Surface material

Abstract

To improve flame retardancy of the skin material as a whole.SOLUTION: A skin material 1 includes a foam layer 2, a skin 3 comprising a knitted fabric impregnated with a flame retardant, for coating the foam layer 2, and a coating layer 4 arranged between the skin 3 and the foam layer 2, which is a coating layer 4 containing the flame retardant.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a surface material.

Background Art

[0002] Conventionally, a laminate structure including a surface material, a polyurethane foam as a cushioning material, and a back base fabric has been known (for example, see Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the laminate structure described in Patent Document 1 above, even if each of the plurality of layers constituting the laminate structure has sufficient flame retardancy, the flame retardancy of the entire laminate structure in which these layers are combined may be inferior to the flame retardancy of each layer.

[0005] Therefore, the present invention provides a surface material capable of improving the flame retardancy of the entire surface material.

Means for Solving the Problems

[0006] The present invention [1] includes a surface material including a foam layer, a surface covering the foam layer and made of a knitted fabric impregnated with a flame retardant, and a coating layer disposed between the surface and the foam layer and containing a flame retardant.

Effects of the Invention

[0007] According to the surface material of the present invention, a coating layer containing a flame retardant is disposed between the surface and the foam layer.

[0008] Therefore, the flame retardant-containing coating layer can suppress the flow of flammable gases generated by the burning of the outer layer into the foam layer.

[0009] This prevents the burning of the outer layer from spreading to the foam layer.

[0010] As a result, the overall flame retardancy of the surface material can be improved. [Brief explanation of the drawing]

[0011] [Figure 1] Figure 1 is a cross-sectional view of a surface material as one embodiment of the present invention. [Modes for carrying out the invention]

[0012] 1.Skin material The surface material 1 is used, for example, as the surface material for a vehicle seat. However, the use of the surface material 1 is not limited. The surface material 1 comprises a foam layer 2, a surface layer 3, a coating layer 4, and a backing fabric 5. The surface material 1 consists only of the foam layer 2, the surface layer 3, the coating layer 4, and the backing fabric 5.

[0013] The thickness of the surface material 1 is, for example, 2.5 mm or more and 3.9 mm or less.

[0014] (1) Foam layer The foam layer 2 has a sheet shape. In the thickness direction of the foam layer 2, the foam layer 2 has a surface S1 and a back surface S2.

[0015] Examples of materials for the foam layer 2 include polyurethane foam, polyethylene foam, and polypropylene foam. Polyurethane foam is preferred as the material for the foam layer 2.

[0016] The thickness of foam layer 2 is, for example, 1.5 mm or more and 2.5 mm or less.

[0017] (2) Epidermis The skin 3 covers the surface S1 of the foam layer 2. The skin 3 is attached to the surface S1 of the foam layer 2 together with the coating layer 4 by frame lamination. Thus, the skin 3, the coating layer 4 and the foam layer 2 are integrated (composite). The skin 3 is made of a knitted fabric impregnated with a flame retardant.

[0018] Examples of the material of the knitted fabric include natural fibers, synthetic fibers, and regenerated fibers. Examples of natural fibers include cotton, hemp, silk, and wool. Examples of synthetic fibers include polyester and nylon. Examples of regenerated fibers include rayon and cupra. Preferably, the material of the knitted fabric is a synthetic fiber, more preferably polyester.

[0019] Examples of the flame retardant include phosphate esters and guanidine phosphates.

[0020] The thickness of the skin 3 is, for example, 0.8 mm or more and 1.2 mm or less.

[0021] The basis weight of the knitted fabric of the skin 3 is, for example, 300 g / m 2 or more and 400 g / m 2 or less.

[0022] (3) Coating layer The coating layer 4 is disposed between the skin 3 and the foam layer 2. The coating layer 4 coats the back surface of the skin 3. The coating layer 4 contains a resin and a flame retardant.

[0023] Examples of the resin include urethane resin and acrylic resin.

[0024] Examples of flame retardants include those mentioned above. Preferably, the flame retardant in the coating layer 4 is the same as the flame retardant in the skin 3. When the flame retardant in the coating layer 4 and the flame retardant in the skin 3 are the same, when the skin 3 and the coating layer 4 burn, the carbonized layer produced by the combustion of the skin 3 and the carbonized layer produced by the combustion of the coating layer 4 are combined to form a dense carbonized layer. As a result, the dense carbonized layer can suppress the flow of flammable gases produced by the combustion of the skin 3 and the coating layer 4 into the foam layer 2. Consequently, the spread of fire from the combustion of the skin 3 to the foam layer 2 can be further suppressed, and the flame retardancy of the entire skin material 1 (i.e., in the state in which the foam layer 2, skin 3, coating layer 4, and backing fabric 5 are combined) can be further improved.

[0025] The thickness of the coating layer 4 is, for example, 0.1 mm or more and 0.2 mm or less.

[0026] (4) Back base fabric The backing fabric 5 covers the back surface S2 of the foam layer 2. The backing fabric 5 is attached to the back surface S2 of the foam layer 2 by frame lamination. As a result, the backing fabric 5 and the foam layer 2 are integrated (composite). In other words, the outer layer 3, coating layer 4, foam layer 2, and backing fabric 5 are integrated (composite).

[0027] Examples of materials for the backing fabric 5 include the natural fibers, synthetic fibers, and regenerated fibers mentioned above. Preferably, synthetic fibers, and more preferably nylon, are used as the material for the backing fabric 5.

[0028] The thickness of the backing fabric 5 is, for example, 0.2 mm or more and 0.25 mm or less.

[0029] 2. Effects According to the surface material 1, as shown in Figure 1, a coating layer 4 containing a flame retardant is placed between the surface layer 3 and the foam layer 2.

[0030] Therefore, the flame retardant-containing coating layer 4 can suppress the flow of flammable gas generated by the combustion of the outer layer 3 into the foam layer 2.

[0031] This prevents the burning of the outer layer 3 from spreading to the foam layer 2.

[0032] As a result, the flame retardancy of the entire surface material 1 can be improved. [Examples]

[0033] The present invention will be further described with reference to the following examples, but the present invention is not limited thereto. Specific numerical values ​​such as blending ratios (content), physical properties, and parameters used in the following description may be replaced with the corresponding upper limits (numerical values ​​defined as "less than or equal to" or "less than") or lower limits (numerical values ​​defined as "greater than or equal to" or "greater than or equal to" or "greater than or equal to") of the blending ratios (content), physical properties, and parameters described in the "Modes for Carrying Out the Invention" above. Note that "parts" and "%" refer to mass unless otherwise specified.

[0034] 1. Manufacturing of the surface material <Examples> A foam layer made of polyurethane foam (thickness: 2 mm) and a polyester surface layer impregnated with a flame retardant (phosphate ester) and backed with a coating layer (made of urethane resin) containing the flame retardant (phosphate ester) are layered in sequence on a nylon backing fabric. The surface layer is then laminated to one side of the foam layer, and the backing fabric is laminated to the other side of the foam layer using frame lamination.

[0035] This resulted in the surface material (thickness: 3.1 mm) shown in Figure 1.

[0036] <Comparative Example> A surface material (thickness: 3.0 mm) was obtained in the same manner as in the example, except that a coating layer was not provided.

[0037] 2. Measurement of maximum combustion speed The flame retardancy of the surface materials obtained in the examples and comparative examples was evaluated using TRIAS 20-J027-01 "Flame Retardancy Test of Interior Materials".

[0038] The surface material used in the example was "non-combustible".

[0039] The maximum burning rate of the surface material in the comparative example was 82 mm / min. [Explanation of Symbols]

[0040] 1 Skin material 2. Foam layer 3 Epidermis 4 Coating layer

Claims

[Claim 1] A foam layer and It consists of a knitted fabric impregnated with a flame retardant, and a surface covering the foam layer, A coating layer disposed between the skin and the foam layer, the coating layer containing a flame retardant Equipped with, The thickness of the foam layer is 1.5 mm or more and 2.5 mm or less. The thickness of the aforementioned epidermis is 0.8 mm or more and 1.2 mm or less. The thickness of the coating layer is 0.1 mm or more and 0.2 mm or less. The flame retardant in the coating layer is the same as the flame retardant in the surface material.

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