Ceiling material and method for manufacturing ceiling material

Abstract

To provide a plate-like laminate for a vehicle, an interior material for the vehicle, and a manufacturing method of the plate-like laminate for the vehicle, capable of reducing weight and cost.SOLUTION: In the vehicular plate-shaped laminate (skin material) 20, a front surface material 21 and a backing material 22 laminated on the back surface side of the front surface material 21 are bonded via a moisture-curable hot melt adhesive 23a.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a laminated plate for a vehicle, an interior material for a vehicle, and a method for manufacturing the laminated plate for a vehicle. [Background technology]

[0002] As one type of vehicle laminate, Patent Document 1 discloses a skin material 1 for use in a vehicle ceiling molded body, which comprises a surface layer 11, a first flexible polyurethane foam 12 laminated on one side 11b of the surface layer 11, and a second flexible polyurethane foam 13 laminated on a side 12b of the first flexible polyurethane foam 12 opposite the side 12a on which the surface layer 11 is laminated. This skin material 1 is manufactured by a frame lamination method. In this frame lamination method, the surface 12a of the first flexible polyurethane foam 12 is heated and melted by the flame of a gas burner 101, and the surface layer 11 is then superimposed on the melted surface and passed between rolls 103 and 104. Through these processes, the first flexible polyurethane foam 12 and the surface layer 11 are welded together. Subsequently, the surface 12b of the first flexible polyurethane foam 12 is heated and melted by the flame of a gas burner 102, and the second flexible polyurethane foam 13 is superimposed thereon, passed between rolls 104 and 105, and wound up into a roll. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2018-176979 Summary of the Invention [Problem to be solved by the invention]

[0004] The skin material disclosed in the above-mentioned Patent Document 1 has a polyurethane foam layer, which causes problems such as relatively high costs and increased weight of the skin material.

[0005] The present invention has been made to solve the above-mentioned problems, and aims to provide a plate-shaped laminate for a vehicle, a vehicle interior material, and a method for manufacturing a plate-shaped laminate for a vehicle, which enable weight reduction and cost reduction. [Means for solving the problem]

[0006] In order to solve the above problems, the plate-shaped laminate for a vehicle according to the present invention is characterized in that a surface material and a backing material laminated on the back side of the surface material are bonded together via a moisture-curing hot melt adhesive.

[0007] According to the plate-like laminate for a vehicle of this invention, the plate-like laminate for a vehicle can be formed by bonding the surface material and the backing material via a moisture-curing hot melt adhesive, and therefore by using a surface material and backing material that are relatively lightweight and low cost, it is possible to reduce the weight and cost of the plate-like laminate for a vehicle.

[0008] In the vehicle laminate according to the present invention, the surface material is preferably formed of a knit material, which is relatively light and low-cost, and thus makes it possible to reduce the weight of the skin material and to maintain high design quality of the skin material at a relatively low cost without increasing costs.

[0009] In the vehicle plate-like laminate according to the present invention, the backing material is preferably formed of a nonwoven fabric, which is relatively light and inexpensive, thereby enabling reductions in the weight and cost of the skin material.

[0010] In the vehicle plate-like laminate according to the present invention, the nonwoven fabric is preferably a spunlace nonwoven fabric, which has a relatively flat surface with few irregularities and can be used as the backing material, thereby making it possible to maintain a high level of appearance of the design surface of the surface material.

[0011] In the plate-like laminate for vehicles according to the present invention, the spunlace nonwoven fabric is preferably a cross-layer spunlace nonwoven fabric, which has high stretchability in both the longitudinal and transverse directions, and therefore can maintain high formability when a vehicle interior material is formed by hot press molding after laminating the plate-like laminate for vehicles on a substrate.

[0012] The vehicle interior material according to the present invention preferably includes a vehicle plate-like laminate having the above-described characteristics. This allows the vehicle interior material to be formed by laminating a vehicle plate-like laminate, in which a surface material and a backing material are bonded via a moisture-curable hot-melt adhesive, onto a substrate and then hot-press molding the laminate. Therefore, the vehicle interior material can maintain high moldability without causing peeling of the vehicle plate-like laminate.

[0013] The method for manufacturing a plate-like laminate for a vehicle according to the present invention is a method for manufacturing a plate-like laminate for a vehicle in which a surface material and a backing material laminated on the back side of the surface material are bonded together via a moisture-curing hot melt adhesive, and is characterized in that the moisture-curing hot melt adhesive is heated and melted, and applied to the back side of the surface material or the surface of the backing material, and then the surface material and the backing material are bonded together and humidified in a laminated state.

[0014] According to the manufacturing method of the plate-like laminate for a vehicle of the present invention, the plate-like laminate for a vehicle can be formed by bonding the surface material and the backing material via a moisture-curing hot melt adhesive. Therefore, by using a surface material and backing material that are relatively lightweight and low cost, it is possible to reduce the weight and cost of the plate-like laminate for a vehicle.

[0015] In the method for manufacturing a vehicle plate-shaped laminate according to the present invention, the moisture-curing hot melt adhesive is preferably applied by spraying the heated and melted moisture-curing hot melt adhesive in a spray form. This makes it possible to control the amount of moisture-curing hot melt adhesive sprayed and the breathability of the skin material, thereby making it possible to suppress the breathability of the skin material even when a surface material with a relatively low basis weight is used. This in turn makes it possible to accommodate a surface material with a relatively low basis weight, thereby enabling the weight and cost of the skin material to be reduced. Furthermore, since it is possible to control the amount of moisture-curing hot melt adhesive sprayed in the skin material manufacturing process, productivity can be improved compared to conventional methods. [Effects of the Invention]

[0016] According to the present invention, it is possible to provide a plate-like laminate for a vehicle, an interior material for a vehicle, and a method for manufacturing a plate-like laminate for a vehicle, which are capable of reducing weight and cost. [Brief explanation of the drawings]

[0017] [Figure 1] 1 is a cross-sectional view schematically showing one embodiment of a vehicle laminate plate and a vehicle interior material according to the present invention. [Figure 2] 1 is a cross-sectional view schematically showing one embodiment of a plate-like laminate for a vehicle and a substrate according to the present invention. [Figure 3] 2 is a schematic diagram for explaining a manufacturing process of the vehicle plate laminate shown in FIG. 1. FIG. [Figure 4] FIG. 2 is a schematic diagram for explaining a manufacturing process of the vehicle interior material shown in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0018] Hereinafter, an embodiment of a plate-like laminate for a vehicle, a vehicle interior material, and a method for manufacturing a plate-like laminate for a vehicle according to the present invention will be described with reference to the drawings. However, the present invention is not limited to this embodiment, and can be embodied in various forms with various modifications and improvements based on the knowledge of those skilled in the art.

[0019] As shown in Fig. 1, the vehicle interior material 10 includes a skin material (vehicle plate-like laminate) 20 and a substrate 30, and the skin material 20 and the substrate 30 are laminated together. In this embodiment, the vehicle interior material 10 is a ceiling material disposed on the ceiling surface inside the vehicle, and is a member provided for sound absorption, sound insulation, heat insulation, etc. within the vehicle cabin. The vehicle interior material 10 is not limited to a ceiling material, and other members such as door interior materials provided inside the vehicle cabin can also be used.

[0020] The skin material 20 includes a surface material 21, a backing material 22 laminated on the back surface side of the surface material 21, and an adhesive layer 23 that bonds the surface material 21 and the backing material 22. The skin material 20 is a plate-like laminate for a vehicle formed by laminating the surface material 21 and the backing material 22 together.

[0021] The surface material 21 is a member located on the surface of the covering material 20. The surface material 21 is preferably formed from a fabric or material such as a woven fabric, knitted fabric, or nonwoven fabric (hereinafter, sometimes referred to as fabric, etc.). Since the surface material 21 is arranged in the vehicle interior and catches the eye of occupants, it is possible to create a high level of design, and it is preferable that it be formed from a material with a good texture. The surface material 21 is preferably formed from a relatively lightweight and low-cost material, and preferably from a material with a relatively low basis weight. In this embodiment, it is more preferable that the surface material 21 be formed from a knit material, which is a knitted fabric. A knit material is a fabric made by knitting yarn into loops using needles, and is a fabric with higher elasticity than a woven fabric. Incidentally, a woven fabric is generally a fabric woven using two threads, a warp thread and a weft thread. Meanwhile, a nonwoven fabric is a sheet-like fabric or material made by intertwining fibers without weaving them.

[0022] The fibers forming the surface material 21 may be synthetic fibers made of, for example, polyester, PP (polypropylene), ethylene-propylene copolymer, or other polyolefin resins. The weight of the fibers forming the surface material 21 is 150 to 300 g / m 2 It is preferable that the density is 170 to 190 g / m 2The fineness of the fibers forming the surface material 21 is preferably 30 to 200 dtex, more preferably 30 to 150 dtex. The thickness of the surface material 21 is preferably about 0.5 mm to 1.5 mm.

[0023] The backing material 22 is a member located on the back surface of the covering material 20, and serves to make the covering material 20 strong and prevent it from losing its shape. The backing material 22 also has a permeation suppression function that prevents the adhesive used to bond the covering material 20 and the substrate 30 together during the heat pressing process from permeating into the covering material 20. To achieve this permeation suppression function, the backing material 22 is generally preferably made of a nonwoven fabric with a fine mesh. Furthermore, it is more preferable that the backing material 22 be made of a nonwoven fabric with a large basis weight, as this can further enhance the permeation suppression function.

[0024] Furthermore, since the backing material 22 is required to have high moldability (high ability to conform to the shape of the mold) in the heat press process, it is more preferable that it be formed from a highly elastic nonwoven fabric. As a highly elastic nonwoven fabric, a spunlace nonwoven fabric can be used. Examples of spunlace nonwoven fabrics include parallel-layer spunlace nonwoven fabrics that have high elasticity in one direction (longitudinal direction), and cross-layer spunlace nonwoven fabrics that have high elasticity not only in the longitudinal direction but also in the lateral direction (two-way elasticity). For the backing material 22, a spunlace nonwoven fabric is preferable, and a cross-layer spunlace nonwoven fabric is more preferable.

[0025] A nonwoven fabric is a sheet-like fabric made by intertwining fibers without weaving or knitting them, such as a fiber sheet, web, or batt, in which the fibers are oriented unidirectionally or randomly and are bonded together by entanglement and / or welding (fusion) and / or adhesion. Spunlace nonwoven fabric is a nonwoven fabric produced by entangling the fibers (especially short fibers) in a web with a high-pressure water jet without using a binder (adhesive).

[0026] The fibers forming the backing material 22 may be synthetic fibers made of polyester, PP (polypropylene), ethylene-propylene copolymer, or other polyolefin resins. The weight of the backing material 22 is 30 to 200 g / m 2 It is preferable that the density is 50 to 150 g / m 2 More preferably, it is 60 to 80 g / m 2 The fineness of the fibers forming the backing material 22 is preferably 0.5 to 3.0 dtex, and more preferably 1.0 to 2.0 dtex. The thickness of the backing material 22 is preferably about 0.3 mm to 1.0 mm.

[0027] The nonwoven fabric used for the backing material 22 is not limited to spunlace nonwoven fabric, but may be formed from other short-fiber nonwoven fabrics, such as needle-punched nonwoven fabrics in which fibers are entangled by reciprocating needles, or thermally bonded nonwoven fabrics using heat-sealed fibers. The nonwoven fabric used for the backing material 22 may be formed from long-fiber nonwoven fabrics, such as spunbonded nonwoven fabrics, meltblown nonwoven fabrics, and flash-spun nonwoven fabrics. Spunbonded nonwoven fabrics are nonwoven fabrics made by melting or dissolving a polymer and spun from a nozzle to form continuous fibers (filaments) that are then layered on a moving screen, using one or more bonding methods. Meltblown nonwoven fabrics are nonwoven fabrics made by spinning a polymer into a high-velocity hot gas stream to form fibers, which are then cooled and accumulated on a moving screen, using one or more bonding methods. Flash-spun nonwoven fabrics are made by spinning a polymer solution through a nozzle under certain conditions, evaporating the solvent immediately after spinning, and then layering the fibers on a moving screen to form highly fibrillated filaments using one or more bonding methods. The polymers mentioned above are high-molecular organic compounds, such as polyamide, polyethylene, polypropylene, polyurethane, and other thermoplastic resins (synthetic resins).

[0028] The adhesive layer 23 is a layer formed of a moisture-curable hot melt adhesive, which is an adhesive for bonding the surface material 21 and the backing material 22. The moisture-curable hot melt adhesive is a urethane-based moisture-curable hot melt adhesive, and its main component is a urethane prepolymer. The moisture-curable hot melt adhesive is obtained by reacting a polyester polyol with an isocyanate compound and has an isocyanate group (NCO) at the terminal. A terminal NCO group of 1 to 3% is particularly preferred. Examples of polyester polyols include 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. The polyester polyol is preferably made from a dicarboxylic acid having 6 or more carbon atoms (e.g., adipic acid, sebacic acid), and more preferably contains 80% or more by weight of a crystalline ester polyol with a melting point of 45°C or higher. The glycol constituting the polyester polyol can be an alcohol having four or more carbon atoms (1,4-butanediol, 1,6-hexanediol, etc.). The isocyanate compound is preferably an aromatic isocyanate, and diphenylmethane diisocyanate (MDI) is particularly preferred. The moisture-curing hot melt adhesive may contain additives such as a tackifier, wax, a crystal nucleating agent, and an antioxidant, as needed. The moisture-curing hot melt adhesive is not limited to urethane-based moisture-curing hot melt adhesives; polyester-based or acrylic-based moisture-curing hot melt adhesives may also be used.

[0029] The moisture-curing hot melt adhesive is applied to the back surface of the surface material 21 by spray application, in which the adhesive is sprayed in a spray form. The moisture-curing hot melt adhesive may be applied only to the back surface of the surface material 21, only to the front surface of the backing material 22, or may be applied to both the back surface of the surface material 21 and the front surface of the backing material 22. A particularly preferred spray application method is the curtain spray method, in which the moisture-curing hot melt adhesive is discharged from a plurality of nozzles arranged in a row under heating and pressure, and is spun into threads while being sprayed onto the surface material for lamination. According to the curtain spray method, thread-like molten resin is spun and stretched by a high-temperature, high-velocity airflow, and then sprayed directly onto the surface material for lamination.

[0030] To ensure easy and smooth spray application, the moisture-curing hot melt adhesive is preferably solid at room temperature, molten at 100°C or higher, and has a melt viscosity at 140°C (JIS K 6862) of 5 to 15 Pa·s (Pascal seconds). "Solid at room temperature" means being solid at 20°C. The temperature range for the molten state can be set appropriately within the range of 100 to 160°C. Furthermore, the moisture-curing hot melt adhesive is preferably a urethane prepolymer containing a crystalline ester polyol. Taking seasonal changes into consideration, the crystalline polyester polyol is preferably (1) solid at room temperature with a melting point of 45°C or higher, and (2) has a solidification time of 1 to 5 minutes at room temperature after melt application. That is, in order for the moisture-curing hot melt adhesive to be applied to a long sheet while being rewound and to dry and cure quickly at room temperature within a specified equipment length, it is preferable that the adhesive contains a crystalline ester polyol, the NCO content of the urethane prepolymer is 1 to 3%, and the number average molecular weight is 1000 to 4000, and more preferably 1500 to 2500.

[0031] The amount of moisture-curing hot melt adhesive applied is 10 to 30 g / m 2 It is preferable that the density is 10 to 25 g / m 2It is more preferable that the coating method is not limited to spray coating, and roll coating may be adopted, in which a roll coater (such as the roll coater 40 described in JP-A-2018-184000) is used for coating.

[0032] The substrate 30 has functions such as maintaining the shape of the ceiling in the vehicle cabin, ensuring rigidity, absorbing sound and insulating heat in the cabin, etc. The substrate 30 has a foamed synthetic resin layer 31. Glass material layers 32 and 33 are laminated on the front and back surfaces of the foamed synthetic resin layer 31 with binders 34 and 35 interposed therebetween. A skin material 20 is laminated on the front surface of the glass material layer 32. A film 36 is laminated on the back surface of the glass material layer 33, and a back surface material 37 is laminated on the back surface of the film 36. In this way, the substrate 30 is formed by laminating the foamed synthetic resin layer 31, the glass material layers 32 and 33, the binders 34 and 35, the film 36, and the back surface material 37. The thickness of the substrate 30 is preferably about 2 mm to 15 mm. Although the binders 34 and 35 are depicted in layers in the drawings for convenience, in reality they are impregnated into the surface of the expandable synthetic resin layer 31, the glass material layers 32 and 33, and the backing material 22, respectively, to provide adhesion and rigidity. The thickness of the expandable synthetic resin layer 31 (after press molding) is preferably about 1 mm to 14 mm. The thickness of the glass material layers 32 and 33 is preferably about 0.1 mm to 3 mm. The thickness of the film 36 is preferably about 0.05 mm to 1 mm. The thickness of the backing material 37 is preferably about 0.05 mm to 1 mm.

[0033] The foamable synthetic resin layer 31 is a porous synthetic resin with fine air bubbles retained inside, and is a foam with a synthetic resin skeleton. Urethane foam (polyurethane foam) made from polyurethane can be used for the foamable synthetic resin layer 31. The urethane foam may be a soft polyurethane foam, a hard polyurethane foam, or a semi-hard polyurethane foam.

[0034] The glass material layers 32 and 33 are provided as fiber reinforcement materials to maintain the shape and rigidity of the entire vehicle interior ceiling. The glass material layers 32 and 33 are formed into a sheet shape (glass fiber mat) by solidifying inorganic glass fiber with a binder.

[0035] A thermosetting adhesive can be used as the binders 34, 35. It is preferable to select a thermosetting resin made of isocyanate resin as the thermosetting adhesive, as this is because it is compatible with the foamable synthetic resin layer 31 made of urethane foam. However, the thermosetting adhesive is not limited to isocyanate resin and can be selected as appropriate. The thermosetting adhesive is applied to the foamable synthetic resin layer 31 by spraying, roll coating, etc. The amount applied is determined to suit the required strength and other various conditions.

[0036] The film 36 is a non-breathable film. The film 36 is made of polypropylene, polyethylene, polyamide, or polyester. A polyethylene terephthalate (PET) resin fiber nonwoven fabric is selected for the backing material 37. Various synthetic fiber nonwoven fabrics such as polyamide, polyester, and polyacrylonitrile can be used for the backing material 37. The foamable synthetic resin layer 31, the glass material layers 32 and 33, the film 36, and the backing material 37 are bonded together with a thermosetting adhesive (for example, a thermosetting resin made from an isocyanate resin).

[0037] As is clear from the above description, the vehicle plate laminate (skin material) 20 according to this embodiment has a surface material 21 and a backing material 22 laminated on the back surface side of the surface material 21 bonded together via a moisture-curing hot-melt adhesive 23a. According to this vehicle plate laminate 20, the vehicle plate laminate 20 can be formed by bonding the surface material 21 and the backing material 22 together via the moisture-curing hot-melt adhesive 23a. Therefore, by using the surface material 21 and backing material 22, which are relatively light and low cost, the vehicle plate laminate 20 can be made lighter and less expensive.

[0038] Furthermore, the surface material 21 and the backing material 22 are bonded together via the moisture-curing hot-melt adhesive 23a, and can be bonded together through a simple manufacturing process of simply applying the molten moisture-curing hot-melt adhesive 23a and laminating them, thereby achieving high productivity in manufacturing the vehicle plate-like laminate 20. Furthermore, the surface material 21 and the backing material 22 bonded together by moisture curing of the moisture-curing hot-melt adhesive 23a are prevented from peeling even when heated after moisture curing, because the moisture-curing hot-melt adhesive 23a does not melt. As a result, when the vehicle interior material 10 is formed by hot press molding after laminating the vehicle plate-like laminate 20 on the substrate 30, high formability can be maintained without peeling of the vehicle plate-like laminate 20. In this way, by bonding the surface material 21 and the backing material 22 via the moisture-curing hot melt adhesive 23a, it is possible to achieve both high productivity when manufacturing the vehicle plate-shaped laminate 20 and high formability during hot press molding after the vehicle plate-shaped laminate 20 is laminated onto the base material 30.

[0039] Furthermore, since the plate-like laminate body 20 for a vehicle can be formed without providing an intermediate layer such as a polyurethane foam layer as in the conventional method, the thickness of the plate-like laminate body 20 for a vehicle can be reduced, and therefore, when forming a vehicle interior material 10 of the same thickness, the thickness of the substrate 30 can be increased, thereby improving the strength of the vehicle interior material 10. Furthermore, in the plate-like laminate body 20 for a vehicle, the surface material 21 and the backing material 22 can be bonded without using a frame lamination method, which allows for a reduction in volatile organic compounds (VOCs).

[0040] Furthermore, in the vehicle plate-like laminate body 20, the surface material 21 is preferably formed of a knit material. This makes it possible to reduce the weight of the skin material 20 because knit materials are relatively light and low cost, and also makes it possible to maintain a high level of design of the skin material 20 at a relatively low cost without increasing costs.

[0041] In addition, in the vehicle plate-like laminate body 20, the backing material 22 is preferably formed of nonwoven fabric. Since nonwoven fabric is relatively light and low-cost, this makes it possible to reduce the weight and cost of the skin material 20.

[0042] Furthermore, in the vehicle plate-like laminate 20, the nonwoven fabric is preferably a spunlace nonwoven fabric. This allows the use of a spunlace nonwoven fabric, which has a relatively flat surface with few irregularities, for the backing material 22, thereby making it possible to maintain a high level of appearance of the design surface of the surface material 21.

[0043] Furthermore, in the vehicle plate-like laminate body 20, the spunlace nonwoven fabric is preferably a cross-layer spunlace nonwoven fabric. This cross-layer spunlace nonwoven fabric has high stretchability in the longitudinal and lateral directions, and therefore, when the vehicle interior material 10 is formed by hot press molding after the vehicle plate-like laminate body 20 is laminated on the substrate 30, it is possible to maintain high formability.

[0044] Furthermore, the vehicle interior material 10 preferably includes a vehicle plate-like laminate 20 having the above-mentioned characteristics. This allows the vehicle interior material 10 to be formed by laminating the vehicle plate-like laminate 20, in which the surface material 21 and the backing material 22 are bonded via a moisture-curing hot-melt adhesive 23a, onto a substrate 30 and then performing hot press molding. Therefore, the vehicle interior material 10 can maintain high formability without causing peeling of the vehicle plate-like laminate 20.

[0045] Next, a manufacturing method of the skin material 20 formed by bonding the surface material 21 and the backing material 22 will be described with reference to Fig. 3. The surface material 21 is unwound from a surface material roll 21A around which the surface material 21 is wound, and supplied onto a transport conveyor 41. The transport conveyor 41 transports the surface material 21 forward at a predetermined speed, for example, a transport speed of 30 to 50 m / min, with the surface (design surface) of the surface material 21 facing downward.

[0046] A spray applicator 42 is provided above the transport conveyor 41. A known example of the spray applicator 42 is disclosed in Japanese Patent Application Laid-Open No. 2017-136735. The spray applicator 42 is provided with a nozzle facing downward. The spray applicator 42 applies a molten moisture-curing hot melt adhesive (hereinafter sometimes simply referred to as adhesive) 23a supplied from a moisture-curing hot melt adhesive storage tank (hereinafter sometimes simply referred to as adhesive storage tank) 43 to the upper surface (rear surface) of the surface material 21 on the transport conveyor 41. The amount of adhesive applied to the surface material 21 is, for example, 10 to 25 g / m. 2 Examples include:

[0047] The nozzle of the spray applicator 42 has multiple discharge (ejection) holes arranged in a row at predetermined intervals (for example, 0.4 mm) along the width direction of the facing material 21. In the spray applicator 42, the adhesive 23a is pumped from the adhesive storage tank 43 in a molten state, discharged from the multiple discharge holes, and stretched by a high-temperature, high-pressure air current. The adhesive 23a is sprayed onto the back surface of the facing material 21 in the form of threads or particles while being stretched, and then laminated, thereby forming a layer of the adhesive 23a.

[0048] After the adhesive 23a is sprayed, the backing material 22 is unwound from the backing material roll 22A and laminated onto the back surface of the surface material 21 to which the adhesive 23a has been applied, and the laminate is then bonded by passing it between pressure rollers 44 and 45. Subsequently, while the laminate is transported by a plurality of rollers (not shown) for a predetermined time, the adhesive 23a naturally cools and reacts with moisture (humidification) in the air, thereby starting to harden. That is, the backing material 22 is bonded to the back surface of the surface material 21 via the adhesive 23a, thereby forming the skin material 20. The skin material 20 is then wound up by a take-up roll (not shown). The curing time required for the adhesive 23a to completely harden by moisture curing is, for example, several hours to several tens of hours. Alternatively, the skin material (vehicle plate-like laminate) 20 may be cut to a predetermined length rather than wound up, and the cut plate-like skin materials 20 may be stacked.

[0049] Next, a manufacturing method for integrally forming the skin material 20 and the substrate 30 by heat pressing will be described with reference to FIG. 4. Heat pressing refers to applying pressure to an object to be pressed while heating it to form it into a desired shape, and then cooling it to form the desired shape. Alternatively, the object to be pressed may be heated and then pressed. The skin material 20 and the substrate 30 are set between molds 51 and 52, whose molding surfaces are formed into the desired curved surface, and heat pressing is performed to integrally form the skin material 20 and the substrate 30, thereby obtaining the vehicle interior material 10. Here, the skin material 20 and the substrate 30 are laminated and heat pressed as shown in FIG. 4.

[0050] The skin material 20 and the substrate 30 are plate-shaped before being heat-pressed. The forming dies 51, 52 have an uneven shape corresponding to the uneven shape of the vehicle interior material 10. The heat-pressing temperature can be varied as needed within a range of 80 to 150°C, and the heat-pressing time can be varied as needed within a range of 10 to 60 seconds. The skin material 20 and the substrate 30 are heated and pressurized by the heat press, and are transformed from a plate-like shape into an uneven shape. As the skin material 20 transforms into an uneven shape, stress is concentrated in parts of the skin material 20, causing it to expand and contract in response to the stress. Thus, even in parts where stress is concentrated and the skin material 20 expands and contracts in part, the skin material 20 of this embodiment prevents the thermosetting adhesive from penetrating into the interior of the skin material 20 and smooths the unevenness according to the uneven shape of the vehicle interior material 10, thereby achieving a smooth design surface for the vehicle interior material 10.

[0051] The manufacturing method of the plate-shaped laminate 20 for a vehicle according to this embodiment is a manufacturing method of the plate-shaped laminate 20 for a vehicle in which a surface material 21 and a backing material 22 laminated on the back side of the surface material 21 are bonded together via a moisture-curing hot melt adhesive 23a, in which the moisture-curing hot melt adhesive 23a is heated and melted and applied to the back side of the surface material 21 or the surface of the backing material 22, and then the surface material 21 and the backing material 22 are bonded together and humidified in a laminated state.

[0052] According to this manufacturing method of the plate-like laminate body 20 for a vehicle, the plate-like laminate body 20 for a vehicle can be formed by bonding the surface material 21 and the backing material 22 via a moisture-curing hot-melt adhesive 23a, and therefore, by using a surface material 21 and a backing material 22 that are relatively light and low cost, it is possible to reduce the weight and cost of the plate-like laminate body 20 for a vehicle. Furthermore, since the surface material 21 and the backing material 22 of the plate-like laminate body 20 for a vehicle are bonded via the moisture-curing hot-melt adhesive 23a, when the vehicle interior material 10 is formed by hot press molding after laminating the plate-like laminate body 20 for a vehicle on the substrate 30, it is possible to maintain high formability without causing peeling of the plate-like laminate body 20 for a vehicle.

[0053] Furthermore, in the manufacturing method of the vehicle plate-like laminate 20, the moisture-curing hot-melt adhesive 23a is preferably applied by spraying the heated and melted moisture-curing hot-melt adhesive 23a in a spray state. This makes it possible to control the amount of the moisture-curing hot-melt adhesive 23a sprayed and to control the breathability of the covering material 20, so that even when a surface material 21 with a relatively low basis weight is used, the breathability of the covering material 20 can be kept low. This in turn makes it possible to accommodate a surface material 21 with a relatively low basis weight, thereby enabling the weight and cost of the covering material 20 to be reduced. Furthermore, since it is possible to control the amount of the moisture-curing hot-melt adhesive 23a sprayed in the manufacturing process of the covering material 20, productivity can be improved compared to conventional methods. [Example]

[0054] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to these examples and can be practiced in various forms with various modifications and improvements based on the knowledge of those skilled in the art.

[0055] [Table 1]

[0056] The surface material 21 and backing material 22 shown in Table 1 were used to create a skin material 20, which is a plate-like laminate for a vehicle, and the skin material 20 was used to create the vehicle interior materials 10 of Examples 1 to 3 and Comparative Examples 1 to 3.

[0057] The surface material 21 of Examples 1 to 3 is made of a knit material, and the knit material is made of synthetic fibers made of polyester. The knit material has a basis weight of 170 to 190 g / m 2 The fineness is 30 to 110 dtex. The thickness of the surface material 21 is about 0.7 mm to 0.9 mm. The backing material 22 in Examples 1 to 3 is formed of a nonwoven fabric, with Example 1 being formed of a cross-layer spunlace nonwoven fabric, Example 2 being formed of a parallel-layer spunlace nonwoven fabric, and Example 3 being formed of a needle-punched nonwoven fabric. The basis weight of the backing material 22 is 55 to 65 g / m 2 and the fineness is 1.4 to 1.6 dtex. The thickness of the surface material 21 is about 0.45 mm to 0.55 mm. The method for bonding the surface material 21 and the backing material 22 in Examples 1 to 3 is a bonding method in which the moisture-curing hot melt adhesive described above is sprayed and applied to bond them.

[0058] The surface material 21 in Comparative Examples 1 to 3 is formed of a knit material, as in Examples 1 to 3. The backing material 22 in Comparative Examples 1 to 3 is formed of a cross-layer spunlace nonwoven fabric, as in Example 1. Furthermore, in Comparative Example 3, an intermediate layer is provided between the surface material 21 and the backing material 22. The intermediate layer is formed of polyurethane foam. One side of the intermediate layer is bonded to the surface material 21 by frame lamination, and the other side is bonded to the backing material 22 by frame lamination. Frame lamination is a lamination process in which polyurethane foam is melted and attached to another member. The surface material 21 and the backing material 22 in Comparative Example 1 are bonded by spraying (applying) a molten hot melt adhesive. The surface material 21 and the backing material 22 in Comparative Example 2 are bonded by heating them with a film-like hot melt adhesive sandwiched between them. The hot melt adhesive is an adhesive that adheres in a molten state after being heated, and is made of a thermoplastic plastic such as ethylene vinyl acetate.

[0059] The exudation resistance, appearance, lightness, productivity, and moldability during hot pressing of the vehicle laminate plate 20 of each example and each comparative example were measured (evaluated), and further a comprehensive evaluation was performed.

[0060] The oozing resistance was measured by visually observing the oozing of the moisture-curing hot-melt adhesive or thermosetting adhesive onto the surface of the covering material 20 for three test pieces. If no oozing was observed in any of the three pieces, the oozing resistance was deemed very good (indicated by ○) and the test was judged to have passed. If slight oozing was observed in one piece and no oozing was observed in the remaining two pieces, the oozing resistance was deemed good (indicated by △) and the test was judged to have passed. Furthermore, if oozing was observed in two or more pieces, the oozing resistance was deemed poor (indicated by ×) and the test was judged to have failed.

[0061] The appearance was evaluated by visually observing the state of wrinkles and irregularities (smoothness) on the surface of the surface material 21 (within a 300 mm square range) of three test pieces in the vehicle plate-like laminate 20 of Examples 1 to 3 and Comparative Examples 1 to 3. When wrinkles, irregularities, etc. were not observed on the surface of the surface material 21 of all three pieces using side light from the inspection table, the appearance was judged to be very good (indicated by ○) and passed. When wrinkles, irregularities, etc. were not observed on the surface of the surface material 21 of all three pieces under natural light, the appearance was judged to be good (indicated by △) and passed. Furthermore, when wrinkles, irregularities, etc. were observed on the surface of the surface material 21 of one or more pieces under natural light, the appearance was judged to be poor (indicated by ×) and passed.

[0062] The total weight was measured by measuring the weight of a test piece of the vehicle plate-like laminate 20 of each example and each comparative example. Then, lightness was evaluated based on the measured weight. If the weight was equal to or greater than that of Comparative Example 3, it was rated as × (failed) as being relatively heavy in terms of lightness, and if the weight was less than that of Comparative Example 3, it was rated as ○ (passed) as being relatively light in terms of lightness.

[0063] The productivity was evaluated based on the number of steps involved in the bonding method (bonding process) for bonding the surface material 21 and the backing material 22. When bonding is performed by spraying adhesive, the number of steps is fewer than bonding methods that require a heating process, such as when a hot melt film is heated and attached, or when a polyurethane foam is melted using frame lamination. Therefore, when the number of steps involved in the bonding process was equal to or greater than the number of steps involved in Comparative Example 2 or Comparative Example 3, it was marked as × (fail), and when the number of steps involved in the bonding process was less than the number of steps involved in Comparative Example 2 or Comparative Example 3, it was marked as ○ (pass).

[0064] The evaluation method for formability during hot pressing was performed by visually observing three test pieces for the vehicle plate-like laminate 20 of Examples 1 to 3 and Comparative Examples 1 to 3 for the presence or absence of peeling of the skin material 20 and the presence or absence of wrinkles, etc., of the surface material 21. When peeling of the skin material 20 and wrinkles, etc., of the surface material 21 were not confirmed in all three pieces, the formability was determined to be very good (indicated by ○) and passed. When peeling of the skin material 20 and wrinkles, etc., of the surface material 21 were confirmed in one piece and peeling of the skin material 20 and wrinkles, etc., of the surface material 21 were not confirmed in the remaining two pieces, the formability was determined to be good (indicated by △) and passed. Furthermore, when peeling of the skin material 20 and wrinkles, etc., of the surface material 21 were confirmed in two or more pieces, the formability was determined to be poor (indicated by ×) and passed.

[0065] The overall evaluation was based on the evaluation results for all evaluation items. In this embodiment, the worst evaluation result among the five evaluation items was used as the overall evaluation result.

[0066] As shown in Table 1, Example 1 received an "○" rating for all five evaluation items, with the worst evaluation (rating) also being "○," so the overall rating was "○." Example 2 received an "△" rating for formability during hot pressing, which was the worst rating of the five evaluation items. Furthermore, Example 3 received an "△" rating for appearance, which was the worst rating of the five evaluation items.

[0067] On the other hand, Comparative Example 1 differs from Example 1 in that the adhesive method involves applying a hot melt adhesive in a spray form, and therefore the formability during heat pressing is "×". As such, the worst evaluation of the five evaluation items was "×" for formability during heat pressing, and therefore the overall evaluation of Comparative Example 1 was "×". Comparative Example 2 differs from Example 1 in that the adhesive method involves bonding using a film-like hot melt adhesive, and therefore the productivity and formability during heat pressing are "×". As such, the worst evaluation of the five evaluation items was "×" for productivity and formability during heat pressing, and therefore the overall evaluation of Comparative Example 2 was "×". Furthermore, Comparative Example 3 differs from Example 1 in that an intermediate layer (polyurethane) is present and the adhesive method involves bonding by frame lamination, and therefore the lightness and productivity are "×". As such, the worst evaluation of the five evaluation items was "×" for lightness and productivity, and therefore the overall evaluation of Comparative Example 3 was "×". [Explanation of symbols]

[0068] 10...vehicle interior material, 20...vehicle plate-shaped laminate (skin material), 21...surface material, 22...backing material, 23...adhesive layer, 23a...moisture-curing hot melt adhesive, 30...substrate.

Claims

1. A laminated plate for vehicles, characterized in that a surface material and a backing material laminated on the back side of the surface material are bonded together via a moisture-curing hot melt adhesive.

2. 2. The vehicle laminate according to claim 1, wherein the surface material is made of a knit material.

3. 3. The vehicle laminate according to claim 1, wherein the backing material is made of a nonwoven fabric.

4. 4. The vehicle laminate plate according to claim 3, wherein the nonwoven fabric is a spunlace nonwoven fabric.

5. 5. The vehicle laminate plate according to claim 4, wherein the spunlace nonwoven fabric is a cross-layer spunlace nonwoven fabric.

6. An interior material for a vehicle, comprising the plate-like laminate for a vehicle according to any one of claims 1 to 5.

7. A method for manufacturing a plate-like laminate for a vehicle in which a surface material and a backing material laminated on the back side of the surface material are bonded via a moisture-curing hot melt adhesive, The moisture-curable hot melt adhesive is heated and melted, and applied to the back surface of the surface material or the surface of the backing material; Thereafter, the surface material and the backing material are bonded together, and the laminated state is humidified.

8. 8. The method for manufacturing a plate-like laminate for a vehicle according to claim 7, wherein the moisture-curable hot melt adhesive is applied by spraying the moisture-curable hot melt adhesive that has been heated and melted in a spray form.

Images