Interior covering material and method for producing same

Abstract

To provide a skin material for interior having a nonwoven fabric as the base material, and capable of suppressing penetration of a foamable resin.SOLUTION: A skin material 101 for interior forms a floor carpet for car interior by including a resin foam layer F at a rear side by filling the rear side with a foamable resin in the inside of a molding die, and heating the product to foam the foamable resin. The skin material 101 for interior has a skin substrate 10 having as the base material, a needle punch nonwoven fabric 5 which is obtained by needle-punch processing a web formed of a synthetic resin fiber 1 of a thickness of 0.5-20 dtex, and having a basis weight of 100-300 g / m2, and a synthetic resin porous layer 60 provided at a lower side of the skin substrate 10 and having an application quantity of 20-100 g / m2 at a non-volatile component conversion. With this, the skin material 101 for interior can suppress penetration of the foamable resin even without using an oil repellent agent when the foamable resin is applied.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an interior covering material having a nonwoven fabric as a base material. [Background technology]

[0002] 2. Description of the Related Art Conventionally, floor carpets have been known that use nonwoven fabric as an interior covering material and have a foamed resin layer on the back side (see, for example, Patent Documents 1 and 2). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2000-177056 A [Patent Document 2] JP 2004-027466 A Summary of the Invention [Problem to be solved by the invention]

[0004] A floor carpet having a foamed resin layer on the back side of an interior covering material is formed by heating a nonwoven fabric as an interior covering material and a foamable resin filled on the back side of the nonwoven fabric in a molding die to foam the foamable resin. However, the interior covering material is required to have air permeability in order to ensure sound absorption. Therefore, conventional interior covering materials have a problem that when the foamable resin is filled in the molding die and then heated, the foamable resin may penetrate the nonwoven fabric and reach the surface side.

[0005] The problem to be solved by the technology of the present specification has been made in view of the above-mentioned points, and an object of the present invention is to provide an interior covering material having a nonwoven fabric as a base material, which is capable of suppressing the penetration of foamable resin. [Means for solving the problem]

[0006] The interior covering material according to the embodiment of the present specification is made of synthetic resin fibers having a thickness of 0.5 to 20 dtex and a basis weight of 100 to 300 g / m 2 The web comprises a skin substrate having a needle-punched nonwoven fabric as a base material, The coating amount of the coating material provided on the underside of the skin substrate is 20 to 100 g / m2 in terms of non-volatile content. 2 A synthetic resin porous layer; The present invention is characterized by having the following.

[0007] The interior covering material according to the embodiment of the present specification is made of synthetic resin fibers having a thickness of 0.5 to 20 dtex and a basis weight of 100 to 300 g / m 2 The web is made of a surface substrate made of needle-punched nonwoven fabric and a non-volatile content of 20 to 100 g / m2. 2 As a result, in the interior skin material according to the embodiment, a porous layer of synthetic resin is formed so as to fill in the gaps in the nonwoven fabric, and therefore, when the back side of the material is filled with a foamable resin in a molding die and then heated, penetration of the foamable resin can be suppressed.

[0008] In the above interior skin material, the synthetic resin porous layer may be impregnated into the skin base material.

[0009] According to this, since the skin base material is impregnated with the synthetic resin porous layer, when the foamable resin is filled on the back side of the skin base material in the molding die and then heated, the interior skin material can suppress the penetration of the foamable resin.

[0010] In the above interior skin material, the synthetic resin porous layer may be formed in a foam rubber shape.

[0011] According to this, a foam rubber-like synthetic resin porous layer is formed on the underside of the skin base material, so that when the foamable resin is filled on the back side of the skin base material in the molding die and then heated, the interior skin material can suppress penetration of the foamable resin.

[0012] In the above-mentioned interior skin material, the skin base material may comprise a permeation-preventing nonwoven fabric below the needle-punched nonwoven fabric, and the needle-punched nonwoven fabric and the permeation-preventing nonwoven fabric may be needle-punched together.

[0013] According to this, the permeation-preventing nonwoven fabric can suppress the permeation of the foamable resin filled on the back surface side of the skin base material.

[0014] In the above-mentioned interior covering material, the permeation-preventing nonwoven fabric may be a spunbond nonwoven fabric, a meltblown nonwoven fabric, or a wet-laid nonwoven fabric.

[0015] This makes it possible for the interior covering material to suitably suppress the penetration of the foamable resin.

[0016] In the above interior skin material, the synthetic resin forming the synthetic resin porous layer may be an acrylic resin.

[0017] This makes it possible to provide an interior covering material with excellent durability.

[0018] In the above interior skin material, thermally expandable capsules may be mixed into the synthetic resin porous layer.

[0019] This makes it possible to reduce the amount of air permeation through the interior covering material.

[0020] Here, the interior skin material according to the embodiment is an interior skin material in which an upper-layer skin substrate and a lower-layer skin substrate are needle-punched, The upper skin substrate is made of synthetic resin fiber having a thickness of 0.5 to 20 dtex and a basis weight of 50 to 200 g / m 2 the web is a nonwoven fabric bonded by needle punching, The lower skin substrate is made of synthetic resin fiber having a thickness of 0.5 to 20 dtex and a basis weight of 50 to 200 g / m 2 The web is a needle punched nonwoven fabric.

[0021] According to this, the interior covering material according to the embodiment is formed from synthetic resin fibers having a thickness of 0.5 to 20 dtex and a basis weight of 50 to 200 g / m 2 The web is formed from a needle-punched upper skin substrate and synthetic resin fibers with a thickness of 0.5 to 20 dtex, and has a basis weight of 50 to 200 g / m 2 The web is needle-punched together with the needle-punched lower-layer skin substrate. Since the two-layer needle-punched nonwoven fabric is needle-punched, the interior skin material according to the embodiment can suppress penetration of the foamable resin when the foamable resin is filled and then heated by the two-layer needle-punched nonwoven fabric.

[0022] In the above-mentioned interior skin material, an intermediate film layer may be interposed between the upper skin substrate and the lower skin substrate.

[0023] According to this, the intermediate film layer can suppress the penetration of the foamable resin. Effect of the Invention

[0024] According to the interior skin material of the embodiment, it is possible to suppress the penetration of the foamable resin when the foamable resin is filled on the back side of the interior skin material in the molding die and then heated. [Brief description of the drawings]

[0025] [Figure 1] 1 is a cross-sectional image of an interior covering material according to a first embodiment. FIG. [Diagram 2] FIG. 6 is a cross-sectional image of an interior covering material according to a second embodiment. [Diagram 3] 1 is an enlarged photograph of the back surface of an interior covering material of Example 3 (first embodiment). [Figure 4] 1 is an enlarged photograph of the back surface of an interior covering material of Example 4 (first embodiment). [Diagram 5] 1 is a graph showing the normal incidence sound absorption coefficient of floor carpets using the interior covering materials of Examples 3 and 4. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] (First embodiment) Hereinafter, an interior covering material 101 according to a first embodiment of the present specification will be described with reference to the drawings. Note that the scope of the present invention is not limited to the scope disclosed in the embodiment. The interior covering material 101 according to the first embodiment is heated in a mold together with a foamable resin filled on its back side, and the foamable resin is foamed to provide a foamed resin layer F on the back side, thereby forming a floor carpet for an automobile interior material. As shown in FIG. 1, the interior covering material 101 according to the first embodiment comprises a skin substrate 10 having a needle-punched nonwoven fabric 5 as a base material, and a foamed resin layer F provided on the underside of the skin substrate 10, the foamed resin layer F having a coating amount of 20 to 100 g / m2 in terms of nonvolatile content. 2 and synthetic resin porous layer 60. As a result, interior skin material 101 according to the first embodiment can suppress the penetration of foamable resin when the foamable resin is filled on the back side of the interior skin material 101 in the molding die and then heated, even without using an oil repellent.

[0027] The needle-punched nonwoven fabric 5, which is the base material of the skin substrate 10, is produced by needle-punching a web made of synthetic resin fibers 1. The synthetic resin fibers 1 can be fully melted synthetic resin fibers 1 made of a single resin, or core-sheath type synthetic resin fibers 1, which are composite fibers with a core-sheath structure in which a high-melting-point resin is in the core and a low-melting-point resin is in the sheath. It is also possible to use a combination of multiple types of these synthetic resin fibers 1.

[0028] In an embodiment, the fully fused synthetic resin fiber 1 made of a single resin may be a polyester fiber, a polyolefin fiber (PE (polyethylene), PP (polypropylene), etc.), a PA (polyamide) fiber, an acrylic resin fiber, a polyvinyl alcohol fiber, etc. In another embodiment, the fully fused synthetic resin fiber 1 may be a polyester fiber having excellent strength and water resistance, and in yet another embodiment, a PET (polyethylene terephthalate) fiber of polyester fiber may be used.

[0029] In the embodiment, the sheath-core type synthetic resin fiber 1 made of a core-sheath composite fiber may be expressed as PET / low melting point PET, PET / PE, PET / PP, PET / PA, PP / PE, PA / PA, etc. In another embodiment, the sheath-core type synthetic resin fiber 1 may be made of PET / low melting point PET, PET / PE, or PET / PP, which are excellent in strength, and in yet another embodiment, PET / low melting point PET may be used.

[0030] In the embodiment, the thickness of the synthetic resin fiber 1 can be 0.5 to 20 dtex in terms of the fineness (dtex) which is the weight of 10,000 m of the fiber. This is because the needle-punched nonwoven fabric 5 formed from the synthetic resin fiber 1 can be easily formed, and the interior covering material 101 can suppress the penetration of the foamable resin when the interior covering material 101 is formed and the back side of the interior covering material 101 is filled with the foamable resin in a molding die and then heated. If the fineness of the synthetic resin fiber 1 is less than 0.5 dtex, the synthetic resin fiber 1 is thin and there is a risk of poor production efficiency. On the other hand, if the fineness of the synthetic resin fiber 1 is more than 20 dtex, the synthetic resin fiber 1 is thick and there is a risk of the interior covering material 101 not suppressing the penetration of the foamable resin when the interior covering material 101 is formed and the foamable resin is filled and then heated. In another embodiment, the fineness of the synthetic resin fiber 1 can be 1 to 10 dtex, and in yet another embodiment, the fineness of the synthetic resin fiber 1 can be 2 to 5 dtex.

[0031] In an embodiment, the length of the synthetic resin fiber 1 may be 20 to 100 mm. This is because the needle-punched nonwoven fabric 5 can be easily formed. If the length of the synthetic resin fiber 1 is less than 20 mm, the needle-punched nonwoven fabric 5 may not be formed because of its short length. On the other hand, if the length of the synthetic resin fiber 1 exceeds 100 mm, the needle-punched nonwoven fabric 5 may be difficult to form because of its long length. In another embodiment, the length of the synthetic resin fiber 1 may be 25 to 90 mm, and in yet another embodiment, 30 to 80 mm.

[0032] In the embodiment, the basis weight of the web (the basis weight of the needle-punched nonwoven fabric 5) is 100 to 300 g / m 2 This is because when the interior covering material 101 is formed from the needle-punched nonwoven fabric 5, and the foamable resin is filled on the back side of the interior covering material 101 in a molding die and then heated, the interior covering material 101 can suppress the penetration of the foamable resin. 2 If the weight per unit area of ​​the needle-punched nonwoven fabric 5 is less than 300 g / m, the interior covering material 101 may not be able to suppress the penetration of the foamable resin when the interior covering material 101 is formed from the needle-punched nonwoven fabric 5, filled with the foamable resin, and then heated. 2 If the amount exceeds this range, the penetration of the foaming resin can be suppressed, but the amount becomes excessive, which may be uneconomical. 2 In yet another embodiment, 220 to 280 g / m 2 It can be said that:

[0033] The skin substrate 10 used in the interior covering material 101 of the embodiment includes a permeation-preventing nonwoven fabric 20 on the underside of the needle-punched nonwoven fabric 5, and the needle-punched nonwoven fabric 5 and the permeation-preventing nonwoven fabric 20 can be needle-punched. This is because the permeation-preventing nonwoven fabric 20 allows the interior covering material 101 to further suppress the permeation of the foamable resin when the foamable resin is filled on the back side of the interior covering material 101 in the mold and then heated. As the permeation-preventing nonwoven fabric 20, a nonwoven fabric such as a spunbond nonwoven fabric, a melt-blown nonwoven fabric, or a wet-laid nonwoven fabric can be used. As another embodiment, the permeation-preventing nonwoven fabric 20 can be a spunbond nonwoven fabric.

[0034] The interior skin material 101 of the embodiment includes a synthetic resin porous layer 60 on the lower side of the skin substrate 10. The synthetic resin porous layer 60 is formed from a synthetic resin emulsion, and one of an impregnation layer 61 or a foam rubber layer 62 is formed depending on the application method. The impregnation layer 61 is formed as the synthetic resin porous layer 60 in which the synthetic resin emulsion is impregnated or semi-impregnated into the interior skin material 101 by applying the synthetic resin emulsion to the back surface of the skin substrate 10 using a doctor knife. The foam rubber layer 62 is formed as the synthetic resin porous layer 60 by applying a foamed synthetic resin emulsion to the back surface of the skin substrate 10. The synthetic resin porous layer 60 includes one of the impregnation layer 61 or the foam rubber layer 62, and when the foam rubber layer 62 is formed, the synthetic resin porous layer 60 includes an impregnation layer in which a part of the synthetic resin emulsion is impregnated into the skin substrate 10.

[0035] The amount of synthetic resin emulsion applied to form the synthetic resin porous layer 60 is 20 to 100 g / m2 in terms of non-volatile content, regardless of whether it is the impregnated layer 61 or the foam rubber layer 62. 2 This is because it is possible to suppress the penetration of the foamable resin and to impart an appropriate rigidity to the interior covering material 101. The amount of synthetic resin emulsion applied (hereinafter, the amount of application is calculated as the non-volatile content) is 20 g / m 2If the application amount of the synthetic resin emulsion is less than 100 g / m, there is a risk that the penetration of the foamable resin cannot be suppressed and that appropriate rigidity cannot be imparted to the interior covering material 101. 2 If the amount exceeds this range, the amount becomes excessive and may be uneconomical. In another embodiment, the amount of synthetic resin emulsion applied is 30 to 80 g / m 2 In another embodiment, the thickness is 40 to 60 g / m 2 It can be said that:

[0036] The synthetic resin emulsion may be made of an acrylic resin, a vinyl acetate resin, a vinyl versatate resin, an ethylene-vinyl acetate copolymer resin, a styrene-butadiene resin, etc. In another embodiment, an acrylic resin emulsion having excellent weather resistance may be used.

[0037] In other words, the acrylic resin emulsion is a copolymer emulsion containing modified acrylic ester. As the structural unit that becomes the copolymer of acrylic ester, (meth)acrylic acid, di(meth)acrylic acid, 2-hydroxyethyl (meth)acrylate, methoxypolyethylene glycol (meth)acrylate, 2-aminoethyl (meth)acrylate, (meth)acrylamide, N-methylol (meth)acrylamide, N-(2-hydroxyethyl) (meth)acrylamide, (meth)acrylonitrile, and mixtures thereof, as well as mixtures of these with styrene, can be used. As the resin to be modified, urethane modification, silicone modification, vinyl chloride modification, etc. can be used. Of course, an acrylic ester copolymer emulsion that has not been modified can also be used. As another embodiment, an acrylic resin emulsion containing acrylonitrile can be used as the structural unit that becomes the copolymer of acrylic ester. In yet another embodiment, an acrylic resin emulsion containing acrylonitrile and styrene in the structural unit that becomes an acrylic acid ester copolymer can be used. For example, an acrylonitrile-styrene-acrylic acid ester copolymer emulsion or a mixture of an acrylonitrile-acrylic acid ester copolymer emulsion can be used.

[0038] The acrylic resin (modified acrylic acid ester copolymer) constituting the acrylic resin emulsion may have a glass transition temperature (Tg) of 0 to 50°C. This is because it is possible to impart an appropriate rigidity to the interior skin material 101. If the Tg of the acrylic resin is less than 0°C, the resin is soft and may not be able to impart an appropriate rigidity to the interior skin material 101. On the other hand, if the Tg of the acrylic resin exceeds 50°C, the film formation temperature (≒Tg) is high and it may be difficult to form a film of the acrylic resin. In another embodiment, the glass transition temperature (Tg) of the resin may be 5 to 30°C, and in yet another embodiment, 10 to 20°C.

[0039] The Tg of an acrylic resin can be adjusted by adjusting the type and amount of the monomer (structural unit that becomes a copolymer of acrylic acid ester) used. Tg can be calculated from the FOX formula (formula (1) below). Wi indicates the mass fraction of monomer i, Tgi indicates the Tg (℃) of monomer i, and the Tg of a monomer can be a known value such as the value listed in the Polymer Handbook (John Willey & Sons). 1 / (273+Tg)=Σ(Wi / (273+Tgi))···(1) Acrylic resin emulsion can be made into a synthetic resin emulsion by polymerizing the monomer components by adding a pre-emulsion (monomer components, emulsion surfactant, water, etc. pre-emulsified) and a polymerization initiator dropwise over a period of about 2 hours into a reactor where an aqueous solution containing a surfactant etc. is placed in a polymerization reaction vessel and the aqueous solution is adjusted to 80-90°C. It is also possible to make an emulsion with a core-shell structure by preparing two or more types of pre-emulsion and dropping them in sequence.

[0040] The synthetic resin porous layer 60 (impregnated layer 61, foam rubber layer 62) can be mixed with thermally expandable capsules 70. By mixing the thermally expandable capsules 70 in the synthetic resin porous layer 60, the interior skin material 101 can suppress the amount of air permeability (woven and knitted fabric test method (JIS L 1096:2010) 8.26 Air Permeability A Method (Fragile type method)), and when the foamable resin is filled on the back side of the interior skin material 101 in the molding die and then heated, the penetration of the foamable resin in the interior skin material 101 can be suppressed and appropriate rigidity can be imparted to the interior skin material 101. The thermally expandable capsules 70 have a particle diameter of 10 to 50 μm before expansion, and expand to a particle diameter of 30 to 200 μm when heated. In another embodiment, the thermally expandable capsules 70 may have a particle size of 15 to 40 μm before expansion, and may expand to a particle size of 50 to 180 μm when heated.

[0041] In an embodiment, a commercially available product can be used as the thermally expandable capsule 70. Examples of commercially available products that can be used include Kureha Microsphere (manufactured by Kureha Corporation), Advancel EM (manufactured by Sekisui Chemical Co., Ltd.), and Expancel (manufactured by Japan Ferrite Co., Ltd.).

[0042] Next, a method for manufacturing the interior covering material 101 according to the first embodiment of the present specification will be described. The method for manufacturing the interior covering material 101 according to the first embodiment includes a carding process in which the synthetic resin fibers 1 used in the needle-punched nonwoven fabric 5 are unraveled to form a web (fibrous sheet), a needle-punching process in which the fibers in the formed web are entangled and bonded with minute needle protrusions to form the needle-punched nonwoven fabric 5, a lamination process in which the needle-punched nonwoven fabric 5 and the permeation-preventing nonwoven fabric 20 are attached by needle-punching to form the skin substrate 10, a smoothing process process in which the skin substrate 10 is smoothed using a heated roller, and a coating process in which a synthetic resin emulsion containing thermally expandable capsules 70 is applied to the skin substrate 10 to form the synthetic resin porous layer 60, which are carried out in this order. The lamination process and the smoothing process process are processes that can be incorporated as necessary and can be omitted.

[0043] In the carding process, synthetic resin fibers 1, which are the raw material for the needle-punched nonwoven fabric 5, were mixed in a specific ratio, and the mixed fibers were loosened and arranged in a carding machine to form a sheet-like mass, thereby forming a web.

[0044] In the needle punching process, needles (a flat plate with countless needles standing at approximately right angles on one side) are pressed against the web formed in the carding process at high speed and repeatedly, and the tiny protrusions of the needles entangle and bond the fibers to form the needle punched nonwoven fabric 5. In this embodiment, needle punching is performed on only one side of the web.

[0045] In the laminating step, the needle-punched nonwoven fabric 5 and the permeation-preventing nonwoven fabric 20 were attached to each other by needle punching to form the skin substrate 10. In this embodiment, needle punching was performed from the upper side (needle-punched nonwoven fabric 5 side). In an embodiment not including the permeation-preventing nonwoven fabric 20, the laminating step is omitted, and the needle-punched nonwoven fabric 5 itself serves as the skin substrate 10.

[0046] In the smoothing process, a heated roller is pressed against the upper side of the skin substrate 10 to heat and smooth the upper side of the skin substrate 10. At this time, the set temperature of the roller is adjusted to a temperature at which the synthetic resin fibers 1 forming the skin substrate 10 (needle-punched nonwoven fabric 5) soften and the synthetic resin fibers 1 are fused together. When the synthetic resin fibers 1 are PET / low-melting-point PET, the set temperature of the roller is 190 to 200° C. The smoothing process is a process that is incorporated as necessary and can be omitted.

[0047] In the coating process, a synthetic resin emulsion mixed with thermally expandable capsules 70 was coated on the back surface (lower side) of the skin substrate 10, and dried by heating to form a synthetic resin porous layer 60. There are two types of coating methods: a method in which the synthetic resin emulsion is coated on the back surface of the skin substrate 10 using a doctor knife to form an impregnation layer 61, and a method in which a foamed synthetic resin emulsion is coated on the back surface of the skin substrate 10 to form a foam rubber layer 62. In the coating process, either the method in which the impregnation layer 61 is formed or the method in which the foam rubber layer 62 is formed is performed. The thermally expandable capsules 70 are mixed as necessary, and may be omitted depending on the embodiment. The thermally expandable capsules 70 are thermally expanded by heating and drying after the synthetic resin emulsion is applied.

[0048] The interior covering material 101 thus manufactured is formed from synthetic resin fibers 1 having a thickness of 0.5 to 20 dtex and a basis weight of 100 to 300 g / m 2 The surface substrate 10 is made of the needle-punched nonwoven fabric 5 as a base material, and a coating amount of 20 to 100 g / m2 in terms of non-volatile content is formed on the underside of the surface substrate 10. 2and a synthetic resin porous layer 60. Since the synthetic resin porous layer (synthetic resin porous layer 60) is formed in the interior skin material 101 so as to fill in the gaps in the skin substrate 10 (needle-punched nonwoven fabric 5), even if the interior skin material 101 does not contain an oil repellent, it is possible to suppress the penetration of the foamable resin when the foamable resin is filled on the back side of the interior skin material 101 in the molding die and then heated.

[0049] The interior covering material 101 thus manufactured has an air permeability of 10 to 100 cc / cm 2 / sec, which allows both rigidity and resistance to resin seepage to be achieved. In another embodiment, the air permeability is 20 to 80 cc / cm 2 / sec, and in yet another embodiment, 25 to 55 cc / cm 2 / sec.

[0050] Second embodiment Hereinafter, an interior covering material 102 according to a second embodiment of the present specification will be described with reference to the drawings. In the second embodiment, the same components as those in the first embodiment are designated by the same reference numerals, and the description thereof will be omitted.

[0051] As shown in Fig. 2, the interior covering material 102 according to the second embodiment is formed by joining an upper-layer skin substrate 10A and a lower-layer skin substrate 10B by needle punching. Since the two layers of needle punched nonwoven fabric are joined by needle punching, the interior covering material 102 according to the embodiment can suppress the penetration of the foamable resin even without an oil repellent when the foamable resin is filled on the back side of the fabric in a mold and then heated. In the interior covering material 102 according to the second embodiment, an intermediate film layer 30 made of a synthetic resin film that suppresses the penetration of the foamable resin can be interposed between the upper-layer skin substrate 10A and the lower-layer skin substrate 10B.

[0052] The upper layer skin substrate 10A is made of synthetic resin fiber 1 having a thickness of 0.5 to 20 dtex and a basis weight of 50 to 200 g / m2 The web is a needle-punched nonwoven fabric, and the lower surface base material 10B is formed from synthetic resin fibers 1 having a thickness of 0.5 to 20 dtex and a basis weight of 50 to 200 g / m 2 The web is a needle-punched nonwoven fabric. The synthetic resin fibers 1 used in the upper-layer skin substrate 10A and the lower-layer skin substrate 10B may be the same as the synthetic resin fibers 1 used in the needle-punched nonwoven fabric 5 of the first embodiment.

[0053] The intermediate film layer 30 is made of a synthetic resin film, and is a film that can be provided to further suppress the penetration of the foamable resin when the foamable resin is filled into the back surface of the interior skin material 102 and then heated. In the embodiment, the material that can be used for the intermediate film layer 30 includes polyester film, polyolefin film (PE (polyethylene), PP (polypropylene), etc.), PA (polyamide) film, acrylic resin film, polyvinyl alcohol film, etc. Furthermore, a multilayer film in which these films are laminated can also be used for the intermediate film layer 30, and either a stretched film or an unstretched film can be used.

[0054] Next, a method for manufacturing the interior skin material 102 according to the second embodiment of the present specification will be described. The method for manufacturing the interior skin material 102 according to the second embodiment includes a carding step of forming a web from the synthetic resin fiber 1 used for the upper-layer skin substrate 10A (lower-layer skin substrate 10B), a needle punching step of forming the upper-layer skin substrate 10A (lower-layer skin substrate 10B) from the formed web, a bonding step of bonding the upper-layer skin substrate 10A, the lower-layer skin substrate 10B, and a synthetic resin film (intermediate film layer 30) interposed therebetween by needle punching, and a smoothing step of smoothing the surface of the bonded multilayer skin substrate 10C using a heated roller. The synthetic resin film (intermediate film layer 30) is used as necessary and can be omitted.

[0055] The carding and needle punching steps are the same as those in the first embodiment.

[0056] In the bonding step, the upper-layer skin substrate 10A, the lower-layer skin substrate 10B, and the synthetic resin film (intermediate film layer 30) interposed therebetween were bonded together by needle punching. In an embodiment not including the intermediate film layer 30, the synthetic resin film is omitted.

[0057] In the smoothing process, a heated roller is pressed against the upper side or the upper and lower sides of the laminated multilayered skin substrate 10C to heat and smooth the surface of the multilayered skin substrate 10C. Through the smoothing process, the multilayered skin substrate 10C becomes an interior skin material 102. The roller temperature is set to the same temperature as that of the first embodiment.

[0058] The interior covering material 102 thus manufactured is made of synthetic resin fibers 1 having a thickness of 0.5 to 20 dtex and a basis weight of 50 to 200 g / m 2 The web is formed from a needle-punched upper surface substrate 10A, a synthetic resin film (intermediate film layer 30) that is inserted as necessary, and synthetic resin fibers 1 having a thickness of 0.5 to 20 dtex, and a basis weight of 50 to 200 g / m. 2 The web is needle-punched together with the needle-punched lower-layer skin substrate 10B. Because the two layers of needle-punched nonwoven fabric are needle-punched, the interior skin material according to the embodiment, even if it does not contain an oil repellent, can suppress the penetration of the foamable resin when the foamable resin is filled on the back side of the web in the molding die and then heated, by the two layers of needle-punched nonwoven fabric. EXAMPLES

[0059] The present invention will be described in further detail below with reference to examples. The properties of the synthetic resin fiber 1 used are shown in Table 1, the properties of the permeation-blocking nonwoven fabric 20 in Table 2, the properties of the synthetic resin emulsion forming the synthetic resin porous layer 60 in Table 3, the properties of the thermally expandable capsules 70 in Table 4, and the properties of the intermediate film layer 30 in Table 5. The synthetic resin emulsion N in Table 3 is a mixture of an acrylonitrile-styrene-acrylic ester copolymer emulsion and an acrylonitrile-acrylic ester copolymer emulsion.

[0060] [Table 1]

[0061] [Table 2]

[0062] [Table 3]

[0063] [Table 4]

[0064] [Table 5]

[0065] The performance of the interior covering materials 101 and 102 of the examples was evaluated in terms of normal incidence sound absorption coefficient, air permeability, rigidity, and resin exudation resistance. The evaluation methods are described below.

[0066] (Vertical incidence sound absorption coefficient) The normal incidence sound absorption coefficient was measured according to Measurement of sound absorption coefficient and impedance by acoustic tube - Part 2: Transfer function method (JIS A 1405-2:2007 (ISO 10534-2:1998)). Then, it was evaluated as follows: those superior to the comparative example (Table 6) are marked with ○, those equivalent to the comparative example are marked with △, and those inferior to the comparative example are marked with ×.

[0067] (Ventilation volume) The air permeability was measured according to 8.26 Air Permeability A (Fragile method) of the fabric testing method for woven and knitted fabrics (JIS L 1096:2010). The lower the air permeability value, the better the results.

[0068] (rigidity) The rigidity was evaluated by comparing with the comparative example (Table 6). Then, the rigidity was evaluated as ◯ if it was superior to the comparative example (Table 6), △ if it was equivalent to the comparative example, and × if it was inferior to the comparative example.

[0069] (Resin seepage resistance) The resin bleeding resistance was evaluated by filling the back side of the interior covering materials 101, 102 with a foamable resin in a molding die, heating it, and checking the degree of bleeding to the front side of the interior covering materials 101, 102. The resin was then rated as ◯ when no bleeding was observed, △ when bleeding was observed but not to the extent that the texture of the surface was impaired, and × when bleeding was observed and the texture of the surface was impaired.

[0070] Table 6 shows the formulations and physical property evaluations for the examples and comparative examples of the first embodiment. The comparative examples are conventional interior covering materials. Examples 3 and 4 are examples in which the best mode is achieved. An enlarged photograph of the back surface of the interior covering material 101 of Example 3 is shown in FIG. 3, and an enlarged photograph of the back surface of the interior covering material 101 of Example 4 is shown in FIG. 4. FIG. 5 shows a graph of the normal incident sound absorption coefficients of the floor carpets of Examples 3 and 4 (interior covering material 101 with a foamed resin layer F on the back surface side). The solid line is Example 3, and the dotted line is Example 4.

[0071] [Table 6]

[0072] Example 1 is different from the comparative example in that the basis weight of the needle-punched nonwoven fabric 5 is increased and the amount of synthetic resin emulsion applied to form the synthetic resin porous layer 60 is increased. In Example 1, the resin exudation resistance was such that, although exudation was observed, the surface texture was not impaired.

[0073] In Example 2, by blending the thermally expandable capsules 70 in the synthetic resin emulsion, it was possible to achieve resistance to resin bleeding, with no confirmed bleeding, even if the amount of synthetic resin emulsion applied was reduced. It was also confirmed that the use of the thermally expandable capsules 70 has the effect of filling the spaces between the fibers of the spunbond nonwoven fabric (permeation-preventing nonwoven fabric 20) and reducing the breathability.

[0074] In Example 3, it was confirmed that high rigidity could be obtained by changing the synthetic resin emulsion to an acrylic synthetic resin emulsion containing acrylonitrile and styrene. It was also confirmed that the resin exudation resistance was improved by increasing the amount of the thermally expandable capsules 70.

[0075] In Example 4, even without the incorporation of the thermally expandable capsules 70, a foam rubber layer 62 (synthetic resin porous layer 60) is formed from a synthetic resin emulsion as shown in Figure 4, thereby making it possible to achieve resistance to resin seepage such that no seepage is observed.

[0076] In Example 5, the synthetic resin emulsion was changed from an acrylic synthetic resin emulsion containing acrylonitrile and styrene to an acrylic synthetic resin emulsion, and the foam rubber layer 62 was formed from the synthetic resin emulsion in the same manner as in Example 4. Although the resin seepage resistance was good, the acrylic synthetic resin emulsion did not sufficiently impregnate the skin substrate 10, resulting in poor rigidity.

[0077] In Example 6, the permeation-preventing nonwoven fabric 20 was changed to a wet-laid nonwoven fabric made of pulp and rayon. An interior covering material 101 with excellent performance was obtained.

[0078] In Example 7, the permeation-preventing nonwoven fabric 20 was changed to a melt-blown nonwoven fabric. An interior covering material 101 with excellent performance was obtained.

[0079] Table 7 shows the formulations and physical property evaluations of examples of the second embodiment.

[0080] [Table 7]

[0081] In Example 8, an upper-layer skin substrate 10A and a lower-layer skin substrate 10B were needle-punched. Both the front and back surfaces were smoothed with a heated roller, so that the interior skin material 102 of Example 8 had excellent resistance to resin bleeding and was also excellent in rigidity.

[0082] In Example 9, the PP (polypropylene) fiber of the synthetic resin fiber 1 of the lower-layer skin substrate 10B in Example 8 was changed to a PET (polyester) fiber. In the smoothing process, the melting point of the PET fiber was high and it was not thermally fused, so the resin bleeding resistance was inferior.

[0083] Example 10 is obtained by adding an intermediate film layer 30 (single layer of polyurethane) between the upper-layer skin substrate 10A and the lower-layer skin substrate 10B of Example 9. The intermediate film layer 30 improved the resistance to resin seepage, but the intermediate film layer 30 also deteriorated the sound absorption properties. In addition, in the lamination process in which the films are attached by needle punching, a large amount of film pieces adhered to the barbs of the needles, resulting in poor work efficiency.

[0084] In Example 11, the polyurethane single layer of the intermediate film layer 30 of Example 10 was changed to a three-layer film. The results were the same as in Example 10, and the intermediate film layer 30 improved the resistance to resin seepage, but the sound absorption was inferior. Furthermore, by changing the intermediate film layer 30 to a three-layer film, adhesion of film pieces to the barbs of needles during the lamination process in which the films are laminated by needle punching was reduced, making the film more practical. [Explanation of symbols]

[0085] 1...synthetic resin fiber, 5...needle-punched nonwoven fabric, 10...skin substrate, 10A...upper layer skin substrate, 10B...lower layer skin substrate, 10C...multilayer skin substrate, 20...permeation-preventing nonwoven fabric, 30...middle film layer, 60...synthetic resin porous layer, 61...impregnated layer, 62...foam rubber layer, 70...thermally expandable capsule, 101...interior skin material, 102...interior skin material, F...foamed resin layer.

Claims

1. It is made of synthetic resin fibers with a thickness of 0.5 to 20 dtex and a basis weight of 100 to 300 g / m 2 The web comprises a skin substrate having a needle-punched nonwoven fabric as a base material, the surface substrate is provided with a permeation-preventing nonwoven fabric below the needle-punched nonwoven fabric, and the needle-punched nonwoven fabric and the permeation-preventing nonwoven fabric are needle-punched together; The coating amount of the coating material provided on the underside of the skin substrate is 20 to 100 g / m2 in terms of non-volatile matter. 2 and a synthetic resin porous layer, The synthetic resin porous layer is impregnated into the skin substrate, The interior skin material is characterized in that thermally expandable capsules are mixed into the synthetic resin porous layer.

2. 2. The interior covering material according to claim 1, wherein the permeation-preventing nonwoven fabric is a spunbonded nonwoven fabric, a meltblown nonwoven fabric, or a wet-laid nonwoven fabric.

3. 3. The interior skin material according to claim 1, wherein the synthetic resin emulsion forming the synthetic resin porous layer is an acrylic resin emulsion.

4. 4. The interior skin material according to claim 3, wherein the synthetic resin emulsion is an acrylic resin emulsion containing acrylonitrile and styrene.

5. 5. The interior skin material according to claim 3, wherein the glass transition temperature (Tg) of the resin constituting the synthetic resin emulsion is 10 to 20.degree.

6. 6. The interior skin material according to claim 1, wherein the upper side of the skin substrate is heated and smoothed.

7. A method for producing an interior skin material according to claim 1, comprising the steps of: The synthetic resin fiber has a thickness of 0.5 to 20 dtex and a basis weight of 100 to 300 g / m 2 a carding step of forming the web of a needle punching step in which the fibers of the formed web are entangled and bonded with tiny needle protrusions to form a needle punched nonwoven fabric; a lamination step of laminating the needle-punched nonwoven fabric and the permeation-preventing nonwoven fabric by needle punching to form the skin substrate; a coating step of coating the skin substrate with a synthetic resin emulsion containing the thermally expandable capsules to form the synthetic resin porous layer; 2. A method for producing an interior skin material comprising the steps of:

8. 8. The method for producing an interior skin material according to claim 7, further comprising a smoothing step between the laminating step and the coating step, in which a heated roller is pressed against an upper side of the skin substrate to heat and smooth the upper side of the skin substrate.

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