JP7238889B2 - Laminated sheets and laminates for automobile interior materials - Google Patents

Description

TECHNICAL FIELD The present invention relates to a laminate sheet for automotive interior materials and a laminate.

A skin composed of a vinyl chloride resin layer containing a plasticizer and a laminate obtained by lining the skin with a foamed polyurethane resin layer are used as automobile interior materials for automotive interior parts such as automobile instrument panels and door trims. Widely used. In order to enhance the design and marketability of the skin made of the vinyl chloride resin layer containing such a plasticizer, a stitch pattern is sometimes applied by sewing.

Here, if the above-described skin is sewn with a stitch pattern and then lined with a foamed polyurethane resin layer, there is a problem that the components of the foamed polyurethane resin layer leak onto the skin through the seams.

To solve this problem, for example, by laminating a tape as a backing member on the sewn part of the back surface of the outer skin (that is, the side on which the foamed polyurethane resin layer is lined), the leakage from the sewn part through the hole. It is conceivable to prevent leakage of components of the foamed polyurethane resin layer.
Here, when a foamed polyurethane resin layer is lined against a skin having a tape laminated on the back surface (hereinafter sometimes referred to as a "laminated sheet for automobile interior materials"), the skin (a chloride containing a plasticizer) is formed. Various components contained in the skin and the polyurethane foam resin layer migrate between the vinyl resin layer) and the foamed polyurethane resin layer, discoloring the skin. However, since it is difficult for these various components to pass through the part where the backing tape is laminated, when the skin is viewed from the surface (that is, the side opposite to the side where the foamed polyurethane resin layer is lined), the backing tape The appearance of the epidermis deteriorates as traces appear where the tape is laminated.

Therefore, in recent years, there has been a demand for the development of a technique for suppressing the appearance of traces of a backing tape when a foamed polyurethane resin layer is backed on a laminated sheet for automotive interior materials.

For example, in Patent Document 1, a tape comprising a base material having a porous structure and an adhesive layer is used as a backing tape, and the adhesive layer is positioned closer to the vinyl chloride resin layer than the base material. Placing a tape is suggested.
Further, Patent Document 2 proposes using a tape comprising a base material having a fiber braided structure and an adhesive layer as a backing tape and arranging the tape in the same manner as in Patent Document 1.

WO2016/147637 WO2016/147638

However, in the above-described prior art, there is still room for improvement in terms of suppressing the appearance of traces of the backing tape when the foamed polyurethane resin layer is backed on the laminated sheet for automotive interior materials.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a laminated sheet for automotive interior materials that can satisfactorily suppress the appearance of traces of a backing tape when a foamed polyurethane resin layer is backed.
Another object of the present invention is to provide a laminate comprising the laminate sheet for automotive interior materials and capable of satisfactorily suppressing the appearance of traces of the backing tape.

The inventor of the present invention has made intensive studies with the aim of solving the above problems. The present inventor has found that a backing tape comprising a base material made of a polyurethane resin and an adhesive layer made of a polyurethane resin having a flow initiation temperature higher than a predetermined value is arranged on one side in the thickness direction of the vinyl chloride resin layer. And, if the adhesive layer is a laminated sheet for automobile interior materials arranged between the vinyl chloride resin layer and the base material, the appearance of traces of the backing tape when the foamed polyurethane resin layer is backed. have been found to be able to satisfactorily suppress, and the present invention has been completed.

That is, an object of the present invention is to advantageously solve the above problems, and a laminated sheet for automobile interior materials of the present invention comprises a vinyl chloride resin layer containing a plasticizer and a thickness of the vinyl chloride resin layer A laminated sheet for automotive interior materials, comprising a backing tape arranged on one side in a direction, the backing tape comprising a polyurethane resin base material and a polyurethane resin adhesive layer, the polyurethane resin adhesive layer being the It is arranged between the vinyl chloride resin layer and the polyurethane resin substrate, and the polyurethane resin adhesive layer has a flow initiation temperature of 70° C. or higher. Thus, a backing tape comprising a polyurethane resin base material and a polyurethane resin adhesive layer having a flow initiation temperature equal to or higher than the predetermined temperature is arranged on one side in the thickness direction of the vinyl chloride resin layer, and the polyurethane resin is A laminated sheet for automobile interior materials in which the adhesive layer is arranged between the vinyl chloride resin layer and the polyurethane resin base material is favorable in the appearance of traces of the backing tape when the foamed polyurethane resin layer is backed. can be suppressed to
In addition, the "flow initiation temperature" in this specification is measured using the JIS K7210 standard.

Here, in the laminate sheet for automotive interior materials of the present invention, it is preferable that the thickness of the polyurethane resin base material is 100 μm or less. When the thickness of the polyurethane resin base material is not more than the above predetermined thickness, it is possible to more satisfactorily suppress the appearance of traces of the backing tape when the laminated sheet for automotive interior materials is backed with the foamed polyurethane resin layer.

In addition, in the laminated sheet for automotive interior materials of the present invention, the ratio of the thickness of the polyurethane resin substrate to the thickness of the polyurethane resin adhesive layer (thickness of polyurethane resin substrate/thickness of polyurethane resin adhesive layer) is 5/2. The following are preferred. If the ratio of the thickness of the polyurethane resin base material to the thickness of the polyurethane resin adhesive layer (thickness of the polyurethane resin base material/thickness of the polyurethane resin adhesive layer) is equal to or less than the above upper limit, the laminated sheet for automotive interior materials may contain polyurethane foam. The appearance of traces of the backing tape when the resin layer is backed can be more effectively suppressed.

Furthermore, the laminated sheet for automotive interior materials of the present invention can be suitably used for automotive instrument panels.

In the laminated sheet for automotive interior materials of the present invention, the vinyl chloride resin layer is sewn, and the backing tape is arranged so as to cover the sewn portion of the vinyl chloride resin layer. preferable. If the vinyl chloride resin layer is sewn and arranged so as to cover the sewn portion, when the foamed polyurethane resin layer is lined, the surface of the skin (vinyl chloride resin layer) While preventing the component of the foamed polyurethane layer from leaking out, the appearance of traces of the backing tape can be suppressed satisfactorily.

Another object of the present invention is to advantageously solve the above problems, and the laminate of the present invention comprises a foamed polyurethane resin layer and any of the laminated sheets for automotive interior materials described above. The laminate is characterized in that the backing tape is arranged between the foamed polyurethane resin layer and the vinyl chloride resin layer. In this way, if it is a laminate obtained by arranging any of the laminated sheets for automobile interior materials described above so that the backing tape is positioned between the foamed polyurethane resin layer and the vinyl chloride resin layer, the backing Appearance of tape traces can be well suppressed.

According to the present invention, it is possible to provide a laminated sheet for automobile interior materials that can satisfactorily suppress the appearance of traces of a backing tape when a foamed polyurethane resin layer is backed.
Further, according to the present invention, it is possible to provide a laminate comprising the laminate sheet for automobile interior materials and capable of satisfactorily suppressing the appearance of traces of the backing tape.

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described in detail.
Here, the laminated sheet for automotive interior materials of the present invention can be used, for example, for producing the laminate of the present invention. The laminated sheet for automobile interior materials of the present invention can be suitably used as automobile interior materials, such as skins of automobile interior parts such as automobile instrument panels.

(Laminated sheet for automobile interior materials)
The laminate sheet for automobile interior materials of the present invention is a laminate sheet for automobile interior materials comprising a vinyl chloride resin layer containing a plasticizer and a backing tape disposed on one side in the thickness direction of the vinyl chloride resin layer. , the backing tape comprises a polyurethane resin base material and a polyurethane resin adhesive layer having a flow initiation temperature higher than a predetermined temperature, and the polyurethane resin adhesive layer is provided between the vinyl chloride resin layer and the polyurethane resin base material. It is characterized by being arranged. In the laminated sheet for automobile interior materials of the present invention, a backing tape comprising a polyurethane resin base material and a polyurethane resin adhesive layer having a flow initiation temperature of a predetermined temperature or higher is provided on one side in the thickness direction of the vinyl chloride resin layer. and the polyurethane resin adhesive layer is arranged between the vinyl chloride resin layer and the polyurethane resin base material, so that when the foamed polyurethane resin layer is backed, the traces of the backing tape are less likely to appear. can be suppressed to Therefore, the laminated sheet for automobile interior materials of the present invention is suitably used as an automobile interior member, specifically, for example, as the skin of automobile interior parts such as automobile instrument panels and door trims. It is suitably used for the skin of the panel.

Here, the laminated sheet for automobile interior materials of the present invention usually has a structure in which a backing tape is directly adhered to at least a part of one surface of a vinyl chloride resin layer containing a plasticizer. A layer other than the vinyl chloride resin layer and the backing tape may be further provided as long as the desired effect of the invention is not significantly impaired. Specifically, without particular limitation, the laminated sheet for automotive interior materials of the present invention includes, for example, a layer for improving heat aging resistance as described in International Publication No. 2011/086813. It may be provided between the vinyl resin layer and the backing tape. Further, in the laminated sheet for automobile interior materials of the present invention, for example, a decorative layer for imparting design to automobile interior members is formed on the other side in the thickness direction of the vinyl chloride resin layer (the side on which the backing tape is arranged). opposite side).

<Vinyl chloride resin layer>
The vinyl chloride resin layer is a member that constitutes the skin of the laminated sheet for automotive interior materials of the present invention. The vinyl chloride resin layer used in the laminate sheet for automotive interior materials of the present invention contains a plasticizer. If the vinyl chloride resin layer does not contain a plasticizer, the laminate sheet for automotive interior materials of the present invention cannot exhibit good flexibility as a skin for automotive interior parts.

Here, the vinyl chloride resin layer is preferably sewn. If a sewn vinyl chloride resin layer is used as the vinyl chloride resin layer, the obtained laminate sheet for automotive interior materials can be more suitably used as a skin for automotive interior parts. Here, as a sewing method, a known sewing method such as thread sewing using a needle can be used. When the laminated sheet for automobile interior materials of the present invention has an additional layer between the vinyl chloride resin layer and the backing tape, the sewing process is not particularly limited, and the vinyl chloride resin layer alone is sewn. It may be performed on the laminate of the vinyl chloride resin layer and the additional layer.

The thickness of the vinyl chloride resin layer is not particularly limited, but is preferably 100 μm or more, more preferably 500 μm or more, even more preferably 800 μm or more, and is preferably 1000 μm (1 mm) or more. Particularly preferably, it is 3 mm or less, more preferably 2 mm or less, and even more preferably 1.5 mm or less. This is because, when the thickness of the vinyl chloride resin layer is at least the above lower limit, good flexibility and strength can be imparted to the obtained laminate sheet for automotive interior materials. On the other hand, if the thickness of the vinyl chloride resin layer is equal to or less than the above upper limit, it is possible to prevent the obtained laminated sheet for automotive interior materials from becoming too large.

The vinyl chloride resin layer is usually obtained by forming a vinyl chloride resin composition containing a plasticizer into a sheet.

<<Vinyl chloride resin composition>>
The vinyl chloride resin composition contains a vinyl chloride resin and a plasticizer, and may optionally further contain various additives.

[vinyl chloride resin]
Here, the vinyl chloride resin contained in the vinyl chloride resin composition may contain, for example, one type or two or more types of vinyl chloride resin particles, and optionally one type or two or more types of vinyl chloride resin fine particles. can be further included. Above all, the vinyl chloride resin preferably contains at least vinyl chloride resin particles, and more preferably contains vinyl chloride resin particles and vinyl chloride fine particles.
In this specification, "resin particles" refer to particles having a particle diameter of 30 µm or more, and "resin fine particles" refer to particles having a particle diameter of less than 30 µm. The vinyl chloride resin particles usually function as a matrix resin (base material), and the vinyl chloride resin fine particles usually function as a dusting agent (powder fluidity improver). The vinyl chloride resin particles are preferably produced by a suspension polymerization method, and the vinyl chloride resin fine particles are preferably produced by an emulsion polymerization method.
Also, vinyl chloride resin can be produced by any conventionally known production method such as a suspension polymerization method, an emulsion polymerization method, a solution polymerization method, and a bulk polymerization method.

Vinyl chloride resins include homopolymers composed of vinyl chloride monomer units, and vinyl chloride copolymers containing vinyl chloride monomer units in an amount of preferably 50% by mass or more, more preferably 70% by mass or more. mentioned. Specific examples of monomers (comonomers) that can be copolymerized with vinyl chloride monomers that can constitute vinyl chloride copolymers include olefins such as ethylene and propylene; allyl chloride, vinylidene chloride, Halogenated olefins such as vinyl fluoride and ethylene trifluorochloride; carboxylic acid vinyl esters such as vinyl acetate and vinyl propionate; vinyl ethers such as isobutyl vinyl ether and cetyl vinyl ether; allyl-3-chloro-2-oxypropyl ether, allyl ethers such as allyl glycidyl ether; acrylic acid, maleic acid, itaconic acid, 2-hydroxyethyl acrylate, methyl methacrylate, monomethyl maleate, diethyl maleate, unsaturated carboxylic acids such as maleic anhydride, its esters or its acid anhydrides; unsaturated nitriles such as acrylonitrile and methacrylonitrile; acrylamides such as acrylamide, N-methylolacrylamide, acrylamido-2-methylpropanesulfonic acid and (meth)acrylamidopropyltrimethylammonium chloride; allylamine and derivatives thereof such as allylamine benzoate and diallyldimethylammonium chloride; The monomers exemplified above are only a part of comonomers, and examples of comonomers include "Polyvinyl chloride" edited by the Kinki Chemical Society Vinyl Section, Nikkan Kogyo Shimbun (1988) 75- Various monomers exemplified on page 104 can be used. Only one of these comonomers may be used, or two or more thereof may be used. The vinyl chloride resin includes resins such as ethylene-vinyl acetate copolymer, ethylene-methyl methacrylate copolymer, ethylene-ethyl acrylate copolymer, and chlorinated polyethylene, and (1) vinyl chloride or ( 2) Resins obtained by graft polymerization of vinyl chloride and the comonomer are also included.
Here, in this specification, "(meth)acryl" means acryl and/or methacryl.

[Plasticizer]
As the plasticizer contained in the vinyl chloride resin composition, for example, the primary plasticizer and secondary plasticizer described in WO 2016/098344 can be used. These components may be used singly or in combination of two or more at any ratio.
Among the plasticizers described above, it is preferable to use at least the primary plasticizer as the plasticizer from the viewpoint of easily obtaining the vinyl chloride resin composition and the vinyl chloride resin layer. Combined use is more preferable. Specifically, as the plasticizer, it is preferable to use trimellitic acid ester and/or pyromellitic acid ester, more preferably at least trimellitic acid ester, and trimellitic acid ester and epoxidized soybean oil are preferably used. Combined use is more preferable.

Here, the content of the plasticizer is not particularly limited, but it is preferably 30 parts by mass or more, more preferably 60 parts by mass or more, and 90 parts by mass or more with respect to 100 parts by mass of the vinyl chloride resin. More preferably, it is 110 parts by mass or more, particularly preferably 200 parts by mass or less, more preferably 170 parts by mass or less, and even more preferably 160 parts by mass or less. This is because, when the content of the plasticizer is at least the above lower limit, good flexibility can be imparted to the resulting laminate sheet for automotive interior materials. Moreover, if the content of the plasticizer is equal to or less than the above upper limit, it is possible to further suppress stickiness on the surface of the laminated sheet for automotive interior materials to be obtained, and to further increase the surface slipperiness.

[Additive]
The vinyl chloride resin composition may further contain various additives in addition to the components described above. Examples of additives include, but are not limited to, stabilizers such as perchloric acid-treated hydrotalcite, zeolite, β-diketone, and fatty acid metal salts; release agents; Sting agent; impact modifier; perchlorate compound other than perchloric acid-treated hydrotalcite (sodium perchlorate, potassium perchlorate, etc.); antioxidant; antifungal agent; flame retardant; antistatic agent; fillers; light stabilizers; foaming agents; moldability modifiers (such as silicone oil); and coloring agents.
Such additives are not particularly limited, and for example, those described in International Publication No. 2016/098344 can be used.

[Method for preparing vinyl chloride resin composition]
The vinyl chloride resin composition can be prepared by mixing the above components without any particular limitation.
Here, the method for mixing the vinyl chloride resin, the plasticizer, and various additives that are further used as necessary is not particularly limited. A method of mixing the components to be excluded by dry blending, and then adding and mixing the dusting agent may be mentioned. Here, it is preferable to use a Henschel mixer for dry blending. Moreover, the temperature during dry blending is not particularly limited, and is preferably 50° C. or higher, more preferably 70° C. or higher, and preferably 200° C. or lower.

<<Method for Forming Vinyl Chloride Resin Layer>>
The vinyl chloride resin layer can be formed, for example, by molding the vinyl chloride resin composition described above by any method, preferably powder molding, more preferably powder slush molding.

For example, in powder slush molding, the following methods can be used without particular limitation. That is, a mold heated to an arbitrary temperature range is sprinkled with a vinyl chloride resin composition, left to stand for 5 seconds or more and 30 seconds or less, then the excess vinyl chloride resin composition is shaken off, and the mold is heated to an arbitrary temperature. , Leave for 30 seconds or more and 3 minutes or less. After that, the mold is cooled to 10° C. or more and 60° C. or less, and the obtained vinyl chloride resin layer is removed from the mold. Then, the demolded vinyl chloride resin layer is obtained, for example, as a sheet-like molded article having the shape and pattern of the mold.
Here, the mold temperature to be heated during molding is not particularly limited, and is preferably 200° C. or higher, more preferably 220° C. or higher, preferably 300° C. or lower, and 280° C. or lower. is more preferable.

<Backing tape>
The backing tape includes a polyurethane resin base material and a polyurethane resin adhesive layer having a flow initiation temperature higher than a predetermined temperature. Usually, the backing tape has a structure in which a polyurethane resin base material and a polyurethane resin adhesive layer are adjacent to each other in the thickness direction, one surface of the backing tape is composed of the polyurethane resin base material, and the other surface is composed of the polyurethane resin. Consists of an adhesive layer. The polyurethane resin substrate and the polyurethane resin adhesive layer are usually directly adhered to each other. may intervene.

The backing tape is arranged on one side in the thickness direction of the vinyl chloride resin layer described above. At this time, the polyurethane resin adhesive layer is arranged between the vinyl chloride resin layer and the polyurethane resin substrate. Incidentally, the backing tape is usually directly adhered to one surface of the vinyl chloride resin layer described above. That is, normally, the surface of the backing tape on the side of the polyurethane resin adhesive layer is directly adhered to one surface of the vinyl chloride resin layer. However, another layer may be interposed between the backing tape (polyurethane resin adhesive layer) and the vinyl chloride resin layer as long as it does not significantly impair the desired effect of the present invention. Specific examples of other layers include the layer for improving the heat aging resistance described above in the section "Laminate sheet for automobile interior materials".

Also, the backing tape is arranged at an arbitrary position on one side of the vinyl chloride resin layer in the thickness direction. Here, the backing tape is usually arranged on a part of one side in the thickness direction of the vinyl chloride resin layer. For example, a backing tape is usually adhered directly to a portion of one surface of the vinyl chloride resin layer.

Furthermore, when the vinyl chloride resin layer is sewn, the backing tape is preferably arranged so as to cover the sewn portion on one side in the thickness direction of the vinyl chloride resin layer. If the vinyl chloride resin layer is sewn and the backing tape is arranged so as to cover the sewn portion on one side of the vinyl chloride resin layer in the thickness direction, the vinyl chloride resin produced by the sewing process Since the holes in the layer can be closed with the backing tape, when the foamed polyurethane resin layer is lined on the laminate sheet for automobile interior materials, the components of the foamed polyurethane resin layer will not leak onto the surface of the skin (vinyl chloride resin layer). It is possible to satisfactorily suppress the appearance of traces of the backing tape while preventing it from coming out.

Here, when the laminated sheet for automobile interior materials of the present invention is lined with a foamed polyurethane resin layer, the backing tape provided for the laminated sheet for automobile interior materials of the present invention is composed of a polyurethane resin base material and a flow start temperature of at least a predetermined temperature. It has a polyurethane resin adhesive layer and is arranged between the vinyl chloride resin layer and the foamed polyurethane resin layer, so the backing tape traces appear on the surface of the skin for unknown reasons. can be well suppressed.

The thickness of the backing tape is not particularly limited, but is preferably 20 μm or more, more preferably 40 μm or more, still more preferably 60 μm or more, even more preferably 80 μm or more, and 250 μm or less. preferably 200 μm or less, still more preferably 150 μm or less, even more preferably 140 μm or less, even more preferably 120 μm or less, and even more preferably 110 μm or less. preferable. If the thickness of the backing tape is at least the above lower limit, the backing tape can maintain good handleability. On the other hand, if the thickness of the backing tape is equal to or less than the above upper limit, it is possible to more satisfactorily suppress the appearance of traces of the backing tape when the laminated sheet for automotive interior materials is lined with the foamed polyurethane resin layer.

<< Polyurethane resin base material >>
The polyurethane resin constituting the polyurethane resin substrate is not particularly limited as long as the desired effects of the present invention can be obtained, and known polyurethane resins can be used. As the polyurethane resin, one kind of polyurethane resin may be used alone, or plural kinds of polyurethane resins may be mixed at an arbitrary ratio and used. The polyurethane resin that constitutes the polyurethane resin substrate is usually a thermoplastic polyurethane resin.
Here, the thermoplastic polyurethane resin is generally a polymer having a urethane bond in the molecule obtained by subjecting polyols, isocyanates, and a chain extender to a polyaddition reaction using a catalyst as necessary. It is coalesced and softens by heating to show fluidity. Known polyols, isocyanates, chain extenders, and catalysts can be used to prepare the thermoplastic polyurethane resin. Each component of polyols, isocyanates, chain extenders, and catalysts may be used singly, or plural kinds may be mixed and used in an arbitrary ratio.
Moreover, the polyurethane resin base material may contain components other than the polyurethane resin described above within the range in which the desired effects of the present invention can be obtained.
It should be noted that the polyurethane resin substrate is generally non-foamed.

Here, the flow initiation temperature of the polyurethane resin substrate is preferably 140° C. or higher, preferably 150° C. or higher, more preferably 160° C. or higher, and particularly preferably 180° C. or higher. , 300° C. or less. When the flow initiation temperature of the polyurethane resin base material is at least the above lower limit, the polyurethane resin base material can be prevented from being melted by heating during the production of the laminated sheet for automotive interior materials, which will be described later. can be produced efficiently. On the other hand, if the flow initiation temperature of the polyurethane resin base material is equal to or lower than the above upper limit, the polyurethane resin base material has a certain degree of flexibility, and the polyurethane resin base material can be bent during the production of the laminated sheet for automotive interior materials described later. It is possible to prevent brittle fracture caused by such as.

The thickness of the polyurethane resin substrate is preferably 10 μm or more, preferably 100 μm or less, more preferably 70 μm or less, even more preferably 50 μm or less, and 30 μm or less. Especially preferred. When the thickness of the polyurethane resin base material is at least the above lower limit, the backing tape can maintain good handleability. On the other hand, if the thickness of the polyurethane resin substrate is equal to or less than the above upper limit, it is possible to more satisfactorily suppress the appearance of traces of the backing tape when the foamed polyurethane resin layer is backed on the laminated sheet for automotive interior materials.

<<Polyurethane resin adhesive layer>>
The flow initiation temperature of the polyurethane resin adhesive layer must be 70° C. or higher, preferably 80° C. or higher, more preferably 90° C. or higher, and even more preferably 100° C. or higher. It is preferably 110° C. or less. When the flow initiation temperature of the polyurethane resin adhesive layer is at least the above lower limit, it is possible to satisfactorily suppress the appearance of traces of the backing tape when the foamed polyurethane resin layer is backed on the laminated sheet for automotive interior materials. On the other hand, if the flow initiation temperature of the polyurethane resin adhesive layer is equal to or lower than the above upper limit, the polyurethane resin adhesive layer is sufficiently melted and exhibits good adhesiveness during the production of the laminated sheet for automobile interior materials described later, so that it is A laminated sheet for interior materials can be produced efficiently.

Here, the polyurethane resin constituting the polyurethane resin adhesive layer is not particularly limited as long as the flow initiation temperature is within the predetermined range, and known polyurethane resins can be used. Moreover, as said polyurethane resin, one type may be used independently, and multiple types may be mixed and used by arbitrary ratios. The polyurethane resin that constitutes the polyurethane resin substrate is usually a thermoplastic polyurethane resin, and the components that can be used for preparing the thermoplastic polyurethane resin are those described above in the section "Polyurethane resin substrate". can be appropriately selected and used.
In addition, the polyurethane resin adhesive layer may contain components other than the polyurethane resin described above within the range in which the desired effects of the present invention can be obtained.
It should be noted that the polyurethane resin adhesive layer is generally non-foamed.

The thickness of the polyurethane resin adhesive layer is preferably 10 µm or more, more preferably 20 µm or more, still more preferably 30 µm or more, preferably 150 µm or less, and preferably 110 µm or less. It is more preferably 80 μm or less, even more preferably 70 μm or less, and even more preferably 50 μm or less. If the thickness of the polyurethane resin adhesive layer is at least the above lower limit, it is possible to further effectively suppress the appearance of traces of the backing tape when the foamed polyurethane resin layer is lined on the laminated sheet for automobile interior materials, and the thickness of the backing tape is reduced. Good handleability can be maintained. On the other hand, if the thickness of the polyurethane resin adhesive layer is equal to or less than the above upper limit, it is possible to maintain good handling properties of the backing tape and to maintain good backing processability of the foamed polyurethane resin layer.

Furthermore, the ratio of the thickness of the polyurethane resin substrate to the thickness of the polyurethane resin adhesive layer (thickness of polyurethane resin substrate/thickness of polyurethane resin adhesive layer) is preferably 5/2 or less, and preferably 7/4 or less. is more preferably 5/3 or less, even more preferably 1/1 or less, even more preferably 5/7 or less, and even more preferably 3/5 or less , is particularly preferably 3/8 or less, most preferably 3/11 or less, and preferably 1/4 or more. If the ratio of the thickness of the polyurethane resin base material/thickness of the polyurethane resin adhesive layer is equal to or less than the above upper limit, the occurrence of traces of the backing tape when the laminated sheet for automotive interior materials is backed with the foamed polyurethane resin layer is further improved. can be suppressed. On the other hand, if the ratio of the thickness of the polyurethane resin substrate/thickness of the polyurethane resin adhesive layer is at least the above lower limit, the handling of the backing tape will be good.

<Method for manufacturing laminated sheet for automotive interior materials>
The method for producing the laminated sheet for automotive interior materials of the present invention is not particularly limited, and for example, the following method can be used. That is, in a state in which the backing tape described above is placed on one surface of the vinyl chloride resin layer so that the polyurethane resin adhesive layer is positioned between the vinyl chloride resin layer and the polyurethane resin substrate, a heated roller is applied. A laminate sheet for automotive interior materials can be produced by pressing a polyurethane resin substrate from above to melt the polyurethane resin adhesive layer, thereby directly adhering a backing tape to one surface of the vinyl chloride resin layer. . The material of the roller is preferably metal, but is not particularly limited as long as it has good thermal conductivity and can maintain a solid state during operation. Specific examples of roller materials other than metal include metal oxides such as alumina, ceramics, and the like.
Here, the temperature of the heated roller is not particularly limited, and can be appropriately set in consideration of the flow starting temperature of the polyurethane resin substrate and the polyurethane resin adhesive layer of the backing tape to be used, but it should be 110° C. or higher. is preferable, and it is preferably 130° C. or less. If the temperature of the heated roller is equal to or higher than the above lower limit, the polyurethane resin adhesive layer can be sufficiently melted and good adhesiveness can be exhibited, so the laminated sheet for automobile interior materials can be efficiently produced. . On the other hand, if the temperature of the heated roller is equal to or lower than the above upper limit, it is possible to prevent the polyurethane resin base material from melting and adhering to the roller, so that the laminated sheet for automotive interior materials can be produced efficiently.
Also, the backing tape is not particularly limited, and a commercially available product can also be used.

(Laminate)
The laminate of the present invention is a laminate having a foamed polyurethane resin layer and the laminate sheet for automotive interior materials described above. The laminate of the present invention has a structure in which a backing tape is interposed between the foamed polyurethane resin layer and the vinyl chloride resin layer. In general, the foamed polyurethane resin layer is lined on the side of the laminate sheet for automobile interior materials on which the backing tape is arranged, and the polyurethane foam resin layer and the laminate sheet for automobile interior materials are adjacent to each other in the thickness direction. ing.

And since the above-described laminated sheet for automotive interior materials usually has a structure in which a backing tape is arranged on a part of one side in the thickness direction of the vinyl chloride resin layer, the laminate of the present invention is usually , a structure in which a vinyl chloride resin layer and a foamed polyurethane resin layer are adjacent to each other via a backing tape, and a structure in which a vinyl chloride resin layer and a foamed polyurethane resin layer are adjacent to each other without a backing tape therebetween.

Further, in the laminated sheet for automotive interior materials, a backing tape comprising a polyurethane resin substrate and a predetermined polyurethane resin adhesive layer is arranged on one side in the thickness direction of the vinyl chloride resin layer, and the polyurethane resin adhesive Since the layer has a structure in which the layer is arranged between the vinyl chloride resin layer and the polyurethane resin base material, in the structure in which the vinyl chloride resin layer and the foamed polyurethane resin layer are adjacent to each other via the backing tape, the thickness direction A vinyl chloride resin layer, a polyurethane resin adhesive layer, a polyurethane resin substrate, and a foamed polyurethane resin layer are laminated in this order. In addition, other layers may be interposed between the constituent elements described above as long as the desired effects of the present invention are not significantly impaired.

Since the laminate of the present invention includes the laminate sheet for automotive interior materials described above, it is possible to satisfactorily suppress the appearance of traces of the backing tape. Therefore, the laminate of the present invention is suitably used as an automotive interior material for automotive interior parts such as automotive instrument panels and door trims, and is particularly suitable for automotive instrument panels.

In addition, the method for manufacturing the laminate of the present invention is not particularly limited, and for example, the following method can be used. That is, on the surface of the laminate sheet for automobile interior materials on which the backing tape is arranged, isocyanates and polyols, which are raw materials for the foamed polyurethane resin layer, are reacted to polymerize and polymerized by a known method. An example of the laminate of the present invention can be produced by foaming polyurethane and directly forming a foamed polyurethane resin layer on the surface of the laminate sheet for automotive interior materials on which the backing tape is arranged. .

EXAMPLES The present invention will be specifically described below based on examples, but the present invention is not limited to these examples. In the following description, "%" and "parts" representing amounts are based on mass unless otherwise specified.
The method of conducting the cycle test and the method of evaluating the results are as follows.

<Cycle test>
The obtained laminate is treated using Isuzu Manufacturing Co., Ltd.'s "HPAV-120-40" as a device, with one cycle of heating at 90 ° C. for 4 hours and cooling at -40 ° C. for 1.5 hours. was repeated, and the degree of appearance of traces of the backing tape after completion of 10 cycles and after completion of 20 cycles was evaluated by visual observation according to the following criteria.
A: Traces of backing tape are not visible B: Traces of backing tape are not visible from the front, but are faintly visible when changing the angle C: Traces of backing tape are faintly visible from the front without changing the angle D : The trace of the backing tape is clearly visible from the front without changing the angle.

(Example 1)
<Preparation of vinyl chloride resin composition>
Of the ingredients of the vinyl chloride resin layer shown in Table 1, the ingredients excluding the plasticizer and the dusting agent were placed in a Henschel mixer and mixed. Then, when the temperature of the mixture rises to 80° C., all the plasticizer is added, and the temperature is further raised to dry up (the plasticizer is absorbed by the particulate thermoplastic resin and the mixture becomes smooth. It refers to the state in which the Thereafter, a vinyl chloride resin composition was prepared by adding a dusting agent when the dried mixture was cooled to a temperature of 100° C. or less.

<Formation of vinyl chloride resin layer>
Sprinkle the vinyl chloride resin composition obtained above on a mold with texture heated to a temperature of 250 ° C., leave it for an arbitrary time of about 8 to 20 seconds to melt, and then remove the excess vinyl chloride resin composition. shook off. After that, the textured mold sprinkled with the vinyl chloride resin composition was allowed to stand in an oven set to a temperature of 200° C., and after 60 seconds from standing, the textured mold was cooled with water. When the mold temperature was cooled to 40° C., a vinyl chloride resin sheet having a size of 150 mm long×200 mm wide×1 mm thick was removed from the mold as a vinyl chloride resin layer.

<Formation of laminated sheet for automotive interior materials>
A substrate made of thermoplastic polyurethane resin A (flow initiation temperature: 180° C.) is placed on the back surface of the vinyl chloride resin layer obtained above (the surface that is not in direct contact with the mold and is not textured) A piece of backing tape (length: 140 mm, width: 25 mm) comprising an adhesive layer (thickness: 50 μm) made of thermoplastic polyurethane resin B (flow initiation temperature: 110° C.) was placed. At this time, the adhesive layer of the backing tape arranged on the back surface of the vinyl chloride resin layer is in contact with the vinyl chloride resin layer, and the base material of the backing tape is not in contact with the vinyl chloride resin layer. was located outside. Then, a SUS roller heated to 120° C. was pressed from above the base material of the backing tape to adhere the backing tape to the vinyl chloride resin layer, thereby obtaining a laminate sheet for automotive interior materials.

(Laminate)
The laminated sheet for automotive interior materials obtained above is placed in a mold of 200 mm long x 300 mm wide x 10 mm thick with the surface of the laminated sheet for automotive interior materials (skin surface with a textured pattern) facing down. laid.
Separately, 50 parts of PO (propylene oxide)/EO (ethylene oxide) block adduct of propylene glycol (hydroxyl value 28, content of terminal EO units = 10%, content of internal EO units 4%), PO of glycerin - 50 parts of EO block adduct (hydroxyl value 21, content of terminal EO units = 14%), 2.5 parts of water, ethylene glycol solution of triethylenediamine (manufactured by Tosoh Corporation, trade name "TEDA-L33") 0.2 parts, 1.2 parts of triethanolamine, 0.5 parts of triethylamine, and 0.5 parts of a foam stabilizer (manufactured by Shin-Etsu Chemical Co., Ltd., trade name "F-122") are mixed to obtain a polyol A mixture was obtained. Further, a mixed liquid was prepared by mixing the obtained polyol mixture and polymethylene polyphenylene polyisocyanate (polymeric MDI) at a ratio of 98 in index. Then, the prepared mixed solution was poured over the back surface (the surface to which the backing tape is adhered) of the laminated sheet for automotive interior materials laid in the mold as described above. After that, the mold was covered with an aluminum plate of 348 mm×255 mm×10 mm to seal the mold. By leaving the mold for 5 minutes after sealing, a laminate in which the laminated sheet for automobile interior materials was lined with a foamed polyurethane layer (thickness: 9 mm, density: 0.2 g/cm ³ ) was formed in the mold. Been formed.
Then, the formed laminate was taken out from the mold and subjected to a cycle test according to the method described above. Table 1 shows the results.

(Examples 2-8)
Same as Example 1 except that the thickness of the backing tape base and/or adhesive layer and/or the type of thermoplastic polyurethane resin constituting the adhesive layer (flow initiation temperature) was changed as shown in Table 1. Then, a vinyl chloride resin composition, a vinyl chloride resin layer, a laminate sheet for automotive interior materials, and a laminate were produced. Then, a test was conducted in the same manner as in Example 1. In addition, in the cycle tests of Examples 6 to 8, evaluation was performed only after 10 cycles. Table 1 shows the results.

(Comparative example 1)
A vinyl chloride resin composition and a vinyl chloride resin layer were prepared in the same manner as in Example 1, except that the constituent resins (flow initiation temperatures) and thicknesses of the backing tape substrate and adhesive layer were changed as shown in Table 1. , a laminated sheet for automobile interior materials, and a laminate. Then, a test was conducted in the same manner as in Example 1. In the cycle test, evaluation was performed only after 10 cycles. Table 1 shows the results.

(Comparative example 2)
As the backing tape, 3M's "High Protection Film Tape SJ8584" (base material: polyurethane resin (thickness 150 μm), adhesive layer: acrylic resin (thickness 100 μm)) was used, and a heated roller was not used, and the temperature was kept at room temperature. In the same manner as in Example 1, except that the backing tape was adhered to the vinyl chloride resin layer to produce a laminated sheet for automobile interior materials, the vinyl chloride resin composition, the vinyl chloride resin layer, and the laminate for automobile interior materials Sheets and laminates were produced. Then, a test was conducted in the same manner as in Example 1. In the cycle test, evaluation was performed only after 10 cycles. Table 1 shows the results.

1) Manufactured by Shin-Daiichi Vinyl Corporation, product name “ZEST (registered trademark) 2500Z”
2) Manufactured by Shin-Daiichi PVC Co., Ltd., product name “ZEST PQLTX”
3) Manufactured by Kao Corporation, product name “Trimex N-08”
4) Made by ADEKA, product name “ADEKA CIZER O-130S”
5) Kyowa Chemical Industry Co., Ltd., product name "Alkamizer (registered trademark) 5"
6) Manufactured by Mizusawa Chemical Industry Co., Ltd., product name "MIZUKALIZER DS"
7) Showa Denko Co., Ltd., product name "Karenzu DK-1"
8) Made by ADEKA, product name “ADEKA STAB 522A”
9) Made by ADEKA, product name “ADEKA STAB LA-72”
10) Product name “SAKAI SZ2000” manufactured by Sakai Chemical Industry Co., Ltd.
11) Made by ADEKA, product name “ADEKA STAB LS-12”
12) Dainichiseika Co., Ltd., product name “DA PX 1720 (A) Black”

According to Table 1, a backing tape comprising a polyurethane resin substrate and a polyurethane resin adhesive layer having a flow initiation temperature of a predetermined temperature or higher is disposed on one side of the vinyl chloride resin layer in the thickness direction, and If the laminate of Examples 1 to 8 using the laminate sheet for automobile interior materials in which the polyurethane resin adhesive layer is arranged between the vinyl chloride resin layer and the polyurethane resin base material, the backing tape It can be seen that the appearance of traces can be suppressed satisfactorily.
On the other hand, it can be seen that the laminate of Comparative Example 1, which uses a backing tape having a polyurethane resin adhesive layer whose flow initiation temperature is less than a predetermined temperature, is inferior in performance for suppressing the appearance of traces of the backing tape.
It is also found that the laminate of Comparative Example 2, in which a backing tape having an adhesive layer made of a resin other than polyurethane resin is used as the adhesive layer, is also inferior in the performance of suppressing the appearance of backing tape traces.

According to the present invention, it is possible to provide a laminated sheet for automobile interior materials that can satisfactorily suppress the appearance of traces of a backing tape when a foamed polyurethane resin layer is backed.
Further, according to the present invention, it is possible to provide a laminate comprising the laminate sheet for automobile interior materials and capable of satisfactorily suppressing the appearance of traces of the backing tape.

Claims (8)

A laminated sheet for automobile interior materials , comprising a vinyl chloride resin layer containing a plasticizer and used as a skin, and a backing tape disposed on one side in the thickness direction of the vinyl chloride resin layer,
The backing tape comprises a polyurethane resin substrate and a polyurethane resin adhesive layer,
The polyurethane resin adhesive layer is disposed between the vinyl chloride resin layer and the polyurethane resin substrate,
A laminate sheet for automotive interior materials, wherein the polyurethane resin adhesive layer has a flow initiation temperature of 70°C or higher. 2. The laminate sheet for automotive interior materials according to claim 1, wherein the polyurethane resin base material has a thickness of 100 [mu]m or less. 3. The automobile according to claim 1, wherein the ratio of the thickness of said polyurethane resin substrate to the thickness of said polyurethane resin adhesive layer (thickness of polyurethane resin substrate/thickness of polyurethane resin adhesive layer) is 3/8 or less. Laminated sheet for interior materials. The laminate sheet for automobile interior materials according to any one of claims 1 to 3, which is used for automobile instrument panels. The vinyl chloride resin layer is sewn,
5. The laminated sheet for automobile interior materials according to claim 1, wherein the backing tape is arranged so as to cover the portion where the vinyl chloride resin layer is sewn. The laminate sheet for automotive interior materials according to any one of claims 1 to 5, wherein the polyurethane resin base material has a thickness of 70 µm or less. The laminate sheet for automotive interior materials according to any one of claims 1 to 6, wherein the polyurethane resin adhesive layer has a thickness of 50 µm or less. a foamed polyurethane resin layer;
A laminated sheet for automotive interior materials according to any one of claims 1 to 7 ;
A laminate having
A laminate in which the backing tape is arranged between the foamed polyurethane resin layer and the vinyl chloride resin layer.