Plate-shaped laminate for vehicles, interior material for vehicles, and method for manufacturing plate-shaped laminate for vehicles

Abstract

To provide a plate-like laminate for vehicles that allows reduction in weight and cost, an interior material for vehicles and a method for producing a plate-like laminate for vehicles.SOLUTION: A plate-like laminate for vehicles (skin material) 20 comprises a surface material 21 and a backing material 22 laminated on the back side of the surface material 21, the surface material 21 and the backing material 22 bonded together through a moisture-curable hot-melt adhesive 23a.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a plate-shaped laminate for vehicles, an interior material for vehicles, and a method for manufacturing a plate-shaped laminate for vehicles. [Background technology]

[0002] Patent Document 1 discloses a surface material 1 for use in a molded ceiling of a vehicle, which has 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 the side 12b of the first flexible polyurethane foam 12 opposite to the side 12a on which the surface layer 11 is laminated. This surface 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 with the flame of a gas burner 101, and the surface layer 11 is placed on top of it and passed between rolls 103 and 104. Through these processes, the first flexible polyurethane foam 12 and the surface layer 11 are welded together. Next, the surface 12b of the first flexible polyurethane foam 12 is heated and melted by the flame of the gas burner 102, and the second flexible polyurethane foam 13 is placed on top of it and passed between rolls 104 and 105 to be wound into a roll. [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2018-176979 [Overview of the project] [Problems that the invention aims to solve]

[0004] The surface material disclosed in Patent Document 1 mentioned above has a polyurethane foam layer, which has the problem of making the surface material relatively expensive and heavy.

[0005] The present invention was made to solve the above-mentioned problems, and aims to provide a plate-shaped laminate for vehicles, an interior material for vehicles, and a method for manufacturing a plate-shaped laminate for vehicles that can be made lighter and less expensive. [Means for solving the problem]

[0006] To solve the above problems, the plate-shaped laminate for vehicles 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-shaped laminate for vehicles of this invention, the plate-shaped laminate for vehicles can be formed by bonding a surface material and a 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 make the plate-shaped laminate for vehicles lighter and lower in cost.

[0008] In the plate-shaped laminate for vehicles according to the present invention, the surface material is preferably made of knitted material. This is because knitted material is relatively lightweight and inexpensive, making it possible to reduce the weight of the surface material and maintain a high level of design quality of the surface material at a relatively low cost without increasing costs.

[0009] In the plate-shaped laminate for vehicles according to the present invention, the backing material is preferably made of nonwoven fabric. This is because nonwoven fabric is relatively lightweight and low-cost, making it possible to reduce the weight and cost of the surface material.

[0010] In the plate-shaped laminate for vehicles according to the present invention, the nonwoven fabric is preferably a spunlace nonwoven fabric. This allows a spunlace nonwoven fabric, which has fewer surface irregularities and is relatively flat, to be used as the backing material, making it possible to maintain a high level of aesthetic appeal on the surface material.

[0011] In the plate-shaped laminate for vehicles according to the present invention, the spunlace nonwoven fabric is preferably a cross-layer spunlace nonwoven fabric. This is because the cross-layer spunlace nonwoven fabric has high elasticity in the longitudinal and transverse directions, so when the vehicle interior material is formed by hot press molding after laminating the plate-shaped laminate for vehicles onto a base material, it is possible to maintain high moldability.

[0012] The vehicle interior material according to the present invention preferably comprises a plate-shaped laminate for vehicles having the above-described features. According to this, the vehicle interior material can be formed by laminating a plate-shaped laminate for vehicles, in which a surface material and a backing material are bonded via a moisture-curing hot-melt adhesive, onto a base material and then forming it by hot-press molding. Therefore, in the vehicle interior material, it is possible to maintain high moldability without causing peeling of the plate-shaped laminate for vehicles.

[0013] The present invention relates to a method for manufacturing a plate-shaped laminate for vehicles, wherein 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, characterized in that the moisture-curing hot-melt adhesive is heated and melted, 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 method for manufacturing a plate-shaped laminate for vehicles of this invention, the plate-shaped laminate for vehicles can be formed by bonding a surface material and a 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 make the plate-shaped laminate for vehicles lighter and lower in cost.

[0015] In the method for manufacturing a plate-like laminate for a vehicle according to the present invention, it is preferable that the moisture-curing hot-melt adhesive is applied by spraying the heat-melted moisture-curing hot-melt adhesive in a spray form. According to this, it becomes possible to control the spraying amount of the moisture-curing hot-melt adhesive, and it becomes possible to control the air permeability of the skin material. Therefore, even when using a surface material with a relatively low basis weight, it is possible to suppress the air permeability of the skin material to a low level. As a result, it becomes possible to correspond to a surface material with a relatively low basis weight, and it becomes possible to achieve weight reduction and cost reduction of the skin material. Further, in the manufacturing process of the skin material, since it becomes possible to control the spraying amount of the moisture-curing hot-melt adhesive, it becomes possible to improve productivity as compared with the conventional method.

Effect of the Invention

[0016] According to this 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 can achieve weight reduction and cost reduction.

Brief Description of the Drawings

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

Mode for Carrying Out the Invention

[0018] Hereinafter, an embodiment of 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 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 implemented 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 base material 30, and the skin material 20 and the base material 30 are laminated. 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. inside the vehicle compartment. The vehicle interior material 10 is not limited to the ceiling material, and other members such as door interior materials provided inside the vehicle compartment can be adopted.

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

[0021] The surface material 21 is a member located on the surface of the skin material 20. The surface material 21 is preferably formed of a fabric such as a woven fabric, a knitted fabric, or a non-woven fabric (hereinafter sometimes referred to as a fabric, etc.). Since the surface material 21 is disposed inside the vehicle compartment and catches the eye of the occupant, it is preferable that the surface material 21 is formed of a material that can create a higher design quality and has a good texture. The surface material 21 is preferably formed of a relatively lightweight and low-cost material, and is preferably formed of a material with a relatively low basis weight. In this embodiment, it is more preferable that the surface material 21 is formed of a knitted material that is a knitted fabric. The knitted material is a fabric knitted by looping yarn using needles, and is a fabric with higher stretchability than a woven fabric. Incidentally, a woven fabric is generally a woven fabric using two yarns, a warp yarn and a weft yarn. A non-woven fabric is a sheet-like fabric or fabric in which fibers are intertwined without being woven.

[0022] For the fibers forming the surface material 21, for example, synthetic fibers made of polyolefin resins such as polyester, PP (polypropylene), and ethylene-propylene copolymer can be used. The basis weight of the fibers forming the surface material 21 is preferably 150 to 300 g / m 2 and preferably 170 to 190 g / m 2It is more preferable that the surface material 21 has a fineness of 30 to 200 dtex, and 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 component located on the back surface of the outer material 20, and its purpose is to strengthen the outer material 20 and suppress deformation. The backing material 22 also has a penetration-inhibiting function that prevents the adhesive used to bond the outer material 20 and the base material 30 during the heat pressing process from penetrating the outer material 20. In order to exhibit this penetration-inhibiting function, the backing material 22 is generally preferably made of a fine-mesh nonwoven fabric. Furthermore, it is even more preferable to make it of a nonwoven fabric with a larger basis weight, because this can further enhance the penetration-inhibiting function.

[0024] Furthermore, since the backing material 22 is required to have high moldability (high conformability to the shape of the mold) in the hot pressing process, it is more preferable that it be formed from a highly elastic nonwoven fabric. As a highly elastic nonwoven fabric, spunlace nonwoven fabric can be used. Examples of spunlace nonwoven fabrics include parallel layer spunlace nonwoven fabric, which has high elasticity in one direction (longitudinal direction), and cross layer spunlace nonwoven fabric, which has high elasticity not only in the longitudinal direction but also in the transverse direction (two-way elasticity). Spunlace nonwoven fabric is preferred for the backing material 22, and cross layer spunlace nonwoven fabric is more preferred.

[0025] Nonwoven fabrics are sheet-like fabrics in which fibers are intertwined without weaving or knitting. They are fiber sheets, webs, or batts in which the fibers are oriented in one direction or randomly, and the fibers are bonded together by entanglement, and / or welding (fusion), and / or adhesion. Spunlace nonwoven fabrics are nonwoven fabrics manufactured by entangling the fibers (especially short fibers) in the web with a high-pressure water jet without using a binder (adhesive).

[0026] The fibers forming the backing material 22 can be synthetic fibers made of polyolefin resin such as polyester, PP (polypropylene), or ethylene-propylene copolymer. The basis weight of the backing material 22 is 30 to 200 g / m². 2 Preferably, it is 50-150 g / m 2 It is more preferable that the density be 60-80 g / m 2 It is even more preferable that the fibers forming the backing material 22 have a fineness of 0.5 to 3.0 dtex, and more preferably 1.0 to 2.0 dtex. The thickness of the backing material 22 is also 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 moving a needle back and forth, or thermal-bonded nonwoven fabrics using heat-welded fibers. The nonwoven fabric used for the backing material 22 may also be formed from long-fiber nonwoven fabrics, such as spunbond nonwoven fabrics, meltblown nonwoven fabrics, or flash-spun nonwoven fabrics. Spunbond nonwoven fabric is a nonwoven fabric made by laminating continuous fibers (filaments) spun from a nozzle by melting or dissolving a polymer onto a moving screen using one or more bonding methods. Meltblown nonwoven fabric is a nonwoven fabric made by spinning a polymer into fibers in a high-speed hot gas flow, accumulating them on a moving screen after cooling, and using one or more bonding methods. Flash-spun nonwoven fabrics are nonwoven fabrics made of highly fibrillated filaments created by spinning a polymer solution from a nozzle under specific conditions, evaporating the solvent immediately after spinning, and laminating these fibers on a moving screen using one or more bonding methods. The aforementioned polymers are high-molecular-weight organic compounds, such as thermoplastic resins (synthetic resins) like polyamides, polyethylene, polypropylene, and polyurethane.

[0028] The adhesive layer 23 is a layer formed with a moisture-curing hot melt adhesive, which is an adhesive for bonding the surface material 21 and the backing material 22. The moisture-curing hot melt adhesive is a urethane-based moisture-curing hot melt adhesive, mainly composed of a urethane prepolymer. The moisture-curing hot melt adhesive is obtained by the reaction of a polyester polyol with an isocyanate compound and has an isocyanate group (NCO) at its terminal. Particularly preferred is one in which the terminal NCO% is 1 to 3%. 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 of a dicarboxylic acid (adipic acid, sebacic acid, etc.) having 6 or more carbon atoms, and more preferably contains 80% by weight or more of crystalline ester polyol with a melting point of 45°C or higher as the polyol component. Furthermore, the glycol constituting the polyester polyol can be an alcohol with 4 or more carbon atoms (such as 1,4-butanediol or 1,6-hexanediol). As the isocyanate compound, aromatic isocyanates are preferred, and diphenylmethane diisocyanate (MDI) is particularly preferred. The moisture-curing hot melt adhesive may also contain additives such as tackifiers, waxes, nucleating agents, and antioxidants as needed. Moreover, the moisture-curing hot melt adhesive is not limited to urethane-based 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, which involves spraying it in a spray form. The moisture-curing hot melt adhesive may be applied not only to the back surface of the surface material 21, but also only to the surface of the backing material 22, or to both the back surface of the surface material 21 and the surface of the backing material 22. As for spray application, a curtain spray method is particularly preferred, in which the moisture-curing hot melt adhesive is heated and pressurized, discharged from multiple nozzles arranged in a row, and sprayed onto the surface while being spun into threads for lamination. According to the curtain spray method, thread-like molten resin is spun and stretched using a high-temperature, high-speed airflow, and then directly sprayed onto the surface material for lamination.

[0030] To facilitate and ensure good 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 (JIS K 6862) of 5 to 15 Pa·s (Pascal-seconds) at 140°C. Note that "solid at room temperature" means solid at 20°C. The molten temperature range can be appropriately set 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. 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, even considering seasonal variations. In other words, for a moisture-curing hot melt adhesive to be applied to a long sheet while being rolled up, and to dry and cure quickly at room temperature within a predetermined equipment length, it is preferable that the adhesive contains a crystalline ester polyol, has an NCO content of 1-3% in the urethane prepolymer, and has a number average molecular weight of 1000-4000, more preferably 1500-2500.

[0031] Furthermore, the application rate for moisture-curing hot melt adhesive is 10-30 g / m². 2 Preferably, it is 10-25 g / m 2It is more preferable that this be the case. Furthermore, the coating method is not limited to spray coating; a roll coating method using a roll coater (for example, roll coater 40 described in Japanese Patent Publication No. 2018-184000) may also be employed.

[0032] The base material 30 has functions such as maintaining the shape of the ceiling in the vehicle interior, ensuring rigidity, sound absorption in the vehicle interior, and heat insulation. The base material 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 via binders 34 and 35. A surface 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 backing material 37 is laminated on the back surface of the film 36. Thus, the base material 30 is formed by laminating the foamed synthetic resin layer 31, glass material layers 32 and 33, binders 34 and 35, film 36, and backing material 37. The thickness of the base material 30 is preferably about 2 mm to 15 mm. Although binders 34 and 35 are depicted as upper layers in the drawings for convenience, in reality they impregnate the surface of the foamed synthetic resin layer 31, the glass material layers 32 and 33, and the backing material 22, respectively, providing adhesion and rigidity. The thickness of the foamed 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 foamed synthetic resin layer 31 is a porous synthetic resin that retains fine air bubbles inside, and is a foam with a synthetic resin backbone. The foamed synthetic resin layer 31 can be made from polyurethane foam (polyurethane foam). The polyurethane foam may be flexible polyurethane foam, rigid polyurethane foam, or semi-rigid 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 ceiling inside the vehicle. The glass material layers 32 and 33 are formed into a sheet shape (glass fiber mat) by hardening inorganic glass fibers with a binder.

[0035] Thermosetting adhesives can be used as binders 34 and 35. It is preferable to select a thermosetting resin made of isocyanate resin, as it readily adheres to the foamed 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 foamed synthetic resin layer 31 by spray, roll coater, etc. The amount applied is determined to suit the required strength and other various conditions.

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

[0037] As is clear from the above description, in this embodiment, the plate-shaped laminate (surface material) 20 for vehicles is formed by bonding a surface material 21 and a backing material 22 laminated on the back side of the surface material 21 via a moisture-curing hot-melt adhesive 23a. With this plate-shaped laminate 20 for vehicles, since the plate-shaped laminate 20 for vehicles can be formed by bonding the surface material 21 and the backing material 22 via a moisture-curing hot-melt adhesive 23a, it is possible to make the plate-shaped laminate 20 for vehicles lighter and lower in cost by using a surface material 21 and backing material 22 that are relatively lightweight and low cost.

[0038] Furthermore, since the surface material 21 and the backing material 22 are bonded via a moisture-curing hot melt adhesive 23a, and the surface material 21 and the backing material 22 can be bonded by a simple manufacturing process that involves only applying the molten moisture-curing hot melt adhesive 23a and laminating them, high productivity can be obtained when manufacturing the plate-shaped laminate 20 for vehicles. Moreover, even if the surface material 21 and the backing material 22 bonded by the moisture curing of the moisture-curing hot melt adhesive 23a are heated after moisture curing, the moisture-curing hot melt adhesive 23a will not melt, thus suppressing delamination. As a result, when the interior material 10 for vehicles is formed by hot press molding after laminating the plate-shaped laminate 20 for vehicles onto a base material 30, it is possible to maintain high moldability without causing the plate-shaped laminate 20 for vehicles to peel off. In this way, by bonding the surface material 21 and the backing material 22 via a moisture-curing hot-melt adhesive 23a, it is possible to achieve both high productivity when manufacturing the vehicle plate-shaped laminate 20 and high moldability during hot-press molding after laminating the vehicle plate-shaped laminate 20 onto the base material 30.

[0039] Furthermore, since the vehicle plate-shaped laminate 20 can be formed without providing an intermediate layer such as a polyurethane foam layer as in the conventional method, the thickness of the vehicle plate-shaped laminate 20 can be reduced, and consequently, when forming a vehicle interior material 10 of the same thickness, the thickness of the base material 30 can be increased, making it possible to improve the strength of the vehicle interior material 10. In addition, in the vehicle plate-shaped laminate 20, the surface material 21 and the backing material 22 can be bonded together without using the frame lamination method, thus reducing volatile organic compounds (VOCs).

[0040] Furthermore, in the plate-shaped laminate 20 for vehicles, it is preferable that the surface material 21 is formed of knitted material. This is because knitted material is relatively lightweight and low-cost, making it possible to reduce the weight of the surface material 20, and to maintain a high level of design quality of the surface material 20 at a relatively low cost without increasing costs.

[0041] Furthermore, in the plate-shaped laminate 20 for vehicles, it is preferable that the backing material 22 is made of nonwoven fabric. This is because nonwoven fabric is relatively lightweight and low-cost, making it possible to reduce the weight and cost of the surface material 20.

[0042] Furthermore, in the plate-shaped laminate 20 for vehicles, it is preferable that the nonwoven fabric is a spunlace nonwoven fabric. This allows a spunlace nonwoven fabric, which has fewer surface irregularities and is relatively flat, to be used as the backing material 22, thereby maintaining a high level of aesthetic appeal on the surface of the surface material 21.

[0043] Furthermore, in the plate-shaped laminate 20 for vehicles, it is preferable that the spunlace nonwoven fabric is a cross-layer spunlace nonwoven fabric. This is because the cross-layer spunlace nonwoven fabric has high elasticity in the longitudinal and transverse directions, so when the vehicle interior material 10 is formed by hot press molding after laminating the plate-shaped laminate 20 for vehicles onto the base material 30, it is possible to maintain high moldability.

[0044] Furthermore, it is preferable that the vehicle interior material 10 comprises a vehicle plate-shaped laminate 20 having the above-described features. According to this, the vehicle interior material 10 can be formed by laminating a vehicle plate-shaped laminate 20, in which a surface material 21 and a backing material 22 are bonded via a moisture-curing hot-melt adhesive 23a, onto a base material 30 and then forming it by hot-press molding. Thus, in the vehicle interior material 10, it is possible to maintain high moldability without causing the vehicle plate-shaped laminate 20 to peel off.

[0045] Next, a method for manufacturing the surface material 20, which is formed by bonding the surface material 21 and the backing material 22, will be described with reference to Figure 3. The surface material 21 is unwound from the surface material roll 21A on which the surface material 21 is wound and supplied onto the conveyor belt 41. The conveyor belt 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 downwards.

[0046] A spray coating device 42 is provided above the conveyor belt 41. A spray coating device 42 is known from the one disclosed in Japanese Patent Application Publication No. 2017-136735. The spray coating device 42 is configured with its nozzle facing downwards. The spray coating device 42 applies 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) 43, to the upper surface (back surface) of the surface material 21 on the conveyor belt 41. The amount applied to the surface material 21 is, for example, 10-25 g / m². 2 These are some examples.

[0047] The nozzle of the spray coating device 42 has multiple discharge (injection) holes arranged in a row at predetermined intervals (for example, 0.4 mm) along the width direction of the surface material 21. In the spray coating device 42, 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 airflow. On the back surface of the surface material 21, a layer of adhesive 23a is formed by spraying the adhesive 23a in a thread-like or particulate form while it is stretched and then laminating it.

[0048] After spray-applying the adhesive 23a, 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 then bonded by passing it between the pressure rollers 44 and 45. Subsequently, while being transported by multiple rollers (not shown) for a predetermined time, the adhesive 23a reacts with natural cooling and moisture (humidification) in the air, and the hardening process begins. That is, the backing material 22 is bonded to the back surface of the surface material 21 via the adhesive 23a, thereby forming the surface material 20. The surface material 20 is then wound up by a winding roll (not shown). The hardening time required for the adhesive 23a to completely harden due to moisture curing is, for example, several hours to more than ten hours. Alternatively, the surface material (vehicle plate-shaped laminate) 20 may be cut to a predetermined length instead of being wound up, and the cut plate-shaped surface material 20 may be stacked.

[0049] Furthermore, a manufacturing method for integrally forming the surface material 20 and the base material 30 by hot pressing will be explained with reference to Figure 4. Hot pressing is a method of forming a desired shape by heating and applying pressure to the object to be pressed, and then cooling it to form the desired shape. Alternatively, the object to be pressed may be heated first and then pressed. The surface material 20 and the base material 30 are set between molds 51 and 52, which have molding surfaces formed to a desired curved shape, and by performing hot pressing, the surface material 20 and the base material 30 are integrally formed, and the vehicle interior material 10 can be obtained. Here, the surface material 20 and the base material 30 are laminated and hot pressed as shown in Figure 4.

[0050] The surface material 20 and base material 30 are in a plate shape before heat pressing. The molding dies 51 and 52 have a surface shape corresponding to the surface shape of the vehicle interior material 10. The heat pressing temperature can be appropriately changed within the range of 80 to 150°C, and the heat pressing time can be appropriately changed within the range of 10 to 60 seconds. The surface material 20 and base material 30 are heated and pressurized by heat pressing, causing them to deform from a plate shape to a shape with irregularities. In the process of the surface material 20 deforming into a shape with irregularities, stress is concentrated in parts of the surface material 20, and it expands and contracts in response to the stress. In this way, even in parts where stress is concentrated and it expands and contracts, the surface material 20 of this embodiment suppresses the penetration of the thermosetting adhesive into the interior of the surface material 20, and smooths the irregularities according to the surface shape of the vehicle interior material 10, thereby making the design surface of the vehicle interior material 10 a smooth surface.

[0051] The method for manufacturing the plate-shaped laminate 20 for vehicles according to this embodiment is a method for manufacturing a plate-shaped laminate 20 for vehicles 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, wherein 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 method for manufacturing the plate-shaped laminate for vehicles 20, the plate-shaped laminate for vehicles 20 can be formed by bonding a surface material 21 and a backing material 22 via a moisture-curing hot-melt adhesive 23a. Therefore, by using a relatively lightweight and low-cost surface material 21 and backing material 22, it is possible to make the plate-shaped laminate for vehicles 20 lighter and lower in cost. Furthermore, since the plate-shaped laminate for vehicles 20 is bonded between the surface material 21 and the backing material 22 via a moisture-curing hot-melt adhesive 23a, when the interior material for vehicles 10 is formed by hot-press molding after laminating the plate-shaped laminate for vehicles 20 onto a base material 30, it is possible to maintain high moldability without causing the plate-shaped laminate for vehicles 20 to peel off.

[0053] Furthermore, in the manufacturing method of the plate-shaped laminate 20 for vehicles, it is preferable to apply the moisture-curing hot melt adhesive 23a by spraying the heated and melted moisture-curing hot melt adhesive 23a. This makes it possible to control the amount of moisture-curing hot melt adhesive 23a sprayed, and thus control the breathability of the surface material 20. As a result, even when using a surface material 21 with a relatively low basis weight, the breathability of the surface material 20 can be kept low. Consequently, it becomes possible to use a surface material 21 with a relatively low basis weight, and the weight and cost of the surface material 20 can be reduced. In addition, since it is possible to control the amount of moisture-curing hot melt adhesive 23a sprayed in the manufacturing process of the surface material 20, productivity can be improved compared to conventional methods. [Examples]

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

[0055] [Table 1]

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

[0057] The surface materials 21 of Examples 1 to 3 are formed of a knit material. For the knit material, synthetic fibers formed of polyester or the like are used. The basis weight of the knit material is 170 to 190 g / m 2 and the fineness is 30 to 110 dtex. Also, the thickness of the surface material 21 is about 0.7 mm to 0.9 mm. The backing materials 22 of Examples 1 to 3 are formed of a non-woven fabric. Example 1 is formed of a cross-layer spunlace non-woven fabric, Example 2 is formed of a parallel-layer spunlace non-woven fabric, and Example 3 is formed of a needle-punched non-woven 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. Also, the thickness of the surface material 21 is about 0.45 mm to 0.55 mm. The bonding method between the surface material 21 and the backing material 22 of Examples 1 to 3 is a bonding method in which the above-described moisture-curing hot melt adhesive is sprayed and applied for bonding.

[0058] The surface material 21 in Comparative Examples 1 to 3 is formed from knitted material, similar to Examples 1 to 3. The backing material 22 in Comparative Examples 1 to 3 is formed from cross-layer spunlace nonwoven fabric, similar to Example 1. In Comparative Example 3, an intermediate layer is provided between the surface material 21 and the backing material 22. The intermediate layer is made 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 bonded to other components. The bonding method for Comparative Example 1 between the surface material 21 and the backing material 22 is a bonding method in which molten hot melt adhesive is sprayed (applied) to bond them. The bonding method for Comparative Example 2 between the surface material 21 and the backing material 22 is a bonding method in which a film-like hot melt adhesive is sandwiched between the two materials and heated to bond them. Hot melt adhesives are adhesives that bond materials in a molten state after being heated. Thermoplastic plastics such as ethylene vinyl acetate are commonly used as hot melt adhesives.

[0059] For each example and comparative example of the plate-shaped laminate 20 for vehicles, the resistance to seepage, appearance, lightness, productivity, and moldability during hot pressing were measured (evaluated), and an overall evaluation was performed.

[0060] The stain resistance was measured by visually observing the staining of moisture-curing hot-melt adhesive or thermosetting adhesive onto the surface of the surface material 20 on three test pieces. If no staining was observed on any of the three pieces, the stain resistance was considered very good (indicated by ○) and the test was judged to pass. If slight staining was observed on one piece and no staining was observed on the other two pieces, the stain resistance was considered good (indicated by △) and the test was judged to pass. Furthermore, if staining was observed on two or more pieces, the stain resistance was considered poor (indicated by ×) and the test was judged to fail.

[0061] The appearance evaluation method for the plate-shaped laminate 20 for vehicles in Examples 1 to 3 and Comparative Examples 1 to 3 was performed by visually observing the wrinkles and unevenness (smoothness) of the surface (300 mm square area) of the surface material 21 of three test pieces. If no wrinkles or unevenness could be observed on the surface of the surface material 21 of all three pieces using side lighting from the inspection stand, the appearance was judged to be very good (indicated by ○) and was deemed to pass. If no wrinkles or unevenness could be 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 was deemed to pass. Furthermore, if wrinkles or unevenness could be 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 was deemed to fail.

[0062] The total weight was measured by weighing the test specimens of the plate-shaped laminate 20 for vehicles for each example and comparative example. Based on the measured weight, the lightweight properties were evaluated. If the weight was greater than or equal to that of Comparative Example 3, it was marked as relatively heavy (×, fail) in terms of lightweight properties. If the weight was less than that of Comparative Example 3, it was marked as relatively lightweight (○, pass) in terms of lightweight properties.

[0063] Productivity was evaluated based on the man-hours required for the bonding method (bonding process) between the surface material 21 and the backing material 22. When bonding by spraying adhesive, the man-hours are fewer compared to bonding methods that require a heating process, such as when hot melt film is heated and applied, or when frame lamination involves melting polyurethane foam. Therefore, if the man-hours required for the bonding process were greater than or equal to those required for Comparative Example 2 or Comparative Example 3, it was marked as × (fail), and if the man-hours required for the bonding process were less than those required for Comparative Example 2 or Comparative Example 3, it was marked as ○ (pass).

[0064] The method for evaluating the formability during hot pressing was performed by visually observing three test pieces of the plate-shaped laminate 20 for vehicles in Examples 1 to 3 and Comparative Examples 1 to 3 for the presence or absence of peeling of the outer material 20 and wrinkles on the surface material 21. If no peeling of the outer material 20 and wrinkles on the surface material 21 were observed in all three pieces, the formability was considered very good (indicated by ○) and the piece was judged to pass. If peeling of the outer material 20 and wrinkles on the surface material 21 were observed in one piece, but not in the remaining two pieces, the formability was considered good (indicated by △) and the piece was judged to pass. Furthermore, if peeling of the outer material 20 and wrinkles on the surface material 21 were observed in two or more pieces, the formability was considered poor (indicated by ×) and the piece was judged to fail.

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

[0066] As shown in Table 1, in Example 1, all five evaluation items were "○", and the worst evaluation item (judgment) was "○", so the overall judgment was "○". In Example 2, the worst evaluation item among the five evaluation items was "△" for moldability during hot pressing, so the overall judgment was "△". Furthermore, in Example 3, the worst evaluation item among the five evaluation items was "△" for appearance, so the overall judgment was "△".

[0067] On the other hand, Comparative Example 1 differs from Example 1 in that the bonding method involves spraying hot-melt adhesive, resulting in a "×" rating for moldability during hot pressing. Thus, since the worst evaluation among the five evaluation items was "×" for moldability during hot pressing, the overall judgment for Comparative Example 1 was "×". Comparative Example 2 differs from Example 1 in that the bonding method involves bonding with a film-type hot-melt adhesive, resulting in "×" ratings for productivity and moldability during hot pressing. Thus, since the worst evaluation among the five evaluation items was "×" for productivity and moldability during hot pressing, the overall judgment for Comparative Example 2 was "×". Furthermore, Comparative Example 3 differs from Example 1 in that it has an intermediate layer (polyurethane) and the bonding method involves bonding by frame lamination, resulting in "×" ratings for lightness and productivity. Thus, since the worst evaluation among the five evaluation items was "×" for lightness and productivity, the overall judgment for Comparative Example 3 was "×". [Explanation of Symbols]

[0068] 10...Interior material for vehicles, 20...Laminated sheet material for vehicles (surface material), 21...Surface material, 22...Backing material, 23...Adhesive layer, 23a...Moisture-curing hot melt adhesive, 30...Base material.

Claims

1. A plate-shaped laminate for vehicles, wherein 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, wherein the surface material is made of knitted material and the backing material is made of nonwoven fabric, and the plate-shaped laminate for vehicles, A substrate having a foamed synthetic resin layer and a glass material layer laminated together, A ceiling material installed on the ceiling surface inside a vehicle, which is made up of stacked layers. The basis weight of the aforementioned nonwoven fabric is 30 to 80 g / m². ２ A ceiling material characterized by the following:

2. The aforementioned moisture-curing hot-melt adhesive is obtained by the reaction of a polyester polyol with an isocyanate compound. The ceiling material according to claim 1, characterized in that the polyester polyol is obtained by the reaction of a dicarboxylic acid having 6 or more carbon atoms with 1,4-butanediol or 1,6-hexanediol.

3. A method for manufacturing a ceiling material according to claim 1 or claim 2, A method for manufacturing a ceiling material, comprising integrally forming the aforementioned plate-shaped laminate for vehicles and the aforementioned base material by hot pressing.

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