JP7454972B2 - Interior surface material - Google Patents

Description

The present invention relates to an interior surface material that can be used for vehicle interior materials such as ceiling materials, door trims, dash outer parts, and pillar garnishes, partitions, wallpapers, and the like.

Nonwoven fabrics have conventionally been used as materials constituting interior surface materials. In addition, interior surface materials are required to have wear resistance in order to prevent deterioration due to rubbing when touched.

As an interior surface material with excellent abrasion resistance that satisfies such requirements, the present applicant has developed the following material on one main surface A side of a base mat in which constituent fibers are bonded to each other with a binder. A skin material characterized in that the amount of binder present is greater than that on the other main surface B side, and the base mat has a resin layer over the entire surface of the one main surface A.'' (Patent Document 1) ) was proposed.

Japanese Patent Application Publication No. 2019-043101

The skin material according to Patent Document 1 has a resin layer on the entire surface of one main surface, so it is certainly a skin material with excellent wear resistance, but the resin layer strengthens the bond between the fibers of the skin material. As a result, the modulus of the skin material increased, and it was necessary to apply a large force during molding, resulting in insufficient moldability.

The present invention was made under these circumstances, and aims to provide an interior surface material that has excellent wear resistance, can be molded with small force when molding the surface material, and has excellent moldability.

The invention according to claim 1 of the present invention provides that ``A binder containing particles and a binder resin is adhered to a fiber sheet, and the amount of the binder containing the particles and the binder resin is 20 g/ ^m2 or more, and An interior surface material having a value of 20% modulus strength in the direction (N/3 cm)/binder amount including particles and binder resin (g/m ² )} of 2.0 or less.

The invention according to claim 2 of the present invention is "the interior surface material according to claim 1, wherein the percentage of the mass of the particles contained in the binder with respect to the mass of the binder resin contained in the binder is less than 25% by mass." It is.

The invention according to claim 3 of the present invention includes: ``(1) bonding a binder A containing a binder resin to a fiber sheet to produce a binder A-bonded fiber sheet; (3) A step of adhering binder B containing resin to the binder A and B adhesive fiber sheets; (3) A step of adhering binder C containing binder resin to the binder A and B adhesive fiber sheets to manufacture an interior surface material. , and the total amount of binders A to C is 20 g/m2 or ^more , and {20% modulus strength in the vertical direction (N/3 cm)/total amount of binders A to C including particles and binder resin (g/m ² )} is 2.0 or less.

In the interior surface material according to claim 1 of the present invention, a binder containing particles and a binder resin is adhered to a fiber sheet, and the amount of the binder containing the particles and the binder resin is 20 g/m ² or more, and the fiber It has excellent wear resistance because a large amount of binder is adhered to the sheet. In addition, {20% modulus strength in the vertical direction (N/3cm)/amount of binder including particles and binder resin (g/m ² )} is 2.0 or less, even though the amount of binder is large. It is possible to realize an interior surface material with a low 20% modulus strength in the vertical direction and excellent moldability. This can be achieved by including particles in the binder and interposing the particles at the intersections of fibers and between the fibers, thereby weakening the adhesion between the fibers and, as a result, reducing the modulus strength.

In the interior surface material according to claim 2 of the present invention, the percentage of the mass of the particles contained in the binder with respect to the mass of the binder resin contained in the binder is less than 25% by mass, and the mass of the particles with respect to the mass of the binder resin. Since the particles do not weaken the interfiber adhesion too much, the interior surface material has excellent wear resistance.

The method for manufacturing an interior surface material according to claim 3 of the present invention is to adhere a binder A containing a binder resin to a fiber sheet, then adhere a binder B containing the binder resin and particles, and then adhere the binder A containing a binder resin to a fiber sheet. Binder C is bonded to produce an interior surface material, and the total amount of binders A to C is 20 g/ ^m2 or more, resulting in excellent wear resistance. /3cm)/total amount of binders A to C including particles and binder resin (g/m ² )}, and is a manufacturing method that can produce an interior surface material with excellent moldability.

The fiber sheet constituting the interior surface material of the present invention refers to a sheet-like fiber structure such as a woven fabric, a knitted fabric, or a nonwoven fabric. In particular, it is preferable that the fiber sheet used in the present invention is a nonwoven fabric because it is flexible and easily follows the shape of a mold. Among nonwoven fabrics, a dry nonwoven fabric has a certain thickness and is easy to mold. It is more preferable because it has excellent properties.

The constituent fibers of the fiber sheet constituting the interior surface material of the present invention are not particularly limited, but may be, for example, polyester fibers, nylon fibers, acrylic fibers, vinylon fibers, rayon fibers, etc. Among these, it is preferable to include polyester fibers that are excellent in heat resistance, light resistance, antifouling properties, etc., and/or rayon fibers that are excellent in flame retardancy. Furthermore, the constituent fibers may be single fibers or composite fibers containing two or more types of resin, such as core-sheath type or side-by-side type. Further, the cross section of the constituent fibers may be circular, or may have an irregular shape such as an ellipse, a square, or a Y-shaped cross section. Additionally, it may contain fibrillated fibers.

The constituent fibers may be white or colored. When the constituent fibers are colored, the fibers themselves may be spun-dyed fibers containing pigments and/or dyes in the constituent resins, or may be fibers colored with pigments and/or dyes. However, spun-dyed fibers are preferable because the fibers are less likely to discolor due to friction.

It is preferable that the constituent fibers include crimped fibers because the structure of the interior surface material becomes dense. Such crimped fibers include, for example, mechanically crimped fibers that are crimped by a machine, and latent crimped fibers that contain two types of resins with different heat shrinkage rates, which are crimped by applying heat to them. Examples include generated crimped fibers.

The fiber length of the constituent fibers is adjusted as appropriate, but in order to provide an interior surface material with excellent moldability, the fiber length of the constituent fibers is preferably 38 to 114 mm, more preferably 38 to 76 mm. The length is preferably 38 to 52 mm, and more preferably 38 to 52 mm. This "fiber length" refers to a value measured according to JIS L 1015 (2010) 8.4.1c) direct method (C method).

When the fineness of the constituent fibers is too thick, it tends to be difficult to use as an interior surface material with a smooth surface. On the other hand, if the fibers are too thin, the strength of the fibers will be low and the strength of the interior surface material will tend to be low. Therefore, the fineness of the constituent fibers of the fiber sheet is preferably 0.9 to 56 dtex, more preferably 1.3 to 17 dtex, and even more preferably 1.7 to 6.7 dtex.

The interior surface material of the present invention may be composed of a single fiber sheet or a plurality of fiber sheets. The interior surface material composed of a plurality of fiber sheets may be composed of fiber sheets having the same fiber composition, or may be composed of fiber sheets having different fiber compositions. Among these, an interior surface material composed of a single fiber sheet is preferred because it can provide a surface material that does not cause delamination during molding and has excellent moldability.

The basis weight of the fiber sheet constituting the interior surface material of the present invention is not particularly limited, but is preferably 50 to 500 g/m ² , more preferably 80 to 300 g/m ² , and 100 to 200 g/m ² More preferred. Note that the basis weight refers to the mass per 1 m ² on the main surface, and the main surface refers to the widest surface.

Further, the thickness of the fiber sheet constituting the interior surface material of the present invention is appropriately selected, but is preferably 0.5 to 5.0 mm, more preferably 1.0 to 3.0 mm, and 1.1 to 2 mm. .5 mm is more preferable. Note that the thickness in the present invention refers to the length between two main surfaces under ^a load of 100 g/5 cm2, and refers to the arithmetic mean value of the thicknesses at 10 randomly selected points.

The interior surface material of the present invention is constructed by adhering a binder containing particles and a binder resin to a fiber sheet. The binder is bonded to the fiber sheet, for example, the binder is present at the intersections of the constituent fibers of the fiber sheet, and the binder is bonded between the constituent fibers other than the intersections of the constituent fibers of the fiber sheet. Examples include a mode in which the bond exists and is adhered.

The particles contained in the binder containing the particles and the binder resin may be organic particles made of an organic resin, inorganic particles made of an inorganic component, or particles containing both an organic resin and an inorganic component. It's okay.

When the particles are organic particles, the components constituting the particles are not particularly limited, and examples include polyurethane resins, acrylic resins, and polyester resins.

When the particles are inorganic particles, the components constituting the particles are not particularly limited, and examples thereof include calcium carbonate, talc, silicon oxide, and the like.

In addition, when organic particles whose surfaces are partly or completely coated with an inorganic component are used as particles, they tend to have good compatibility with the binder, and a liquid in which the particles are uniformly dispersed in the binder can be prepared. It becomes easier to do. As a result, by using this liquid, it is possible to provide an interior surface material that has both wear resistance and moldability by providing a binder in which particles are uniformly distributed, which is preferable.

Regarding the particle size of the particles, the smaller the particle size, the more the particles tend to aggregate and interpose between the fibers of the fiber sheet that constitutes the interior surface material. Since there is a possibility that interfiber adhesion may not be weakened even if the fibers are present at the intersections and between the fibers, the thickness is preferably 1 to 200 μm, more preferably 5 to 150 μm, and even more preferably 10 to 120 μm.

Moreover, the particles may be hollow particles having air inside, or may be solid particles whose insides are clogged.

The density of the particles is preferably 0.01 to 3.0 g/cm 3 , and preferably 0.05 to 2.0 g/cm ³ , since dispersibility within the binder may deteriorate if the density is too large or too small. 0 g/cm ³ is more preferable, and 0.08 to 1.2 g/cm ³ is even more preferable.

The type of binder resin contained in the binder containing the particles and binder resin is appropriately selected, and examples thereof include polyurethane resin, acrylic resin, and polyester resin. Among these, acrylic resins (particularly self-crosslinking acrylic resins) are preferred because they soften appropriately during molding, have excellent conformability to molds, and are less likely to generate wrinkles or fine irregularities. Among acrylic resins, acrylic resins that have a low glass transition temperature and are soft are preferred because they are easy to stretch and have excellent moldability. On the other hand, if the glass transition temperature of the acrylic resin is too low, although the adhesive strength of the binder is improved, the breaking strength of the binder resin is poor, resulting in poor wear resistance. Therefore, the glass transition temperature is preferably -60°C or more and 10°C or less, more preferably -50°C or more and 5°C or less, and even more preferably -45°C or more and 5°C or less. The "glass transition temperature" in the present invention refers to the temperature at the intersection of the tangent to the baseline in the DTA curve measured by a differential thermal analyzer (DTA) and the tangent to the steeply descending position of the endothermic region due to glass transition.

In addition to the particles and binder resin described above, the binder may also contain additives such as flame retardants, fragrances, pigments, antibacterial agents, antifungal agents, emulsifiers, dispersants, and surfactants.

The amount of binder including particles and binder resin contained in the interior surface material of the present invention is 20 g/m ² or more so that the interior surface material has excellent wear resistance. The larger the amount of binder, the better the abrasion resistance of the interior surface material tends to be. Therefore, the amount of binder is more preferably 21 g/m ² or more, and even more preferably 22 g/m ² or more. The upper limit of the amount of binder is preferably 35 g/m ² or less since there is a risk that the molding processability of the interior surface material may be poor.

The amount of particles contained in the interior surface material of the present invention is preferably 12 g/m ² or less. As a result, the particles do not weaken the interfiber adhesion too much, and the interior surface material has excellent wear resistance. In order to improve the abrasion resistance of the interior surface material, the amount of particles is more preferably 11 g/m ² or less, and even more preferably 10 g/m ² or less. On the other hand, if the amount of particles contained in the interior surface material is too small, particles may not be present at the intersections of fibers or between the fibers, and the moldability of the interior surface material may not improve. ² or more is preferred.

The percentage of the mass of the particles contained in the binder with respect to the mass of the binder resin contained in the binder constituting the interior surface material of the present invention is preferably smaller than 25% by mass. As a result, the particles do not weaken the interfiber adhesion too much, and the interior surface material has excellent wear resistance. In order to improve the abrasion resistance of the interior surface material, the percentage is more preferably 23% by mass or less, and even more preferably 20% by mass or less. Furthermore, the lower limit of the percentage is realistically 5% by mass or more, since there is a risk that particles will not be present at fiber intersections or between fibers and the moldability of the interior surface material will not be improved.
Note that the percentage of the mass of the particles contained in the binder with respect to the mass of the binder resin contained in the binder can be calculated by rounding off the value calculated by the following method to the nearest whole number.
A=B/C×100
A: Percentage of the mass of the particles contained in the binder to the mass of the binder resin contained in the binder (unit: mass %)
B: Mass of particles contained in the binder (unit: g/m ² )
C: Mass of binder resin contained in binder (unit: g/m ² )

If the 20% modulus of the interior surface material of the present invention in the vertical direction is too high, moldability may deteriorate, so it is preferably 80 N/3 cm or less, more preferably 60 N/3 cm or less, and 40 N/3 cm. The following are more preferable. On the other hand, if the 20% modulus in the warp direction is too low, the fibers may not be sufficiently bonded to each other and the abrasion resistance may deteriorate, so it is preferably 20 N/3 cm or more. Note that the "vertical direction" in the present invention refers to the longitudinal direction of the interior surface material.

The 20% modulus strength in the longitudinal direction of the present invention is measured by the following method.
(1) A total of three strip-shaped samples (long side: 200 mm, short side (perpendicular to the long side): 30 mm) are collected from the interior surface material to be measured. Note that a strip-shaped sample is taken from the interior surface material to be measured so that the vertical direction and the long side direction of the interior surface material to be measured are parallel.
(2) The sample was fixed between the chucks (distance: 100 mm) of a tensile strength tester (manufactured by Orientec, Tensilon UCT-500 (registered trademark)), and the tensile strength tester was set at a tensile speed of 200 mm/min. The stress was measured when the distance between the chucks became 120 mm (at 20% elongation). The stress was measured for each of the three samples taken, and the obtained values were arithmetic averaged, rounded to the second decimal place, and the result was calculated as the 20% modulus strength in the vertical direction of the measurement object (unit: N/3cm) ).

The interior surface material of the present invention has a value of {20% modulus strength in the vertical direction (N/3 cm)/amount of binder containing particles and binder resin (g/m ² )} of 2.0 or less. Although the amount of binder in the interior surface material is large, the 20% modulus strength in the vertical direction is low, so that the moldability of the interior surface material is excellent. This numerical value can be achieved by including particles in the binder, which are present at the intersections of fibers and between the fibers, weakening the adhesion between the fibers, and as a result, the modulus strength is reduced. The lower the value of {20% modulus strength in the longitudinal direction (N/3cm)/amount of binder including particles and binder resin (g/m ² )}, the better the moldability of the interior surface material is. Therefore, it is more preferably 1.9 or less, and even more preferably 1.8 or less. On the other hand, if the value of 20% modulus strength in the vertical direction (N/3cm)/amount of binder including particles and binder resin (g/m ² ) is too low, the adhesive strength between the constituent fibers of the interior surface material will decrease. 1.0 or more is realistic because there is a possibility that the wear resistance is low and the abrasion resistance is poor. The reason why the evaluation is based on a value that includes 20% modulus strength in the vertical direction is that the modulus strength in the vertical direction is often the highest modulus strength among interior surface materials. In the vertical direction with a high vertical direction, interior surface materials tend to be difficult to stretch and form, so by evaluating the moldability of the parts of interior surface materials with the lowest moldability, This is because the moldability of interior surface materials can be evaluated.

The basis weight of the interior surface material of the present invention is selected as appropriate, but is preferably 70 to 535 g/m ² , more preferably 100 to 335 g/m ² , and even more preferably 120 to 235 g/m ² . Further, the thickness of the interior surface material of the present invention is appropriately selected, but is preferably 0.5 to 5.0 mm, more preferably 1.0 to 3.0 mm, and even more preferably 1.1 to 2.5 mm. .

The interior surface material of the present invention may further include constituent members such as films and foams. These constituent components may be on the main surface of the interior surface material to which the binder is attached or not.

Next, a method for manufacturing an interior surface material of the present invention will be explained.

First, a fiber sheet such as a woven fabric, a knitted fabric, or a nonwoven fabric is manufactured using the above-mentioned fibers. When the fiber sheet is a woven or knitted fabric, it can be manufactured by weaving or knitting the above-mentioned fibers. When the fiber sheet is a nonwoven fabric, for example, a dry nonwoven fabric is produced by a dry process in which the fibers are intertwined by subjecting the above-mentioned fibers to a carding machine or an airlay machine, or a wet process is produced by dispersing the fibers in a solvent and forming a sheet into a sheet to entangle the fibers. wet-laid non-woven fabric by method, direct spinning method [melt blow method, spunbond method, electrostatic spinning method, method of spinning by discharging spinning dope and gas flow in parallel (for example, the method disclosed in JP-A No. 2009-287138, etc.) ) is used to spin fibers and collect them. Certain dry nonwovens are preferred.

When the fiber sheet is a nonwoven fabric, it is preferable to entangle the constituent fibers with water jets or needles during the production of the nonwoven fabric so that it is easy to handle. In particular, it is preferable to entangle the constituent fibers with needles so as not to impair the thickness and, as a result, the moldability. Suitable needle entanglement conditions are not particularly limited, but it is preferable to entangle at a needle density of 300 to 1000 needles/cm ² , more preferably 300 to 600 needles/cm ² .

Next, a binder A containing a binder resin is adhered to the fiber sheet to produce a binder A-adhered fiber sheet. The method of adhering binder A to the fiber sheet is not particularly limited, but for example, by applying a binder liquid to the fiber sheet by impregnation, foaming impregnation, coating, or spraying, and then drying. Binder A can be bonded to the fiber sheet. At this time, it is preferable that the binder A does not contain particles in order to fix the intersections between the fibers of the fiber sheet to some extent and improve the handling of the fiber sheet. Note that the binder resin used at this time can be the binder resin described above. Further, the method of drying the fiber sheet after applying the binder liquid may be adjusted as appropriate, but for example, the dispersion medium/solvent can be removed by heating with a dryer. The type of dryer is not particularly limited, but a can dryer or a dryer with tenter pins is preferred in order to suppress shrinkage due to drying.

The amount of adhesion when adhering binder A to the fiber sheet is not particularly limited, but it is preferably 1.0 to 25 g/m ² , more preferably 1.5 to 20 g/m ² in terms of solid content mass. , 2.0 to 15 g/m ² is more preferred.

Next, binder B containing particles and binder resin is adhered to the binder A-adhesive fiber sheet to produce binder A and B-adhesive fiber sheets. The method of adhering the binder B to the binder A-adhesive fiber sheet is not particularly limited, but the same method as the method of adhering the binder A can be employed. Note that the particles used at this time can be the particles described above, and the binder resin used at this time can be the binder resin described above.

The amount of adhesion when adhering binder B to the binder A-adhesive fiber sheet is not particularly limited, but it is preferably 2.0 to 30 g/m ² in terms of solid mass, and 4.0 to 25 g/m ² is more preferable, and 6.0 to 21 g/m ² is even more preferable.

Finally, binder C containing binder resin is adhered to the binder A and B adhesive fiber sheets to produce an interior surface material. The method for bonding the binder C to the binder A and B bonded fiber sheet is not particularly limited, but a method similar to the method for bonding the binder A can be employed. At this time, binder C has the role of covering the binder A and B adhesive fiber sheets, and if binder C contains particles, there is a risk that binder C will peel off from the interior surface material. It is preferable that the binder C does not contain particles since the properties may be deteriorated. Note that the binder resin used at this time can be the binder resin described above.

The amount of adhesion when adhering binder C to binder A and B adhesive fiber sheets is not particularly limited, but is preferably 2.0 to 30 g/ ^m2 , and 4.0 to 25 g/m2 in terms of solid content mass. m ² is more preferred, and 6.0 to 21 g/m ² is even more preferred.

The total amount of binders A to C that are bonded to the fiber sheet during the production of interior surface materials is 20 g/m ² or more to ensure excellent abrasion resistance. The greater the total amount of binders A to C, the more excellent the wear resistance of the interior surface material tends to be. Therefore, the total amount of binders A to C is preferably 21 g/m2 or ^more , and 22 g/m2 or more. More preferably ² or more. The upper limit of the total amount of binders A to C is preferably 35 g/m ² or less since the moldability of the interior surface material may be poor.

In addition, the interior surface material manufactured by the manufacturing method of the present invention has a ratio of {20% modulus strength in the longitudinal direction (N/3cm)/total amount of binders A to C including particles and binder resin (g/m ² ) } is 2.0 or less. The total amount of binders A to C containing particles and binder resin during the production of interior surface material is the same as the amount of binder containing particles and binder resin in the interior surface material when bonding only binders A to C. Therefore, it has the same meaning as the above-mentioned {20% modulus strength in the longitudinal direction (N/3 cm)/amount of binder including particles and binder resin (g/m ² )}.

Note that a print may be applied to decorate the interior surface material using a binder different from the binders A to C. Note that the arrangement of the prints is not particularly limited, but can be performed by a conventionally known method. For example, a cylinder having an opening corresponding to a desired pattern may be provided, a printing liquid may be printed through the cylinder, and the print may be placed after drying. This print may be applied to the surface of the interior surface material, or it may be applied to the surface having the binder A of the binder A-adhesive fiber sheet and covered with binder B, or it may be applied to the surface of the binder A-adhesive fiber sheet and covered with binder B. It may be applied to the surface having B and then covered with binder C.

The interior surface material of the present invention can be used as a surface material for vehicle interior materials and the like. The molding method is not particularly limited, but for example, a molding method in which the interior surface material is placed in a mold and pressure or heat is applied together with a resin or glass sheet, or a molding method in which the interior surface material is placed in the mold and the interior surface material is Methods such as injection molding, in which resin is poured between the material and the mold, can be used.

Examples of the present invention will be described below, but the present invention is not limited to the following examples.

(Preparation of fiber sheet)
Using 100 mass% of spun-dyed polyester fibers (fineness: 2.2 dtex, fiber length: 38 mm, color: beige), the fibers are opened using a card machine to form a fiber web, and then needles are applied from one side at a needle density of 400 needles/ ^cm2 . Punch processing was performed. Thereafter, the fiber sheet (needle-punched nonwoven fabric) was manufactured by supplying it between thermal calendar rolls at a temperature of 165°C and a roll spacing of 0.6 mm, and thermocompression-bonding the needle-punched fiber web (fabric weight: 180 g/ m ² , thickness: 1.8 mm).

(Preparation of binder liquid A)
Binder liquid A was prepared in the following proportions.
(1) Acrylic binder resin (glass transition temperature: -40°C, solid content concentration: 50 mass%)...2.3 parts by mass (2) Surfactant (solid content concentration: 20 mass%)...0 .2 parts by mass (3) Thickener (solid content concentration: 100% by mass)...0.2 parts by mass (4) 25% ammonia water...0.1 parts by mass (5) Water...97 .2 parts by mass

(Preparation of binder liquid B)
Binder liquid B was prepared in the following proportions.
(1) Acrylic binder resin (glass transition temperature: -40°C, solids concentration: 50% by mass)...10 parts by mass (2) Thickener (solids concentration: 1.5% by mass)...30 Part by mass (3) Antifoaming agent (solid content concentration: 40% by mass)...0.4 part by mass (4) Particles (composed of urethane resin, solid shape, particle size: 10 μm, density: 1.15 g/ ^cm3 )...2.0 parts by mass (5) 25% ammonia water...1.0 parts by mass (6) Water...56.6 parts by mass

(Preparation of binder liquid C)
Binder liquid C was prepared by blending in the following proportions.
(1) Acrylic binder resin (glass transition temperature: -40°C, solids concentration: 50% by mass)...20 parts by mass (2) Thickener (solids concentration: 1.5% by mass)...28 Parts by mass (3) Thickener (solids concentration: 28% by mass)...1.0 parts by mass (4) Antifoaming agent (solids concentration: 40% by mass)...0.4 parts by mass (5 ) 25% ammonia water...1.0 parts by mass (6) Water...49.6 parts by mass

(Preparation of binder liquid D)
Binder liquid D was prepared by blending in the following proportions.
(1) Acrylic binder resin (glass transition temperature: -40°C, solids concentration: 50% by mass)...10 parts by mass (2) Thickener (solids concentration: 1.5% by mass)...30 Part by mass (3) Antifoaming agent (solid content concentration: 40% by mass)...0.4 part by mass (4) Particles (composed of urethane resin, solid shape, particle size: 10 μm, density: 1.15 g/ cm ³ )...5.0 parts by mass (5) 25% ammonia water...1.0 parts by mass (6) Water...53.6 parts by mass

(Preparation of binder liquid E)
Binder liquid E was prepared by blending in the following proportions.
(1) Acrylic binder resin (glass transition temperature: -40°C, solids concentration: 50% by mass)...10 parts by mass (2) Thickener (solids concentration: 1.5% by mass)...30 Part by mass (3) Antifoaming agent (solid content concentration: 40% by mass)...0.4 part by mass (4) Particles (composed of polyacrylonitrile resin, surface coated with talc, hollow shape, particle size: 10~ 30 μm, density: 0.23 g/cm ³ )...0.25 parts by mass (5) 25% ammonia water...1.0 parts by mass (6) Water...58.35 parts by mass

(Preparation of binder liquid F)
Binder liquid F was prepared by blending in the following proportions.
(1) Acrylic binder resin (glass transition temperature: -40°C, solids concentration: 50% by mass)...10 parts by mass (2) Thickener (solids concentration: 1.5% by mass)...30 Part by mass (3) Antifoaming agent (solid content concentration: 40% by mass)...0.4 part by mass (4) Particles (composed of polyacrylonitrile resin, surface coated with talc, hollow shape, particle size: 10~ 30 μm, density: 0.23 g/cm ³ )...1.0 parts by mass (5) 25% ammonia water...1.0 parts by mass (6) Water...57.6 parts by mass

(Preparation of binder liquid G)
Binder liquid G was prepared by blending in the following proportions.
(1) Acrylic binder resin (glass transition temperature: -40°C, solids concentration: 50% by mass)...10 parts by mass (2) Thickener (solids concentration: 1.5% by mass)...30 Part by mass (3) Antifoaming agent (solid content concentration: 40% by mass)...0.4 part by mass (4) Particles (composed of polyacrylonitrile resin, surface coated with talc, hollow shape, particle size: 10~ 30 μm, density: 0.23 g/cm ³ )...1.4 parts by mass (5) 25% ammonia water...1.0 parts by mass (6) Water...57.2 parts by mass

(Preparation of binder liquid H)
Binder liquid H was prepared by blending in the following proportions.
(1) Acrylic binder resin (glass transition temperature: -40°C, solids concentration: 50% by mass)...10 parts by mass (2) Thickener (solids concentration: 1.5% by mass)...30 Part by mass (3) Antifoaming agent (solid content concentration: 40% by mass)...0.4 part by mass (4) Particles (composed of polyacrylonitrile resin, surface coated with talc, hollow shape, particle size: 10~ 30 μm, density: 0.23 g/cm ³ )...4.0 parts by mass (5) 25% ammonia water...1.0 parts by mass (6) Water...54.6 parts by mass

(Preparation of binder liquid I)
Binder liquid I was prepared by blending in the following proportions.
(1) Acrylic binder resin (glass transition temperature: -40°C, solids concentration: 50% by mass)...10 parts by mass (2) Thickener (solids concentration: 1.5% by mass)...30 Parts by mass (3) Thickener (solids concentration: 28% by mass)...5.0 parts by mass (4) Antifoaming agent (solids concentration: 40% by mass)...0.4 parts by mass (5 ) Particles (composed of polyacrylonitrile resin, surface coated with talc, hollow shape, particle size: 10 to 30 μm, density: 0.23 g/cm ³ )...5.0 parts by mass (6) 25% ammonia water. ...2.5 parts by mass (7) Water...47.1 parts by mass

(Preparation of binder liquid J)
Binder liquid J was prepared by blending in the following proportions.
(1) Acrylic binder resin (glass transition temperature: -40°C, solids concentration: 50% by mass)...5 parts by mass (2) Thickener (solids concentration: 1.5% by mass)...30 Part by mass (3) Antifoaming agent (solid content concentration: 40% by mass)...0.4 part by mass (4) Particles (composed of polyacrylonitrile resin, surface coated with calcium carbonate, hollow shape, particle size: 60 ~70μm, density: 0.12g/cm ³ )...1.0 parts by mass (5) 25% ammonia water...1.0 parts by mass (6) Water...62.6 parts by mass

(Preparation of binder liquid K)
Binder liquid K was prepared in the following proportions.
(1) Acrylic binder resin (glass transition temperature: -40°C, solids concentration: 50% by mass)...10 parts by mass (2) Thickener (solids concentration: 1.5% by mass)...30 Parts by mass (3) Thickener (solids concentration: 28% by mass)...0.33 parts by mass (4) Antifoaming agent (solids concentration: 40% by mass)...0.4 parts by mass (5 ) Particles (composed of polyacrylonitrile resin, surface coated with calcium carbonate, hollow shape, particle size: 60 to 70 μm, density: 0.12 g/cm ³ )...2.0 parts by mass (6) 25% ammonia water ...1.2 parts by mass (7) Water...56.07 parts by mass

(Preparation of binder liquid L)
Binder liquid L was prepared by blending in the following proportions.
(1) Acrylic binder resin (glass transition temperature: -40°C, solids concentration: 50% by mass)...10 parts by mass (2) Thickener (solids concentration: 1.5% by mass)...30 Part by mass (3) Antifoaming agent (solid content concentration: 40% by mass)...0.4 part by mass (4) Particles (composed of polyacrylonitrile resin, surface coated with calcium carbonate, hollow shape, particle size: 90 ～120 μm, density: 0.08 g/cm ³ )...4.0 parts by mass (5) 25% ammonia water...1.0 parts by mass (6) Water...54.6 parts by mass

(Example 1)
The foamed binder liquid A was applied to the entire surface of one main surface of the fiber sheet and allowed to penetrate. Thereafter, it was dried in a can dryer at a temperature of 160° C. to prepare a binder-adhesive fiber sheet (fabric weight: 182 g/m ² , thickness: 1.7 mm) to which binder liquid A was applied.
Next, the binder liquid B was applied to the entire surface of the binder-adhesive fiber sheet to which the binder liquid A was applied, starting from the same main surface as that on which the binder liquid A was applied, and allowed to penetrate. Thereafter, it was dried in a dryer at a temperature of 140° C. to prepare a binder-adhesive fiber sheet (fabric weight: 198 g/m ² , thickness: 1.7 mm) to which binder liquids A and B were applied.
Finally, binder liquid C was applied to the entire surface of the binder fiber sheet to which binder liquids A and B were applied, starting from the same main surface as that on which binder liquids A and B were applied, and allowed to penetrate. Thereafter, it was dried with a dryer at a temperature of 140°C to prepare an interior surface material.

(Example 2)
Except that binder liquid D was used instead of binder liquid B to prepare a binder-adhesive fiber sheet (fabric weight: 201 g/m ² , thickness: 1.7 mm) to which binder liquids A and D were applied. An interior surface material was prepared in the same manner as in Example 1.

(Example 3)
Except that binder liquid E was used instead of binder liquid B to prepare a binder-adhesive fiber sheet (fabric weight: 192 g/m ² , thickness: 1.7 mm) to which binder liquids A and E were applied. An interior surface material was prepared in the same manner as in Example 1.

(Example 4)
Except that binder liquid F was used instead of binder liquid B to prepare a binder-adhesive fiber sheet (fabric weight: 192 g/m ² , thickness: 1.7 mm) to which binder liquids A and F were applied. An interior surface material was prepared in the same manner as in Example 1.

(Example 5)
Except that binder liquid G was used instead of binder liquid B to prepare a binder-adhesive fiber sheet (fabric weight: 194 g/m ² , thickness: 1.7 mm) to which binder liquids A and G were applied. An interior surface material was prepared in the same manner as in Example 1.

(Example 6)
Except that binder liquid H was used instead of binder liquid B to prepare a binder-adhesive fiber sheet (fabric weight: 194 g/m ² , thickness: 1.7 mm) to which binder liquids A and H were applied. An interior surface material was prepared in the same manner as in Example 1.

(Example 7)
The interior was prepared in the same manner as in Example 6, except that a binder-bonded fiber sheet (fabric weight: 199 g/m ² , thickness: 1.7 mm) was prepared with a different amount of binder liquid H applied than in Example 6. A surface material for this purpose was prepared.

(Example 8)
Except that binder liquid I was used instead of binder liquid B to prepare a binder-adhesive fiber sheet (fabric weight: 203 g/m ² , thickness: 1.7 mm) to which binder liquids A and I were applied. An interior surface material was prepared in the same manner as in Example 1.

(Example 9)
Except that binder liquid J was used instead of binder liquid B to prepare a binder-adhesive fiber sheet (fabric weight: 188 g/m ² , thickness: 1.7 mm) to which binder liquids A and J were applied. An interior surface material was prepared in the same manner as in Example 1.

(Example 10)
Except that binder liquid K was used instead of binder liquid B to prepare a binder-adhesive fiber sheet (fabric weight: 192 g/m ² , thickness: 1.7 mm) to which binder liquids A and K were applied. An interior surface material was prepared in the same manner as in Example 1.

(Example 11)
Except that binder liquid L was used instead of binder liquid B to prepare a binder-bonded fiber sheet (fabric weight: 194 g/m ² , thickness: 1.7 mm) to which binder liquids A and L were applied. An interior surface material was prepared in the same manner as in Example 1.

(Comparative example 1)
The foamed binder liquid A was applied to the entire surface of one main surface of the fiber sheet and allowed to penetrate. Thereafter, it was dried in a can dryer at a temperature of 160° C. to prepare a binder-adhesive fiber sheet (fabric weight: 182 g/m ² , thickness: 1.7 mm) to which binder liquid A was applied.
Finally, the binder liquid C was applied to the entire surface of the binder fiber sheet to which binder liquid A was applied, starting from the same main surface as that on which binder liquid A was applied, and allowed to penetrate. Thereafter, it was dried with a dryer at a temperature of 140° C. to prepare an interior surface material.

(Comparative example 2)
Interior surface materials were prepared in the same manner as in Comparative Example 1, except that the amount of binder liquid C applied to the binder fiber sheet to which binder liquid A was applied was different.

(Comparative example 3)
An interior surface material was prepared in the same manner as in Example 4, except that binder liquid C was not applied to the binder-bonded fiber sheet to which binder liquids A and F were applied.

(Comparative example 4)
An interior surface material was prepared in the same manner as in Example 5, except that binder liquid C was not applied to the binder-bonded fiber sheet to which binder liquids A and G were applied.

(Comparative example 5)
An interior surface material was prepared in the same manner as in Example 7, except that binder liquid C was not applied to the binder-adhesive fiber sheet to which binder liquids A and H were applied.

(Comparative example 6)
An interior surface material was prepared in the same manner as in Example 10, except that binder liquid C was not applied to the binder-bonded fiber sheet to which binder liquids A and K had been applied.

The amount of binder applied and the constituent resin of particles contained in the binder in Examples and Comparative Examples are shown in Tables 1 and 2 (polyacrylonitrile of the particle composition resin is abbreviated as PAN).

In addition, the interior surface material was evaluated using the following measurement method.

(Measurement of 20% modulus strength in vertical direction)
The 20% modulus strength in the longitudinal direction was measured using the method described above.

(Wear resistance measurement)
According to the Taber type method described in JIS L 1085 (1998) 6.8.2, a wear wheel CS-10 is attached and one wheel is rotated 100 times with a load of 500 g to remove the binder-bearing main surface of the interior surface material. The main surface of the worn interior surface material was observed, and the degree of stringiness in which multiple short fibers were connected in the form of threads was evaluated. The evaluation criteria are shown below.
[Abrasion resistance evaluation criteria]
5: No stringiness observed at all 4: Partial stringiness of 1cm or less observed 3: Threadiness of 1cm or less is observed overall, or stringiness of 1cm or more is partially observed. Item 2: Threading of 1 cm or more is observed overall, or stringing is partially interrupted at the abrasion ring, but appears to be connected in a circle 1: Threading are connected in a circular manner at the traces of wear caused by the wear ring.

Tables 3 and 4 show the physical properties and evaluation results of the interior surface materials of Examples and Comparative Examples.

It has a structure in which the binder contains particles and the value of {20% modulus strength in the longitudinal direction (N/3 cm)/amount of binder including particles and binder resin (g/m ² )} is 2.0 or less When Examples 1, 2, 4-7, 9-11 were compared with Comparative Example 1, which does not have the above structure, the amount of binder contained in the interior surface material was lower in Examples 1, 2, 4-11 than in Comparative Example 1. Although the numbers 7 and 9 to 11 were higher, the 20% modulus strength in the longitudinal direction was lower, and the interior surface material could be stretched with a small force, indicating that it had excellent moldability. Furthermore, a structure in which the binder contains particles and the value of {20% modulus strength in the longitudinal direction (N/3 cm)/amount of binder containing particles and binder resin (g/m ² )} is 2.0 or less Comparing Examples 3 and 8 having the above configuration and Comparative Example 2 not having the above configuration, it was found that although the amount of binder contained in the interior surface material was larger in Examples 3 and 8 than in Comparative Example 2, It was found that the 20% modulus strength in the longitudinal direction was low and the moldability was excellent.

Further, from a comparison between Examples and Comparative Examples 3 to 6, it was found that when the binder amount was 20 g/m ² or more, the wear resistance of the interior surface material was excellent.

The interior surface material of the present invention can be suitably used for vehicle interior materials such as ceiling materials, door trims, dash outer parts, and pillar garnishes, partitions, wallpapers, and the like.

Claims (3)

An interior surface material in which a binder containing particles and a binder resin is adhered to a fiber sheet, the amount of the binder containing the particles and the binder resin is 20 g/ ^m2 or more, the value of {20% modulus strength in the vertical direction (N/3 cm)/amount of binder containing the particles and the binder resin (g/ ^m2 )} is 2.0 or less, and the 20% modulus strength in the vertical direction is 80 N/3 cm or less . The interior surface material according to claim 1, wherein the percentage of the mass of the particles contained in the binder with respect to the mass of the binder resin contained in the binder is less than 25% by mass. (1) A step of bonding binder A containing binder resin to a fiber sheet to produce a binder A-bonded fiber sheet;
(2) a step of bonding binder B containing particles and binder resin to a binder A bonded fiber sheet to produce binder A and B bonded fiber sheets;
(3) A step of bonding binder C containing binder resin to binder A and B bonded fiber sheets to produce an interior surface material;
and the total amount of binders A to C is 20 g/m2 or ^more , and {20% modulus strength in the longitudinal direction (N/3 cm)/total amount of binders A to C including particles and binder resin ( g/m ² )} is 2.0 or less, and the 20% modulus strength in the longitudinal direction is 80 N/3 cm or less,
A method for manufacturing interior surface materials.