and a portion of the back surface material 14.

[0071] As long as the action and effect of the present technology are not impaired, the material constituting the back surface material 14 can be one or a combination of two or more of various materials depending on the use and purpose of the laminated structure 1. For example, the same materials as those usable for the skin material 11 described above can be used, or films, sheets, various board materials, etc. made of resin, wood, metal, etc. can also be used for the back surface material 14.

[0072] The details of the skin material 11 and the foam 12 of the laminated structure 1 constituting the vehicle interior material according to the present technology are the same as the skin material 11 and the foam 12 used in the manufacturing method for the vehicle interior material according to the present technology described above, and therefore will not be described here.

[0073] The present technology can also be configured as follows. [1] A method for manufacturing a vehicle interior material having a laminated structure including a skin material and a foam, comprising: applying water to the skin material; and foaming the foam raw material together with the skin material to which water has been applied. [2] The amount of water applied is 80 g / m 2 The method for producing a vehicle interior material according to [1] above. [3] A vehicle ceiling material having a laminated structure including a skin material and a foam, The vehicle ceiling material, wherein the skin material is impregnated with the foam component of the foam from one side. [4] The weight of the skin material is 150 g / m 2 More than 350g / m 2 The vehicle ceiling material according to [3], which is as follows: [5] the skin material is knitted, The vehicle ceiling material according to [3] or [4], wherein the skin material is impregnated with the foam component to a thickness of 40% or less of the thickness of the skin material. [6] The vehicle ceiling material according to any one of [3] to [5], wherein the one surface of the covering material is not brushed. [Example]

[0074] The present technology will be described in more detail below based on examples. Note that the examples described below are examples of typical examples of the present technology, and the scope of the present technology should not be construed as being narrow.

[0075] <Experimental Example 1> In Experimental Example 1, the influence of differences in the configuration of the laminated structure on the appearance was investigated.

[0076] (1) Manufacturing of laminated structures [Examples 1 to 4] The amount of water shown in Table 1 below was applied to one side of the skin material (knit) shown in Table 1 below, and the material was placed in a mold with the water-coated side facing up. A sheet of 80 g / m2 fabric was then applied to the skin material placed in the mold. 2After laminating the glass fibers, a raw material for polyurethane foam, as an example of a foam, was further injected from the injection points shown in Table 1 below. In this state, the mold was closed, and the raw material for polyurethane foam was foamed together with the skin material to produce a laminated structure.

[0077] [Comparative Examples 1 to 3] A laminated structure was produced in the same manner as in Examples 1 to 4, except that water was not applied to the skin material.

[0078] (2) Evaluation The manufactured laminated structures were evaluated as follows: The laminated structures of Examples 3 and 4 and Comparative Example 3 were photographed from the skin side.

[0079] [Impregnation thickness of foam component] The distance A from the surface of the skin facing the foam to the deepest impregnated part was measured relative to the thickness of the skin, and the impregnation thickness (%) was calculated using the following formula. Impregnation thickness (%) = {distance A (mm) / thickness of skin material (mm)} x 100

[0080] [Bleeding (appearance) evaluation] 5: No bleeding at all 4: No bleeding, but there are some areas where the foam components are visible through the surface. 3: There is some bleeding 2: There is some bleeding in places 1: There is a lot of bleeding 0: There is bleeding all over

[0081] (3) Results The results are shown in Table 1 and FIG.

[0082] [Table 1]

[0083] (4) Discussion As shown in Table 1 and Figure 10, it was confirmed that by forming a laminated structure by integrally foaming the foam raw material with the skin material to which water had been applied, it was possible to prevent the foam components from seeping out onto the surface of the skin material. [Explanation of symbols]

[0084] 1 Laminated structure 11 Skin material 12 Foam 121 Foam raw materials 13 Fiber layer 14 Backing material W water M mold

Claims

1. A method for manufacturing a vehicle interior material having a laminated structure including a skin material and a foam, comprising: applying water to the skin material; and foaming the foam raw material together with the skin material to which the water has been applied.

2. The amount of water applied is 80 g / m ２ The method for producing a vehicle interior material according to claim 1, wherein the above-mentioned step is carried out.

3. A vehicle ceiling material having a laminated structure including a skin material and a foam, The vehicle ceiling material, wherein the skin material is impregnated with the foam component of the foam from one side.

4. The weight of the skin material is 150 g / m ２ 350g / m or more ２ The vehicle ceiling material according to claim 3, wherein:

5. the skin material is knitted, 4. The vehicle ceiling material according to claim 3, wherein the skin material is impregnated with the foam component to a thickness of 40% or less of the thickness of the skin material.

6. The vehicle ceiling material according to claim 3 , wherein the one surface of the covering material is not brushed.

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