CN100587803C - Foam sheet for interior material of automobile and interior material of automobile - Google Patents

Abstract

A foam sheet for an interior material of an automobile formable in a specified shape while maintaining excellent sound absorbing performance, characterized in that hole parts opening to the surface thereof are formed in one surface of a denatured polyphenylene ether-based resin foam sheet with a continuous bubble fraction of 50% or higher. Thus, the foam sheet can develop excellent sound absorbingperformance by smoothly guiding sound vibration energy to the continuous bubbles in the foam sheet (1) through the hole parts to vibrate the bubble walls of the continuous bubbles so as to transformthe vibration energy into thermal energy.

Description

Automobile inside material foam sheet and automobile inside material

Technical field

The present invention relates to be used for the automobile inside material foam sheet of automobile inside materials such as roof of the vehicle material, door member.

Background technology

Past, existing people proposed various automobile inside materials, as this automobile inside material, for example in patent documentation 1, the automobile inside material be made up of skin material and foam duplexer has been proposed, wherein the foam duplexer has in the structure that with Noryl is the stacked non-foam layer of being made up of thermoplastic resin on the two sides of resin as the froth bed of substrate resin, and the expansion ratio of froth bed surpasses 20 times and be below 100 times.

But, above-mentioned automobile inside material is owing to be by making this foam floor height foamed improve the vibrational degree of freedom of non-foam layer stacked on froth bed, and utilize the interference effect of the sound that the vibration by non-foam layer produces thus, make its performance sound absorption qualities, so there are following problems, the vibrational degree of freedom of for example non-foam layer can be subjected to the influence of the shaping form of automobile inside material, sound absorption qualities can change according to the shaping form of automobile inside material, can't make the automobile inside material keep certain sound absorption qualities, if perhaps want the sound absorption qualities that keeps certain, then to limit the shaping form of automobile inside material.

Patent documentation 1: the spy opens the 2000-283482 communique

Summary of the invention

The object of the present invention is to provide the automobile inside material that in the good sound absorption qualities of maintenance, can be configured as required form to carry out the formed automobile inside material of thermoforming with foam sheet with foam sheet and with this automobile inside material.

Is resin as constituting automobile inside material of the present invention with the Noryl of the Noryl resin foam thin slice 1 of foam sheet A, have no particular limits, can enumerate the polyphenylene oxide represented with followingization 1 and the potpourri of polystyrene resin, the Noryl that makes styrenic monomers and above-mentioned polyphenylene oxide graft copolymerization and form, the potpourri of this Noryl and polystyrene resin, making phenol with followingization 2 expression is that monomer and styrenic monomers in the presence of the catalyzer such as amine complex of copper (II) oxidative polymerization take place and the segmented copolymer that obtains, the potpourri of this segmented copolymer and polystyrene resin etc.In addition, Noryl is that resin can use separately also and can and use.

[changing 1]

(R ₁, R ₂The expression carbon number is alkyl or the halogen atom of 1-4, and n represents the degree of polymerization.)

As the polyphenylene oxide of representing with above-mentionedization 1, can enumerate poly-(2,6-dimethyl penylene-1,4-ether), poly-(2,6-diethyl penylene-1,4-ether), poly-(2,6-dichloro penylene-1,4-ether), poly-(2,6-dibromo penylene-1,4-ether), poly-(2-methyl-6-ethyl penylene-1,4-ether), poly-(2-chloro-6-methyl penylene-1,4-ether), poly-(2-methyl-6-isopropyl penylene-1,4-ether), poly-(2,6-di penylene-1,4-ether), poly-(2-bromo-6-methyl penylene-1,4-ether), poly-(2-chloro-6-bromobenzene support-1,4-ether), poly-(2-chloro-6-ethyl penylene-1,4-ether) etc., these can use also also usefulness separately, use the material of above-mentioned polymerization degree n as 10-5000 in addition usually.

[changing 2]

(R ₃, R ₄The expression carbon number is alkyl or the halogen atom of 1-4.)

As the phenol of representing with above-mentionedization 2 is monomer, for example can enumerate 2,6-xylenol, 2,6-diethyl phenol, 2,6-chlorophenesic acid, 2,6-dibromophenol, 2-methyl-6-ethyl-phenol, 2-chloro-6-methylphenol, 2-methyl-6-isopropyl-phenol, 2,6-di phenol, 2-bromo-6-methylphenol, 2-chloro-6-bromophenol, 2-chloro-6-ethyl-phenol etc., these can use separately also and can and use.

As the polystyrene resin that is mixed in above-mentioned polyphenylene oxide, above-mentioned Noryl or the above-mentioned segmented copolymer, can enumerate polystyrene for example, styrene and can with the multipolymer of the vinyl monomer of its copolymerization, high impact polystyrene etc., preferred polystyrene.In addition, polystyrene resin can use separately also and can and use.

In addition, as above-mentioned vinyl monomer, can enumerate for example methyl methacrylate, vinyl cyanide, methacrylonitrile, butyl acrylate etc.In addition, as high impact polystyrene, can enumerate to polystyrene or above-mentioned styrene and can with the multipolymer of the vinyl monomer of its copolymerization in add the material that rubber constituents such as 1-20 weight % Styrene-Butadiene or styrene-butadiene-styrene block copolymer form.

In addition, as with polyphenylene oxide carry out graft copolymerization or with phenol be the styrenic monomers that monomer carries out block copolymerization, can enumerate for example styrene; α-Jia Jibenyixi, 2, alkylated styrenes such as 4-dimethyl styrene, p-methyl styrene, ethyl styrene, p-t-butyl styrene; Halogenated styrenes such as monochlorostyrene, dichlorostyrene etc.

Also have, as above-mentioned Noryl is resin, preferred phenylate composition is that 15-60 weight % and styrene composition are that the Noryl of 85-40 weight % is a resin, more preferably the phenylate composition is that 20-60 weight % and styrene composition are that the Noryl of 80-40 weight % is a resin, and preferred especially phenylate composition is that 25-50 weight % and styrene composition are that the Noryl of 75-50 weight % is a resin.Also have, when when above-mentioned polyphenylene oxide is the above-mentioned polystyrene resin of mixed with resin, the content of above-mentioned phenylate composition and above-mentioned styrene composition is meant the content that comprises above-mentioned polystyrene resin.

If this is that then the thermotolerance of foam sheet descends sometimes, if many on the other hand, then can not obtain good foam sheet sometimes because Noryl is that the phenylate composition is few in the resin.

The above-mentioned automobile inside material continuous air bubbles rate of Noryl resin foam thin slice 1 integral body of foam sheet A, the Noryl resin foam thin slice (hereinafter referred to as " through the Noryl resin foam thin slice of hole processing ") that promptly forms porose 2 is if the continuous air bubbles rate of 1 integral body is low, then the automobile inside material might descend with the sound absorption properties of foam sheet, so be defined as more than 50%, preferred more than 60%, if it is high on the other hand, then the automobile inside material might descend with the physical strength of foam sheet, so more preferably 60-90%, preferred especially 60-85%.

In addition, the continuous air bubbles rate of the Noryl resin foam thin slice of processing through the hole 1 is meant the bubble rate of measuring according to ASTM D2856-87.Specifically, by total length incision at this foam sheet 1 thickness direction, from determining the laminar test film that many length of sides are the plane square shape of 25mm through the Noryl resin foam thin slice 1 of hole processing, afterwards should many test film overlapping and form duplexer, the integral thickness of its thickness direction has reached about 25mm.

Then, use vernier caliper to measure the apparent volume of above-mentioned duplexer exactly, use air comparison expression picnometer afterwards, calculate the continuous air bubbles rate by following formula with 1-1/1-2 pneumatic process measurement volumes.In addition, the volume of the duplexer of measuring according to the 1-1/1-2 pneumatic process can use the air comparison expression picnometer of for example being sold with trade name " air comparison expression picnometer 1000 types " by Tokyo science society to measure.In addition, be not included in the volume of hole described later portion 2 parts that contain in the duplexer in the apparent volume of duplexer.

Continuous air bubbles rate (%)=100 * (volume of the duplexer of apparent volume-measure according to air comparison expression picnometer)/apparent volume

In addition, if above-mentioned automobile inside material is little with the mean air bubble diameter of the Noryl resin foam thin slice of processing through the hole among the foam sheet A 1, then become softness and physical strength of foam sheet 1 descends sometimes, on the other hand, if it is big, the then surface smoothing decline of foam sheet 1 sometimes or become fragile is so be preferably 0.2-1.3mm, 0.3-1.0mm more preferably.In addition, the mean air bubble diameter of the Noryl resin foam thin slice of processing through the hole 1 is meant the mean air bubble diameter according to the test method measuring of ASTM D2842-69.

If above-mentioned automobile inside material is little with the density of the Noryl resin foam thin slice of processing through the hole among the foam sheet A 1, then the automobile inside material uses the physical strength of foam sheet to descend sometimes, on the other hand, if it is big, problems such as breakage take place in the flexible decline that then produces sometimes because of automobile inside material usefulness foam sheet owing to bending, so be preferably 0.03-0.30g/cm ³, more preferably 0.035-0.20g/cm ³In addition, the density of the method measurement of record in the density of the Noryl resin foam thin slice 1 of hole processing is meant according to JIS K7222:1999 " measurement of polyfoam and rubber-apparent density ".

In addition, if above-mentioned automobile inside material is thin with the thickness of the Noryl resin foam thin slice of processing through the hole among the foam sheet A 1, then make of the thickness attenuation of automobile inside material sometimes with the automobile inside material of foam sheet A shaping acquisition, the sound absorption properties of automobile inside material descends, on the other hand, if thick, then the automobile inside material uses the formability of foam sheet A to descend sometimes, so preferred 2-10mm, more preferably 3-8mm.

Also have, above-mentioned automobile inside material preferably has the continuous air bubbles layer that mainly is made of continuous air bubbles with the froth bed of the Noryl resin foam thin slice of processing through the hole among the foam sheet A 1, as this Noryl resin foam thin slice 1, can enumerate that (1) froth bed only is made up of the continuous air bubbles layer 1A that mainly is made of continuous air bubbles and whole continuous air bubbles rate is that foam sheet and (2) 50% or more form the main separated foam layer 12 that is made of separated foam on two faces of the main continuous air bubbles layer 11 that is made of continuous air bubbles, 12 and to form froth bed and whole continuous air bubbles rate be foam sheet more than 50%.

Shown in above-mentioned (1), froth bed only is made up of the continuous air bubbles layer 1A that mainly is made of continuous air bubbles and whole continuous air bubbles rate is in the froth bed of Noryl resin foam thin slice 1 more than 50%, that process through the hole, do not have the separated foam layer that mainly is made of separated foam, froth bed integral body is made of the continuous air bubbles layer 1A that mainly is made of continuous air bubbles.In addition, also can above-mentioned (1) on whole of the two sides of the Noryl resin foam thin slice 1 of hole processing, forming non-foam layer 13,13 is so-called epidermal area.

This Noryl resin foam thin slice 1 through hole processing is made of continuous air bubbles owing to whole, so can form essentially homogenous on the whole foam sheet through the Noryl resin foam thin slice 1 of hole processing.

Therefore, when carrying out compression molding for the automobile inside material is processed as the automobile inside material with the foam sheet shaping, owing to can roughly compressing equably along its thickness direction, the Noryl resin foam thin slice 1 through hole processing is configured as required shape, so can not cause local decline of intensity yet, can keep the intensity of stipulating through the Noryl resin foam thin slice 1 of hole processing.

In addition, the continuous air bubbles layer 1A of above-mentioned Noryl resin foam thin slice 1 through hole processing mainly is made of continuous air bubbles and gets final product, there is no need to make all bubbles to be continuous air bubbles, but the bubble in the bubble that contains among the preferred continuous air bubbles layer 1A more than 70% is a continuous air bubbles, and promptly the continuous air bubbles rate of continuous air bubbles layer 1A is more than 70%.In addition, the continuous air bubbles rate of continuous air bubbles layer 1A is meant the bubble rate of measuring with the measuring method of above-mentioned continuous air bubbles rate.

Then, to shown in above-mentioned (2), the continuous air bubbles rate of foam sheet integral body is that the Noryl resin foam thin slice 1 that forms 50% or more, process through the hole describes when part has mainly the continuous air bubbles layer 11 that is made of continuous air bubbles and be formed with the separated foam layer 12,12 that mainly is made of separated foam continuously on two faces of this continuous air bubbles layer 11 in the central in the froth bed.In addition, continuous air bubbles layer 11 and separated foam layer 12 do not have clear and definite boundary in its interface, and continuous air bubbles layer 11 and separated foam layer 12 are in admixture.Also can be on whole of above-mentioned separated foam layer 12,12 surface, forming non-foam layer 13,13 is so-called epidermal area.

In addition, the continuous air bubbles layer 11 of above-mentioned Noryl resin foam thin slice 1 through hole processing mainly is made of continuous air bubbles and gets final product, not needing all bubbles is continuous air bubbles, but the bubble in the bubble that contains in the preferred continuous air bubbles layer 11 more than 80% is a continuous air bubbles, and promptly the continuous air bubbles rate of continuous air bubbles layer 11 is more than 80%.In addition, the continuous air bubbles rate of continuous air bubbles layer 11 is meant the bubble rate of measuring with the measuring method of above-mentioned continuous air bubbles rate.

Equally, the separated foam layer 12 of above-mentioned Noryl resin foam thin slice 1 through hole processing mainly is made of separated foam and gets final product, not needing all bubbles is separated foam, but the bubble in the bubble that contains in the preferred continuous air bubbles layer 12 more than 60% is a separated foam, and promptly the separated foam rate of separated foam layer 12 is more than 60%.In addition, the separated foam rate of separated foam layer 12 is meant from 100 (%) and deducts the continuous air bubbles rate measured by the measuring method of above-mentioned continuous air bubbles rate and the shared ratio of resin and the value that obtains.

Separated foam rate (%)=100 * [(volume of the duplexer of measuring according to air comparison expression picnometer)-(density of the quality/resin of duplexer)]/apparent volume

In addition, if the thickness of each separated foam layer 12 of the above-mentioned Noryl resin foam thin slice of processing through the hole 1 is thicker, then the automobile inside material uses the sound absorption properties of foam sheet A to descend sometimes, so below 30% of thickness of preferred Noryl resin foam thin slice 1 integral body of processing through the hole, if cross thin, then the air of car inboard ventilates to the car outside with foam sheet by the automobile inside material automobile inside material with the air property the cut off decline of foam sheet A, the pollutant that contains in the air is in the state that is carried out skin material described later 7 filtrations of stacked integrated formation at the automobile inside material with the foam sheet surface, thereby the pollutant that makes skin material 7 becomes showy, perhaps the automobile inside material descends with the physical strength of foam sheet A, therefore 1-25% more preferably.In addition, when forming non-foam layer (epidermal area) 13 on surperficial whole at separated foam layer 12, so-called " thickness of separated foam layer 12 " is meant the thickness of the thickness that comprises non-foam layer 13.

In the present invention, so-called separated foam is meant the bubble that is not communicated with other bubble by whole encirclement of walls.On the other hand, so-called continuous air bubbles is meant all bubbles beyond the separated foam, specifically, refers to be formed with through hole in walls, and is in the bubble of connected state by this through hole and other bubble.

In addition, in the Noryl resin foam thin slice 1 of hole processing, mainly following key element is depended in the difference of continuous air bubbles layer that is made of continuous air bubbles and the separated foam layer that mainly is made of separated foam above-mentioned.

At first, the thickness direction total length incision by at the Noryl resin foam thin slice of processing through the hole 1 goes out the laminar test film that the length of side is the plane square shape of 40mm from 1 section of this foam sheet.

On the other hand, in beaker, supply with the water-based red ink 3cm that distilled water 300g and pen are used ³Make red aqueous solution, in this redness aqueous solution with wire netting by above press the middle body of pressing test film and making it to be in the above-below direction in the red aqueous solution impregnated state fully.In addition, as above-mentioned pen use red ink, can enumerate the ink of for example selling with trade name " パ イ ロ Star ト ink is red " by パ イ ロ Star ト society.

Then, the beaker that makes the state of above-mentioned test film dipping is placed in the decompressor inherence presses 5.3 * 10 ⁴Pa reduced pressure with 30 seconds down.Then, make and return to normal pressure in the decompressor,, remove the red aqueous solution that adheres to the test film surface with the suction towel afterwards by taking out test film in the decompressor.

Afterwards, all sections of the test film that when foam sheet 1 cuts out, forms have been excised.Promptly, by from test film in bow square form peripheral edge portions when seeing test film of thickness direction total length excision, promptly excise its square form peripheral edge portions according to block form in the thickness direction total length from test film, cutting the length of side is the staining test sheet of the plane square shape of 38mm.Then, the colored state of using videomicroscopy to observe this each section of staining test sheet with 50 times multiplying power, coloured part is defined as the continuous air bubbles layer of mainly being made up of continuous air bubbles, on the other hand, non-staining partly is defined as the separated foam layer of mainly forming by separated foam.

In addition, the thickness of the separated foam layer 12 of the Noryl resin foam thin slice of processing through the hole 1 can be measured according to following method.At first, make the staining test sheet from any 5 positions according to method same as described above through the Noryl resin foam thin slice 1 of hole processing.

Then, use videomicroscopy to observe the section of each staining test sheet, measure maximum ga(u)ge and minimum thickness in the separated foam layer 12 in each staining test sheet, and then calculate the arithmetic mean of these thickness with 50 times multiplying power.Afterwards, calculate arithmetic mean again, and it is defined as the thickness of the separated foam layer 12 of the Noryl resin foam thin slice of processing through the hole 1 according to the arithmetic mean of calculating from each staining test sheet.In addition, videomicroscopy is for example to be sold according to trade name " videomicroscopy VMS-300 " by ス カ ラ Co., Ltd..

In addition, above-mentioned automobile inside material with foam sheet A on two faces of the Noryl resin foam thin slice 1 of hole processing, as shown in figs. 1 and 4, it is stacked integrated also can to make Noryl be that resin flake 3,3 carries out.As constituting this Noryl is that the Noryl of resin flake 3 is a resin, can use with the Noryl that constitutes above-mentioned foam sheet 1 is the identical resin of resin, but preferred phenylate composition is 10-50 weight % and styrene composition is that the Noryl of 90-50 weight % is a resin, more preferably the phenylate composition is that 10-40 weight % and styrene composition are that the Noryl of 90-60 weight % is a resin, and preferred especially phenylate composition is that 10-35 weight % and styrene composition are that the Noryl of 90-65 weight % is a resin.In addition, when being that the content of above-mentioned phenylate composition and above-mentioned styrene composition refers to comprise the content of above-mentioned polystyrene resin when mixing above-mentioned polystyrene resin in the resin to above-mentioned polyphenylene oxide.

If this is because Noryl is that the phenylate composition is few in the resin, then Noryl is the thermotolerance and the rigidity decline of resin flake 3 sometimes, and in addition, if many, then the flowability of molten resin descends and can cause extrudability decline.

In addition, also can constitute above-mentioned Noryl be the Noryl of resin flake 3 be in the resin hybrid vehicle built-in material with the recovery article of foam sheet A, at this moment, preferred automobile inside material is that resin 100 weight portions are below 100 weight portions with the recovery article of foam sheet A with respect to Noryl.This is that then Noryl is that the physical strengths such as bending strength of resin flake 3 can descend sometimes because if be that the hybrid vehicle built-in material is with the recovery article of foam sheet A too much in the resin flake 3 at Noryl.

In addition, constituting above-mentioned Noryl is that the Noryl of resin flake 3 is that the glass transition temperature Tg of resin preferably is also low 10-40 ℃ of the glass transition temperature Tg of resin than the Noryl that constitutes above-mentioned Noryl resin foam thin slice 1 through hole processing.

This is because following reason.Promptly, the bubble chamber film of the Noryl resin foam thin slice of processing through the hole 1 is because its thinner thickness, with the Noryl that is made of same material is that resin flake 3 is compared, correspondingly heat that can be less makes it to melt, be out of shape easily, and the bubble of the surface portion of foam sheet 1 can be damaged by pressure because of forming pressure.

On the other hand, carrying out stacked incorporate Noryl on two faces of the Noryl resin foam thin slice of processing through the hole 1 is that resin flake 3 is non-foam, and compare with the bubble chamber film of foam sheet 1, its thickness is very thick, so compare its form retentivity with foam sheet 1 good.

Therefore, to constitute Noryl be that the Noryl of resin flake 3 is that the glass transition temperature Tg of resin is that the glass transition temperature Tg of resin is also low than constituting Noryl through the Noryl resin foam thin slice 1 of hole processing by making, and can make thermotolerance through the Noryl resin foam thin slice 1 of hole processing be better than Noryl is resin flake 3.And, when the automobile inside material is shaped with foam sheet A, can prevent that the bubble of foam sheet 1 surface portion from being damaged by pressure because of forming pressure under by the thermogenetic heating that is shaped, can obtain to have the moulding product of desired thickness.

In addition, also can make Noryl is that resin flake 3 contains colorant, as this colorant, have no particular limits, for example can enumerate pigment such as inorganic fillers such as carbon black, titanium dioxide, zinc paste, iron oxide, aluminium oxide, cyanine indigo plant, cyanine are green, milori blue, indanthrene blue, cadmium red, cadmium yellow, cadmium orange, colcother, ultramarine, phthalocyanine blue etc., preferably be dark-coloured colorant such as black and grey, more preferably carbon black.

In addition, at above-mentioned Noryl is in the resin flake 3, also can add rubber constituent in order to prevent embrittlement, as this rubber constituent, can enumerate for example high impact polystyrene, Styrene-Butadiene, styrene-butadiene-styrene block copolymer etc., preferred high impact polystyrene.

If above-mentioned rubber constituent is that content in the resin flake 3 is few at Noryl, then Noryl is that resin flake 3 can not show the effect that prevents embrittlement sometimes, on the other hand, if it is many, then Noryl is the bending strength and the rigidity decline of resin flake 3 sometimes, so be that resin 100 weight portions are the 1-20 weight portion with respect to Noryl preferably.

Also have, Noryl is a resin flake 3,3 on the two sides that is laminated in above-mentioned Noryl resin foam thin slice 1 through hole processing the time, stays out of adhesive layer and is resin and to constitute Noryl be that the Noryl of resin flake 3 is to carry out stacked integrated securely by thermal welding between the resin constituting Noryl through the Noryl resin foam thin slice 1 of hole processing directly.

Promptly, above-mentioned Noryl is that resin flake 3 and the above-mentioned Noryl resin foam thin slice of processing through the hole 1 are that resin thermal welding has each other been carried out integrated securely by the Noryl that constitutes both, and can be accurately and form the above-mentioned automobile inside material foam sheet A of complicated shape reliably, can avoid Noryl simultaneously is that resin flake 3 is from Noryl resin foam thin slice 1 sur-face peeling through hole processing.

In addition, if above-mentioned Noryl is that the thickness of resin flake 3 is thin, then the automobile inside material uses the physical strength of foam sheet A to descend sometimes, on the other hand, if it is thick, then the automobile inside material uses the formability of foam sheet A and light weight to descend sometimes, so be preferably 50-300 μ m, more preferably 70-200 μ m.

So, as shown in Fig. 1 to Fig. 4, in Noryl resin foam thin slice 1, be formed with the hole portion 2,2 that on its surperficial 1a or Noryl are the surperficial 3a of resin flake 3, carries out opening and reach continuous air bubbles layer 11,1A ..., constituted automobile inside material foam sheet A thus.

Form a plurality of hole portion 2 as described above, the vibrational energy of the sound that produces in hole portion 2 open side can be waltzed through hole portion 2 imports in the foam sheets 1, make foam sheet 1 continuous air bubbles walls vibration and the vibrational energy of sound be converted to heat energy absorb, thereby prevented from effectively to give the automobile inside material good sound absorption qualities of foam sheet A by of the reflection of automobile inside material with the sound of foam sheet A generation.

At first, when only forming through the froth bed of the Noryl resin foam thin slice 1 of hole processing and the continuous air bubbles rate of foam sheet 1 integral body is 50% when above by the continuous air bubbles layer 1A that mainly constitutes by continuous air bubbles, above-mentioned hole portion 2 is under the state of the surperficial 1a opening of Noryl resin foam thin slice, perhaps carrying out on two faces of Noryl resin foam thin slice 1 under the state of surperficial 3a opening that stacked incorporate Noryl is a resin flake, the continuous air bubbles layer 1A (with reference to figure 1 and Fig. 3) that extends to foam sheet 1 gets final product.

The degree of depth of above-mentioned hole portion 2 has no particular limits, if but the degree of depth of hole portion 2 is shallow, then the vibrational energy of sound can not import in the continuous air bubbles of continuous air bubbles layer efficiently sometimes, the automobile inside material descends with the sound absorption properties of foam sheet A, on the other hand, if it is dark, might on foam sheet 1, miss when then on foam sheet 1, forming hole portion 2 sometimes and form through hole, perhaps cause the automobile inside material to descend with the physical strength of foam sheet A, so be preferably the 10-95% of the thickness of the Noryl resin foam thin slice of processing through the hole 1, more preferably 30-90%.

Then, in the froth bed of the Noryl resin foam thin slice of processing through the hole 1, on two faces of the continuous air bubbles layer 11 that mainly constitutes, be formed with the separated foam layer 12 that mainly constitutes by separated foam by continuous air bubbles, 12 and the continuous air bubbles rate of foam sheet 1 integral body be 50% when above, above-mentioned hole portion 2 is under the state of the surperficial 1a opening of Noryl resin foam thin slice 1, perhaps carrying out on two faces of Noryl resin foam thin slice 1 under the state of surperficial 3a opening that stacked incorporate Noryl is a resin flake 3, the continuous air bubbles layer 11 that runs through the separated foam layer 12a (and epidermal area 13a) of a side in the Noryl resin foam thin slice 1 and extend to foam sheet 1 gets final product, and is extensible or do not extend to Noryl resin foam thin slice 1 the opposing party's separated foam layer 12b.

Promptly, as shown in Fig. 2 and Fig. 4, above-mentioned hole portion 2 forms according to the form that the bottom 21 of this hole portion 2 reaches the interface of continuous air bubbles layer 11 and separated foam layer 12a in the Noryl resin foam thin slice 1, perhaps as shown in Fig. 5 and Fig. 6, the form that enters into continuous air bubbles layer 11 inside of Noryl resin foam thin slice 1 according to hole portion 2 bottoms 21 forms, preferably as shown in Fig. 7 and Fig. 8, the form that reaches the interface of the separated foam layer 12b of continuous air bubbles layer 11 and the opposing party in the Noryl resin foam thin slice 1 according to bottom 21 forms.

Also have, angles in the continuous air bubbles layer 11 that the logical via portion 2 of the vibrational energy of sound successfully can be imported foam sheet 1 are considered, preferably the form that enters into continuous air bubbles layer 11 inside of Noryl resin foam thin slice 1 according to hole portion 2 bottoms 21 forms, and more preferably the form that reaches the interface of the separated foam layer 12b of continuous air bubbles layer 11 and the opposing party in the Noryl resin foam thin slice 1 according to hole portion 2 bottoms 21 forms.

With regard to regard to the hole portion 2 openend shapes that form in the above-mentioned Noryl resin foam thin slice 1, as long as the vibrational energy of sound successfully can be guided in the continuous air bubbles of foam sheet 1, just have no particular limits, for example, except circle, ellipse, also can enumerate polygonal shapes such as triangle, square, circular.

In addition, the section shape that forms with foam sheet A surface along the automobile inside material in the above-mentioned hole portion 2 can not change and keeps same shape in its depth direction total length, perhaps, can change along its depth direction yet.

Also have, if the openend area of above-mentioned hole portion 2 is little, then the automobile inside material descends with the sound absorption properties of foam sheet A sometimes, and on the other hand, if big, then the automobile inside material descends with the physical strength of foam sheet A sometimes, so be preferably 0.2-40mm ², 0.3-30mm more preferably ²

In addition, generation type as above-mentioned hole portion 2, have no particular limits, but because the automobile inside material can become inhomogeneous with the physical strength of foam sheet A sometimes, so preferably be formed uniformly, as shown in Figure 9, form a plurality of hole portion 2 with black and white sub-box shape, 2 (2a, 2b) ... be specially, by at each intersection point 41 that on the surperficial 1a of Noryl resin foam thin slice 1 or at Noryl is the imaginary grid 4 described on the surperficial 3a of resin flake 3,41 ... on, with its center 21a, 21a and described intersection point 41,41 ... overlapping state forms the openend with same diameter and is the circular 2a of hole portion, 2a ..., simultaneously with its center 21b, cornerwise each intersection point 42a of the square frame part 42 of 21b and imaginary grid 4,42a ... the 2b of hole portion that equitant state formation openend and the above-mentioned hole 2a of portion have the circle of same diameter, 2b ...In addition, also can not form hole portion 2, only form the 2a of hole portion.

In addition, hole portion 2 is for example really little with total open area ratio on foam sheet A surface with respect to the automobile inside material, then the automobile inside material uses the sound absorption properties of foam sheet A to descend sometimes, on the other hand, if big, then the automobile inside material uses the physical strength of foam sheet A to descend sometimes, so be preferably 2-50%, 3-50% more preferably, preferred especially 3-40%.

Wherein, hole portion 2 is meant the value of measuring according to following key element with respect to the automobile inside material with total aperture area ratio on foam sheet A surface.That is, determine that with the position arbitrarily of foam sheet A surface 1a (3a) length of side is the gage frame of the plane square of 10cm at the automobile inside material.

Afterwards, obtain the summation of the hole portion 2 openend areas that are positioned at this gage frame, calculate the percent of the summation of hole portion 2 openend areas, and then this percentile value is defined as hole portion 2 with respect to the total aperture area ratio of automobile inside material with foam sheet A surface with respect to the gage frame area.In addition, when only the part of porose 2 openend is positioned at gage frame, only the area of hole portion 2 open end portion that are positioned at gage frame as object.

Specifically, as shown in Figure 10, when openend forms black and white sub-box shape for circular hole portion 2, for example, can be along the gage frame 43 of imaginary grid 4 regulation plane squares, to make it to comprise a plurality of hole portion 2, calculate the hole portion 2 openend area summations (oblique line part) that are positioned at this gage frame 43 afterwards, thereby calculate the percent of the summation of hole portion 2 openend areas with respect to the area of gage frame 43.

In addition, when forming the moulding product when making the automobile inside material carry out second time of foaming with foam sheet, the openend shape of secondary frothing forming product mesopore portion 2, openend area and total aperture area ratio satisfy above-mentioned condition and get final product, at this moment, make its automobile inside material that carries out before the second time of foaming not necessarily will satisfy above-mentioned openend shape, openend area and total aperture area ratio with the hole portion 2 of foam sheet.

In addition, shown in Figure 11-14, use on the face (hereinafter referred to as " hole portion forms face ") of the formation hole portion 2 among the foam sheet A at above-mentioned automobile inside material, preferably stacked integrated surface sheets 5,5 on the two sides of automobile inside material usefulness foam sheet A.Stacked when integrated when surface sheets 5,5 is carried out, preferably not stacked integrated Noryl is a resin flake 3 on Noryl resin foam thin slice 1.

In addition, it is stacked when integrated when surface sheets 5,5 is carried out, two surface sheets 5,5 can be that identical type also can be a variety classes, but since produce at the automobile inside material when making sometimes with foam sheet A crooked, so preferred identical type.

Above-mentioned surface sheets 5 contains form and keeps fiber and thermoplastic resin fibre.It is not melt when instigating the automobile interior material material to carry out thermoforming with foam sheet A and keep the fiber of form that the form that constitutes this surface sheets 5 keeps fiber, be preferably selected from least a fiber of glass fibre, carbon fiber, Irish touchstone (バ サ Le ト) fiber and natural fiber, more preferably natural fiber.

In addition,, have no particular limits, can enumerate for example grass fibers such as straw, cogongrass, reed, bamboo, cane suger (dregs that sugarcane has been pressed), Cyperus as above-mentioned natural fiber; Vein fibers such as burnt fiber crops, sisal hemp, pineapple leaves; Bast fibers such as hemp, flax (flax), jute, ramie, mulberry, kenaf (mestha, bluish dogbane), Chu Shu, three forks, wild goose skin; Seed wool fibres such as kapok (silk floss), cotton linters, kapok; Pine, larch, China fir, Japanese cypress, fir, Chinese hemlock spruce, dragon spruce, beech, maple, birch, redly raise, lumber fibres such as elm, paulownia, Chinese chestnut etc., preferred vein fiber, bast fiber, more preferably flaxen fiber, preferred especially sisal hemp, kenaf.

Also have, if above-mentioned form keeps the length of fiber long, then mix with thermoplastic resin when forming nonwoven fabrics, form keeps the distribution of fiber to become inhomogeneous and can cause the in uneven thickness of surface sheets.If make the stacked incorporate automobile inside material of this surface sheets in uneven thickness carry out thermoforming with foam sheet A, then in the thin part of surface sheets (form keeps the not enough part of fiber), because it is too much to put on the heat of modified polyphenylene ether resin foam sheet 1, the foam cell of modified polyphenylene ether resin foam sheet 1 will shrink or broken bubble, thereby the automobile inside material becomes inhomogeneous or physical strength decline with the thickness of foam sheet A, if and shrink or broken bubble and reduce the thermoforming temperature of automobile inside material for the foam cell that prevents above-mentioned modified polyphenylene ether resin foam sheet 1 with foam sheet A, then because underheat, the problem that the dimensional stability that meeting causes the automobile inside material because of the automobile inside material that obtains deform descends, so described length is preferably below the 200mm, if it is and too short, the part that when the automobile inside material is shaped with foam sheet A, is stretched sometimes then, surface sheets can rupture because of not following to stretch, perhaps the automobile inside material descend with the rigidity of foam sheet A and when being assembled into automobile by breakage, in addition, automobile inside material under the high temperature descends with the dimensional stability of foam sheet A, so described length is preferably 20-200mm.Specifically, when form keeps fiber to be natural fiber, be preferably below the 100mm, be preferably below the 200mm when being carbon fiber.

In addition, if above-mentioned form keeps fibre diameter meticulous, then the automobile inside material on the other hand, if thick excessively, then can not make form keep fiber to be uniformly distributed in the surface sheets, so be preferably 5-300 μ m with the rigidity decline of foam sheet A sometimes sometimes.

In addition, if it is very few that form keeps the content of fiber in the above-mentioned foam sheet 5, then the automobile inside material uses the physical strength of foam sheet A to descend or dimensional stability decline sometimes, on the other hand, if too much, then form keeps degree of adhesion between the fiber to descend and causes the automobile inside material to descend with formability and the aesthetic appearance of foam sheet A sometimes, so be preferably 20-90 weight %, more preferably 40-80 weight %.

In addition, as the thermoplastic resin fibre of in the nonwoven fabrics that constitutes above-mentioned surface sheets 5, containing, adhere each other so long as can make fiber, just have no particular limits, except vinylal fibre, polyamide-based fiber, the polyacrylic acid series fiber, acrylic fiber, polyester fiber, polyethylene-based fiber, polypropylene-based fiber, outside the fiber of single layer structures such as polystyrene series fiber, also can enumerate core and the both of sheath portion is that polyethylene terephthalate that resin constitutes and constitute sheath portion is that the fusing point of resin is the also low core-sheath-type fiber of fusing point of resin than the polyethylene terephthalate that constitutes core by polyethylene terephthalate, core is that polyethylene terephthalate is that resin and sheath portion are the core-sheath-type fiber of polyethylene-based resin, core is that polyethylene terephthalate is that resin and sheath portion are the fiber etc. of the two-layer structures such as core-sheath-type fiber of polypropylene-based resin.

Also have, as the fiber of above-mentioned single layer structure, preferred polyester series fiber, more preferably polyethylene terephthalate resin fiber, especially preferably dacron fibre.

In addition, fiber as above-mentioned two-layer structure, the core-sheath-type fiber that also can be core be made of different resins respectively with sheath portion, but preferred core and the both of sheath portion are polyethylene terephthalates is that resin and the polyethylene terephthalate that constitutes sheath portion are that the fusing point of resin is the also low core-sheath-type fiber of fusing point of resin than the polyethylene terephthalate that constitutes core, and more preferably core and the both of sheath portion are the fusing point also low core-sheath-type fiber of the fusing point of polyethylene terephthalate and the polyethylene terephthalate that constitutes sheath portion than the polyethylene terephthalate that constitutes core.

Also have, if above-mentioned thermoplastic resin fibre's length is too short, the servo-actuated decline of surface sheets when then forming the automobile inside material sometimes and can rupturing in the part that surface sheets is stretched with foam sheet A, on the other hand, if it is long, then sometimes in the surface sheets form keep the distribution of fiber to become inhomogeneous, so described length is preferably 4-80mm, 4-60mm more preferably.In addition, above-mentioned thermoplastic resin fibre's diameter is preferably the 1-20 dawn with regard to keeping the fusible viewpoint of fiber with form.

In addition, above-mentioned thermoplastic resin fibre's fusing point Tm (℃) and the Noryl that constitutes Noryl resin foam thin slice 1 be resin glass transition temperature Tg (℃) preferably satisfy following formula 1, more preferably satisfy following formula 2, especially preferably satisfy following formula 3.

Tg-65 ℃＜Tm＜Tg+40 ℃ ... formula 1

Tg-55 ℃＜Tm＜Tg+30 ℃ ... formula 2

Tg-45 ℃＜Tm＜Tg+20 ℃ ... formula 3

If this is because thermoplastic resin fibre's fusing point Tm is low excessively, then the automobile inside material uses the dimensional stability of foam sheet to descend sometimes, the automobile inside material can deform with foam sheet when be in the condition of high temperature in the car summer, on the other hand, if it is too high, then the automobile inside material uses the formability of foam sheet to descend sometimes, and the automobile inside material can rupture with foam sheet when the automobile inside material was configured as complicated shape with foam sheet.

In addition, among the present invention, constituting the automobile inside material is that the glass transition temperature Tg of resin is meant the temperature of measuring according to the method that is recorded in JIS K7121:1987 " the inversion temperature measuring methods of plastics " with the Noryl of foam sheet A, specifically, can use the differential scanning calorimeter of being sold with trade name " DSC200 type " by Seiko electronics industry society is to measure under the condition of 10 ℃/min at programming rate.

In addition, if thermoplastic resin fibre's content is very few in the above-mentioned surface sheets 5, then form keeps the degree of adhesion between the fiber to descend sometimes, thereby cause the automobile inside material to descend with formability and the aesthetic appearance of foam sheet A, on the other hand, if too much, then the automobile inside material uses the physical strength of foam sheet A to descend or dimensional stability decline sometimes, so be preferably 10-80 weight %, more preferably 20-60 weight %.

In addition, pay too smallly if constitute the order of the nonwoven fabrics of above-mentioned surface sheets 5, then the automobile inside material descends with the rigidity of foam sheet A sometimes, on the other hand, if excessive, so the then lightweight decline of automobile inside material usefulness foam sheet A sometimes is preferred 30-200g/m ², more preferably 40-120g/m ²

In addition, if it is thin excessively to constitute the thickness of nonwoven fabrics of above-mentioned surface sheets 5, then the automobile inside material descends with the rigidity of foam sheet A sometimes, on the other hand, if blocked up, then the automobile inside material uses the formability of foam sheet A to descend sometimes, so preferred 0.1-1mm, more preferably 0.2-0.8mm.

In addition, the nonwoven fabrics that constitutes above-mentioned surface sheets 5 also can be to use the nonwoven fabrics of any manufacture method manufacturing of all the time using, as this manufacture method, for example, the dry processes such as, needle point method legal, also can enumerate damp process such as copying the slurry method etc. except chemical bond method, thermojunction.

Also have, as on hole portion formation face 1a, the 3a of above-mentioned automobile inside material, making above-mentioned surface sheets 5 carry out stacked incorporate method with foam sheet A, can adopt that utilize to constitute the automobile inside material be that hot melt relay between resin and the thermoplastic resin fibre who constitutes surface sheets 5 makes automobile inside material usefulness foam sheet A and surface sheets 5 stacked incorporate methods with the Noryl of foam sheet A, perhaps, also can adopt make can and the adhesive layer 6 of both adhesions get involved in the automobile inside material with the method between foam sheet A and the surface sheets 5.

In addition, when making the automobile inside material stacked when integrated with foam sheet A and surface sheets 5 by getting involved adhesive layer 6, from the viewpoint of automobile inside material, preferably manage to avoid the automobile inside material to be stopped up by adhesive layer 6 with hole portion 2 opening portions of foam sheet A with the sound absorption properties of foam sheet A.

As the tackifier that constitutes this adhesive layer 6, as long as can make the automobile interior material material carry out incorporately just can using with foam sheet A and surface sheets 5, have no particular limits, for example can enumerate vinyl acetate and be tackifier, cellulose-based tackifier, acrylic pressure-sensitive adhesive, styrene-butadiene copolymer rubber and be tackifier, polyamide-based tackifier, polyvinyl acetate (PVA) is that tackifier, polyester are thermoplastic adhesives such as tackifier, acrylic pressure-sensitive adhesive; Urethane is that tackifier, melamine are that tackifier, phenol are that tackifier, epoxy are Thermocurable tackifier such as tackifier; Neoprene is that tackifier, nitrile rubber are that tackifier, silicone rubber are that rubber such as tackifier are tackifier; Natural system tackifier such as starch, protein, natural rubber; Heat sealing adhesives such as polyolefin, improved polyalkene system, polyurethane series, ethylene-vinyl acetate copolymer system, polyamide-based, polyester system, thermoplastic elastomer system, Styrene-Butadiene system, styrene-isoprene copolymerization system etc., preferably heat sealing adhesive.

Also have, as shown in Figure 11, above-mentioned adhesive layer 6 gets final product between the opposite face of automobile inside material with foam sheet A and surface sheets 5 at least, but the tackifier that constitutes preferably as shown in Figure 15, this adhesive layer 6 enters the inside of this surface sheets 5 and is impregnated in the whole surface sheets 5 under the condition of the aeration that keeps surface sheets 5.In other words, preferably identical with the tackifier that constitutes adhesive layer 6 tackifier 61 is impregnated in the whole surface sheets 5 under the condition of the aeration that keeps surface sheets 5, and be submerged in tackifier 61 in this surface sheets 5 preferred on the whole interface of surface sheets 5 and adhesive layer 6 with adhesive layer 6 being integral.

As mentioned above, by the tackifier that constitutes adhesive layer 6 is immersed in the whole surface sheets 5, can improve the degree of adhesion between the fiber that constitutes surface sheets 5, thereby reduce the linear expansivity of automobile inside material, can improve the intensity of automobile inside material simultaneously with foam sheet A with foam sheet A.

In addition, as shown in Figure 16, by the tackifier that is immersed in the surface sheets 5 is preferably oozed out in the whole outside of surface sheets 5 in the outside of surface sheets 5, on the surface of surface sheets 5, form epidermis adhesive layer 62, then when carrying out with the folded skin material 7 described later in surface sheets 5 upper stratas of foam sheet A or anti-noise material 8 at the automobile inside material when integrated, can finish stacked integratedly under the condition that need not prepare tackifier in addition, this is preferred in operating aspect.

Also have, if the gluing dosage that is immersed in the above-mentioned surface sheets 5 is very few, then can not improve the intensity of surface sheets 5 sometimes, on the other hand, if too much, then the automobile inside material is the 10-100 weight portion with the light weight decline of foam sheet A so preferably keep fiber and thermoplastic resin fibre's total amount 100 weight portions with respect to form sometimes.

In addition, if above-mentioned automobile inside material is excessive with the linear expansivity of foam sheet A, then the automobile inside material can bend according to the temperature variation in the automobile with foam sheet A sometimes, so be preferably 20 * 10 ^-6/ ℃ below, more preferably 15 * 10 ^-6/ ℃ below, preferred especially 12 * 10 ^-6/ ℃ below.

In addition, the automobile inside material is meant the linear expansivity of measuring according to following method with the linear expansivity of foam sheet A.That is, the automobile inside material being heated to its surface temperature with foam sheet A is the also high 8 ℃ high temperature of glass transition temperature of resin and make it freely carry out second time of foaming than the Noryl that constitutes foam sheet 1.

So, reach when being the also high 8 ℃ high temperature of the glass transition temperature of resin with the surface temperature of foam sheet A at the automobile inside material than the Noryl that constitutes foam sheet, finish of the heating of automobile inside material, the automobile inside material thickness of foam sheet A behind the measurement second time of foaming with foam sheet A.In addition, repeat 3 times aforesaid operations, the thickness of the arithmetic mean of three blocks of automobile inside materials thickness after with the second time of foaming of foam sheet A after as second time of foaming.

Then, the automobile inside material is heated to after its surface temperature is the also high 8 ℃ high temperature of the glass transition temperature of resin than the Noryl that constitutes foam sheet 1 with foam sheet A, this automobile inside material is arranged between the pair of plates shape metal pattern that opposite face forms even surface with foam sheet A, clamp the tabular metal pattern afterwards, on one side the automobile inside material is reached 90% of thickness behind the second time of foaming with foam sheet A along thickness direction compression molding to its thickness, cool off on one side, be lower than with the surface temperature of foam sheet A at the automobile inside material and open pair of plates shape metal pattern when the Noryl that constitutes foam sheet 1 is the glass transition temperature of resin, take out the automobile inside material foam sheet A that is compressed shaping.

Afterwards, cutting out long limit from the automobile inside material that is compressed shaping with foam sheet A is that 300mm and minor face are OBL first and second test film of 40mm, and the short side direction of these test films quadrature each other.

Then, this first and second test film is positioned in 85 ℃ the calibration cell, after 24 hours, is cooled to normal temperature, on the surface of each test film, describe the pair of parallel straight line then along the 280mm of being separated by on the direction on long limit.

Afterwards, this above-mentioned each test film is positioned in 80 ℃ the calibration cell, after 6 hours, from calibration cell, takes out, measure the distance L between a pair of straight line that is depicted in each test film surface immediately ₈₀

Then, this above-mentioned each test film is positioned in 0 ℃ the calibration cell and after 6 hours, from calibration cell, takes out, measure the distance L between a pair of straight line that is depicted in each test film surface immediately ₀, calculate the linear expansivity of first and second test film by following formula, the arithmetic mean of this first and second test film linear expansivity as the linear expansivity of automobile inside material with foam sheet A.

Linear expansivity (/ ℃)=(L ₈₀-L ₀)/(L ₀* 80)

In addition, when making foam sheet 1 by extruding foaming, when the automobile inside material cuts out test film with foam sheet A, the long side direction that makes the short side direction of first test film and second test film and foam sheet 1 to extrude direction consistent.

Then, the manufacture method of automobile inside material with foam sheet A described.At first, as the manufacture method that forms hole portion Noryl resin foam thin slice (hereinafter referred to as " unprocessed Noryl resin foam thin slice ") before, can adopt the manufacture method of in the past using, wherein by adjust extrusion foaming temperature that Noryl is a resin, be installed in the metal pattern temperature on the extruder or just extruded by this metal pattern after the surface cool degree of foam sheet, can obtain to have required continuous air bubbles rate, unprocessed Noryl resin foam thin slice.

Manufacture method as above-mentioned unprocessed Noryl resin foam thin slice, specifically, for example can enumerate (1) is that resin is supplied to extruder carries out being pressed into when fusion is mixed volatile foaming agent in extruder with Noryl, then from being installed in that metal pattern on the extruder is extruded and the manufacture method that makes the foam sheet of its foaming, (2) making volatile foaming agent impregnated in Noryl in advance is in the resin, be supplied to extruder then and carry out fusion and mix, from being installed in that metal pattern on the extruder is extruded and the manufacture method that makes the foam sheet of its foaming.

As above-mentioned volatile foaming agent, so long as just can using of in the past using, have no particular limits, can enumerate that for example organic system gas-development agent, carbon dioxide, water, nitrogen etc. such as ethane, propane, isobutane, normal butane, pentane, dimethyl ether are inorganic is gas-development agent, and these can use separately also and can and use.

In addition, preferably adjust the kind and the amount of above-mentioned volatile foaming agent so that above-mentioned in the Noryl resin foam thin slice 1 of hole processing residual residual foaming dosage be 0.3-4.0 weight %.If this be because above-mentioned in the Noryl resin foam thin slice 1 of hole processing residual foaming dosage very few, then can not obtain the foam sheet 1 of high-quality, in addition, if too much, then the thermotolerance of foam sheet 1 and dimensional stability descend sometimes.

Also have, making Noryl on two faces of the unprocessed Noryl resin foam thin slice 1 that obtains as described above is resin flake 3,3 is stacked when integrated, as make Noryl on two faces of unprocessed Noryl resin foam thin slice is that resin flake carries out stacked incorporate method, for example can enumerating, (1) overlapping Noryl on two faces of unprocessed Noryl resin foam thin slice is a resin flake, on two faces of foam sheet, make above-mentioned thin slice carry out thermal welding and incorporate method by hot-rolling, (2) on two faces of unprocessed Noryl resin foam thin slice, stacked Noryl after just having been extruded by extruder is a resin flake, afterwards by thermal welding with this sheet lamination on the surface of unprocessed Noryl resin foam thin slice and incorporate method, (3) make Noryl resin foam thin slice carry out stacked incorporate method etc. by co-extrusion pressure on two faces of unprocessed Noryl resin foam thin slice.

Usually, on the unprocessed Noryl resin foam thin slice that obtains as described above, form hole portion 2 and make automobile inside material foam sheet A, as the method that on unprocessed Noryl resin foam thin slice, forms hole portion 2, have no particular limits, for example can enumerate (1) by with unprocessed Noryl resin foam thin slice, perhaps making Noryl on two faces is the stacked incorporate unprocessed Noryl resin foam thin slice of resin flake, be supplied between the pair of rolls, described pair of rolls is separated by predetermined distance by parallel setting, its turning axle is parallel to each other, and embedding is provided with a plurality of nails on a roller surface, prick the continuous air bubbles layer 11 (1A) that enters this foam sheet by following closely from a face of unprocessed Noryl resin foam thin slice, form a plurality of hole portion 2 thus, 2 ... method, (2) at unprocessed Noryl resin foam thin slice, be that resin flake carries out on the face of stacked incorporate unprocessed Noryl resin foam thin slice perhaps making Noryl on two faces, extruding embeds the flat board that is provided with a plurality of nails, make nail prick the continuous air bubbles layer 11 (1A) that enters this foam sheet, form a plurality of hole portion 2 thus from face of unprocessed Noryl resin foam thin slice, 2 ... method.

Also have, as at least the automobile inside material of making as described above with the hole portion formation face of foam sheet A on stacked surface sheets 5 and carry out incorporate method, can enumerate for example (1) at least on the hole portion formation face of automobile inside material with foam sheet A, under the state of getting involved the tackifier that constitutes adhesive layer 6, the nonwoven fabrics of stacked formation surface sheets 5 is made duplexer, and this duplexer added hot compression from its both sides along thickness direction, thus at least on the hole portion formation face of automobile inside material with foam sheet A stacked surface sheets 5 carry out incorporate method, (2) tackifier of coating formation adhesive layer 6 on a face of the nonwoven fabrics that constitutes surface sheets 5, above-mentioned nonwoven fabrics is layered on the hole portion formation face of automobile inside material with foam sheet A at least, make this moment its tackifier coated face be positioned at automobile inside material foam sheet A one side, make duplexer thus, and this duplexer added hot compression from its both sides along thickness direction, thereby at least on the hole portion formation face of automobile inside material with foam sheet A stacked surface sheets 5 carry out incorporate method etc.In addition, in any manufacture method of above-mentioned (1), (2), all preferably adjust to avoid adhesive layer 6 to stop up the opening portion of automobile inside material with the hole portion 2 of foam sheet A.

In addition, automobile inside material foam sheet A (with reference to Figure 15) in the tackifier of making formation adhesive layer 6 is submerged in surface sheets 5 integral body, the tackifier that perhaps make to constitute adhesive layer be submerged in surface sheets 5 whole in and also make the tackifier that is immersed in surface sheets 5 be exuded to the outside of surface sheets 5 and on the surface of surface sheets 5, form epidermis adhesive layer 62 and the automobile inside material that forms during with foam sheet A (with reference to Figure 16), tackifier is immersed in constitute on whole of nonwoven fabrics of surface sheets 5, and utilizes the tackifier that is immersed in this nonwoven fabrics on the hole portion formation face of automobile inside material, to make surface sheets 5 stacked integrated with foam sheet A.In addition, in this manufacture method, also preferably adjust the gas penetration potential with ambient atmosphere with retaining hole portion 2.

As the method in the nonwoven fabrics that above-mentioned tackifier be impregnated in constitute surface sheets 5, for example can enumerate (1) is provided with tackifier on the nonwoven fabrics that constitutes surface sheets 5, by being added hot compression along thickness direction, the nonwoven fabrics that is provided with this tackifier make the tackifier fusing make it impregnated in method in the nonwoven fabrics, (2) on the nonwoven fabrics that constitutes surface sheets 5, be coated with general coating process such as spraying process or rolling method, the method of dipping tackifier, (3) by the nonwoven fabrics that constitutes surface sheets 5 being impregnated in make in the emulsion that contains tackifier tackifier to impregnated in method in the nonwoven fabrics, (4) when constituting the nonwoven fabrics of surface sheets 5 with the damp process manufacturing, can the time tackifier be contained in the water copying slurry, when making nonwoven fabrics, make tackifier impregnated in method in the nonwoven fabrics etc.In addition, in any method, all preferably adjust the gas penetration potential of having flooded the nonwoven fabrics of tackifier with maintenance.

In addition, when making tackifier impregnated in the nonwoven fabrics that constitutes surface sheets 5, preferably manage to make the tackifier that impregnated in the nonwoven fabrics to be exuded on two faces of nonwoven fabrics, formation is covered the state of nonwoven surface by this tackifier that oozes out, promptly, be formed on two faces of nonwoven fabrics and make tackifier, from this point of view, preferably use the method for above-mentioned (3), (4) that tackifier be impregnated in the nonwoven fabrics that constitutes surface sheets 5 with the stacked incorporate state of stratiform.

In addition, as Figure 17 and shown in Figure 180, usually on the face that be formed with its hole portion 2 one sides of above-mentioned automobile inside material with foam sheet A, undertaken integrated by getting involved the stacked skin material 7 that is set at the car inboard of adhesive layer (not shown), while stacked noise control sound layer 8 on the face of opposition side carries out integrated, is used as the automobile inside material by the thermoforming shaping for required shape then.

Wherein, the stacked skin material 7 and when integrated when staying out of surface sheets 5 on foam sheet A at the automobile inside material, preferably manage to avoid to make skin material 7 and automobile inside material to stop up the peristome of automobile inside material, enter with the vibrational energy of avoiding adhesive layer to hinder sound in the continuous air bubbles layer 11,1A of foam sheet 1 with the hole portion 2 of foam sheet A with the stacked incorporate adhesive layer of foam sheet A.

Therefore, as on the face of automobile inside material, stay out of with foam sheet A surface sheets 5 between and make skin material 7 carry out stacked incorporate method by adhesive layer, can enumerate following method.For example, can enumerate (1) on the face of automobile inside material with foam sheet A, scatter pulverous tackifier, to avoid stopping up the peristome of its hole portion 2 this moment, and the automobile inside material with the face of foam sheet A on after the stacked skin material 7, be heated to the automobile inside material more than the fusing point of tackifier with foam sheet A, make the automobile inside material push incorporate method afterwards with foam sheet A and skin material 7, (2) in surfacing 7, scatter pulverous tackifier with on opposed of the foam sheet A with the automobile inside material, after more than the fusing point that surfacing 7 is heated to tackifier by pushing from both sides on the surface that makes tackifier anchor at skin material 7, then, this skin material 7 is layered on the face of automobile inside material with foam sheet A, make this moment set have the face of this tackifier to be positioned at automobile inside material foam sheet A one side, afterwards the automobile inside material is heated to the temperature of tackifier fusing with foam sheet A, thereby make the automobile inside material push incorporate method with foam sheet A and skin material 7, (3) coating binder on the face of automobile inside material usefulness foam sheet A, to avoid stopping up the opening portion of its hole portion 2 this moment, getting involved this tackifier afterwards makes the automobile inside material carry out incorporate method with foam sheet A and skin material 7, (4) behind coating binder on whole an of face of unprocessed Noryl resin foam thin slice, form hole portion 2 according to the method described above and make automobile inside material foam sheet A, getting involved above-mentioned tackifier at this automobile inside material on the face of foam sheet A afterwards makes skin material 7 carry out stacked incorporate method, (5) sticking with glue nonwoven fabrics with gas penetration potential or the net that agent forms by intervention is layered on the face of automobile inside material with foam sheet A skin material 7, then the automobile inside material is heated to the temperature that tackifier melts with foam sheet A, makes the automobile inside material push incorporate method etc. afterwards with foam sheet A and skin material 7.

In addition, make surface sheets 5 between the automobile inside material with the state on the foam sheet A under stacked skin material 7 carry out under the incorporate situation, can use tackifier, also can utilize skin material 7 and automobile inside material to carry out, also can utilize the epidermis adhesive layer 62 of surface sheets 5 with the hot melt relay between the surface sheets 5 of foam sheet A.No matter adopt which kind of method, all preferably adjust so that the hole portion 2 of Noryl resin foam thin slice 1 keeps and the gas penetration potential of ambient atmosphere.

As above-mentioned skin material 7, can enumerate nonwoven fabrics, weaving cloth, woven cloth etc., preferably have gas penetration potential.In addition, also can contain fire retardant in order to give skin material 7 anti-flammabilitys.

Also have, as the fiber that constitutes above-mentioned skin material 7, can enumerate synthon such as polyester, polyamide, polyacrylonitrile such as polyethylene terephthalate etc., the preferred polyester fiber is from more preferably dacron fibre of the viewpoint of excellent heat resistance.In addition, the fiber that constitutes above-mentioned skin material 7 can use separately also and can and use.

As above-mentioned adhesive layer, so long as being engaged with foam sheet A, above-mentioned skin material 7 and automobile inside material incorporately just can use, have no particular limits, for example can enumerate thermoplastic adhesive, heat sealing adhesive, rubber and be tackifier, Thermocurable tackifier, monomer reaction type tackifier, inorganic be that tackifier, natural material are tackifier etc., but from being easy to the preferred heat sealing adhesive of bonding viewpoint.

In addition, as above-mentioned heat sealing adhesive, for example can enumerate the tackifier of resins such as polyolefin, improved polyalkene system, polyurethane series, ethylene-vinyl acetate copolymer system, polyamide-based, polyester system, thermoplastic elastic system, Styrene-Butadiene system, styrene-isoprene copolymerization system as composition, these can use also also usefulness separately.

In addition, at above-mentioned automobile inside material with another face of foam sheet A, promptly do not form that stacked noise control sound layer 8 carries out integrated on the face of (opening) hole portion 2, should anti-isefloor 8 be to be used to reduce the fricative structure that the steel plate that constitutes car body produces during with foam sheet A generation sliding friction with the automobile inside material, preferred film of polyolefin resin or the nonwoven fabrics of using more preferably uses nonwoven fabrics.

As the said polyolefins based resin film, can enumerate for example film of polyolefin resin such as polyethylene film, polypropylene film, no matter and how can both reduce the viewpoint that fricative produces long-term and stably from excellent heat resistance and temperature variation on every side, the preferred polypropylene film that does not stretch.In addition, said polyolefins based resin film thickness is preferably 10-100 μ m, 25-35 μ m usually.

In addition, the fiber as the nonwoven fabrics that is configured for above-mentioned anti-isefloor 8 has no particular limits, and can enumerate for example synthetic resin fibers such as dacron, polyethylene fibre, mekralon, polyamide fibre, polyacrylonitrile fibre etc.

At last, in the drawings, on the interface of interface, separated foam layer 12 and the non-bubble layer (epidermal area) 13 of continuous air bubbles layer 11 in the Noryl resin foam thin slice 1 of hole processing and separated foam layer 12, record the boundary line for the ease of understanding, but of the present invention in the Noryl resin foam thin slice 1 of hole processing continuous air bubbles layer 11 and the interface of the interface of separated foam layer 12 and separated foam layer 12 and non-bubble layer (epidermal area) 13 on do not have tangible boundary line.

Then, as mentioned above, carry out stacked noise control sound layer 8 on another face of incorporate while by stacked skin material 7 on the face of above-mentioned automobile inside material with foam sheet A and carry out integratedly, being shaped through thermoforming then is required shape, forms the automobile inside material thus.

As the thermo shaping method of above-mentioned automobile inside material with foam sheet A, can use method in common in the past, for example, heating automobile inside material makes it carry out second time of foaming with foam sheet A, its two sides temperature T during heating ₁(℃) preferably satisfy formula 4, more preferably satisfy formula 5, especially preferably satisfy formula 6, then this automobile inside material through second time of foaming is carried out thermoforming with foam sheet A by general forming processes such as vacuum forming or press moldings.

(Noryl that constitutes foam sheet 1 is glass transition temperature Tg-25 a ℃ of resin)≤T ₁≤ (Noryl that constitutes foam sheet 1 is glass transition temperature Tg+15 a ℃ of resin) ... formula 4

(Noryl that constitutes foam sheet 1 is glass transition temperature Tg-20 a ℃ of resin)≤T ₁≤ (Noryl that constitutes foam sheet 1 is glass transition temperature Tg+10 a ℃ of resin) ... formula 5

(Noryl that constitutes foam sheet 1 is glass transition temperature Tg-20 a ℃ of resin)≤T ₁≤ (Noryl that constitutes foam sheet 1 is glass transition temperature Tg+5 a ℃ of resin) ... formula 6

With the automobile inside material be with the suitable reason that is adjusted in the said temperature scope of the heating-up temperature of foam sheet A, if cross low, can residual deformation take place when then the automobile inside material is with foam sheet A thermoforming sometimes and cause size changing rate to become big, on the other hand, if it is too high, then sometimes the automobile inside material is applied too much heat with foam sheet A and cause the contraction of foam sheet A, thereby cause the automobile inside material to descend or produce shape defect with the physical strength of foam sheet A.

In addition, as vacuum forming or press molding, for example can enumerate plug forming, free drawing (free drawing) shaping, formpiston and protuberance (ridge) be shaped, to matched moulds (matched mold) be shaped, straight line (straight) is shaped, holds court from behind a screen, and (trape) is shaped, reverse drawing (リ バ one ス De ロ one) is shaped, air slides (エ ア ス リ Star プ) shaping, プ ラ ゲ ア シ ス ト shaping, the shaping of プ ラ ゲ ア シ ス ト reverse drawing etc.In addition, preferred use can be regulated the metal pattern of temperature in above-mentioned manufacturing process.

In addition, when through the automobile inside material of second time of foaming with foam sheet A initial stage, thick gauge was decided to be T the time, the gap of metal pattern (clearance) preferably satisfies following formula 7, more preferably satisfies following formula 8.

0.7T the gap≤0.98T of≤metal pattern ... formula 7

0.8T the gap≤0.95T of≤metal pattern ... formula 8

If this is because the gap of metal pattern is narrow, then the thickness of continuous air bubbles layer 11 descends with respect to the ratio of automobile inside material with foam sheet A integral thickness sometimes, thereby sound absorption properties descends, on the other hand, if wide, then can not obtain true-to-shape automobile inside material sometimes.

The invention effect

Automobile inside material foam sheet of the present invention is, by stacked Noryl on two faces of the Noryl resin foam thin slice that constitutes as described above or this Noryl resin foam thin slice is that resin flake carries out on the incorporate sheet material, be formed on that the hole portion of its surface opening forms, so the vibrational energy of sound successfully can be guided in the continuous air bubbles of the Noryl resin foam thin slice of processing through the hole at logical via portion, make the walls vibration of continuous air bubbles, the vibrational energy with sound is converted to heat energy and brings into play good sound absorption properties thus.

Also have, because the automobile inside material is more than 50% with the continuous air bubbles rate of the Noryl resin foam thin slice of foam sheet, so the vibrational energy that enters the sound in the Noryl resin foam thin slice is promptly disperseed in Noryl resin foam thin slice and be converted to heat energy effectively, thereby have good sound absorption properties.

In addition, when above-mentioned automobile inside material with a face of foam sheet on stacked surface sheets carry out when integrated, the automobile inside material thermotolerance of foam sheet, physical strength and excellent size stability, in addition, even the automobile inside material with foam sheet on stacked skin material carry out under the incorporate situation, the opening portion of hole portion is in by the hidden state of surface sheets, even so use soft skin material, can on skin material, not produce the wrinkle that generate because of hole portion yet, thereby can make skin material be stacked in the automobile inside material with on the foam sheet and carry out integrated with smooth state layer.In addition, because automobile inside material foam sheet stacked surface sheets on a face of its foam sheet, so thermotolerance is also good, the excellent size stability during high temperature.

In addition, has the continuous air bubbles layer that mainly constitutes by continuous air bubbles when the froth bed of Noryl resin foam thin slice, and when hole portion reaches the continuous air bubbles layer, by the vibrational energy of sound successfully being guided in the continuous air bubbles layer via hole portion, make the walls vibration of the continuous air bubbles of continuous air bubbles layer, thus vibrational energy is converted to heat energy and brings into play good sound absorption properties.

Also have, when the froth bed of Noryl resin foam thin slice only is made up of the continuous air bubbles layer that mainly is made of continuous air bubbles, spread in whole Noryl resin foam thin slice by the vibrational energy that makes sound via hole portion, make the vibrational energy of sound be converted to heat energy and bring into play good sound absorption properties.

In addition, in the froth bed of Noryl resin foam thin slice, on two faces of the continuous air bubbles layer that mainly constitutes, be formed with the separated foam layer that mainly constitutes by separated foam by continuous air bubbles, and when hole portion reaches the continuous air bubbles layer, by the vibrational energy of sound being introduced in the continuous air bubbles layer of Noryl resin foam thin slice, make vibrational energy be converted to heat energy and bring into play good sound absorption properties via hole portion.In addition, owing to there is the separated foam layer in the froth bed of foam sheet, the automobile inside material is good with the physical strength of foam sheet.Therefore, the automobile inside material carried out thermoforming with foam sheet and the automobile inside material that obtains can keep the thickness before the thermoforming substantially, thickness and precision is good.

Also have, use in the foam sheet at above-mentioned automobile inside material, when the continuous air bubbles rate of Noryl resin foam thin slice is 60-90%, walls by the continuous air bubbles in the continuous air bubbles layer that makes foam sheet is vibrated more effectively, the vibrational energy of sound can be converted to heat energy efficiently, thereby can make the automobile interior material material more outstanding with the sound absorption properties of foam sheet.

In addition, when the thickness of separated foam layer is the 1-25% of Noryl resin foam sheet thickness, the automobile inside material has good sound absorption properties and the air property cut off with foam sheet, not only can absorb the sound that forms the face side from the hole portion of foam sheet, and can cut off effectively from forming the sound of face side opposition side with the hole portion of foam sheet.

In addition, above-mentioned automobile inside material is with in the foam sheet, when hole portion is 2-50% with respect to total aperture area ratio on foam sheet surface, can make the automobile inside material keep with foam sheet giving its good sound absorption properties in the good physical strength.

Also have, above-mentioned automobile inside material is with in the foam sheet, undertaken integrated when making Noryl resin foam thin slice and surface sheets by adhesive layer, and when the tackifier that constitutes this adhesive layer is submerged in the whole surface sheets, can utilize tackifier to make the fiber adhesion more securely each other of formation surface sheets, thereby improve the physical strength of surface sheets, can obtain the automobile inside material foam sheet that linear expansivity is lower and physical strength is better.

Description of drawings

Fig. 1 is the pattern vertical cross-section diagram of expression automobile inside material of the present invention with foam sheet.

Fig. 2 is the pattern vertical cross-section diagram of expression automobile inside material of the present invention with foam sheet another one example.

Fig. 3 is the pattern vertical cross-section diagram of expression automobile inside material of the present invention with foam sheet another one example.

Fig. 4 is the pattern vertical cross-section diagram of expression automobile inside material of the present invention with foam sheet another one example.

Fig. 5 is the pattern vertical cross-section diagram of expression automobile inside material of the present invention with foam sheet another one example.

Fig. 6 is the pattern vertical cross-section diagram of expression automobile inside material of the present invention with foam sheet another one example.

Fig. 7 is the pattern vertical cross-section diagram of expression automobile inside material of the present invention with foam sheet another one example.

Fig. 8 is the pattern vertical cross-section diagram of expression automobile inside material of the present invention with foam sheet another one example.

Fig. 9 is the vertical view of an example of indication window portion generation type.

Figure 10 is the vertical view of an example of indication window portion generation type.

Figure 11 is the pattern vertical cross-section diagram of expression automobile inside material of the present invention with foam sheet.

Figure 12 is the pattern vertical cross-section diagram of expression automobile inside material of the present invention with foam sheet another one example.

Figure 13 is the pattern vertical cross-section diagram of expression automobile inside material of the present invention with foam sheet another one example.

Figure 14 is the pattern vertical cross-section diagram of expression automobile inside material of the present invention with foam sheet another one example.

Figure 15 is the pattern vertical cross-section diagram of expression automobile inside material of the present invention with foam sheet another one example.

Figure 16 is the pattern vertical cross-section diagram of expression automobile inside material of the present invention with foam sheet another one example.

Figure 17 is illustrated in automobile inside material of the present invention carries out incorporate state with stacked skin material and anti-noise material on two faces of foam sheet pattern vertical cross-section diagram.

Figure 18 is illustrated in automobile inside material of the present invention carries out incorporate state with stacked skin material and anti-noise material on two faces of foam sheet pattern vertical cross-section diagram.

Figure 19 is the pattern vertical cross-section diagram of expression by the moulding product of embodiment acquisition.

Figure 20 is the curve of expression automobile inside material with the sound absorption properties result of foam sheet.

Figure 21 is the sound absorption properties result's of expression secondary frothing forming product a curve.

Figure 22 is the curve of expression automobile inside material with the sound absorption properties measurement result of foam sheet.

Figure 23 is the sound absorption properties result's of expression secondary frothing forming product a curve.

Among the figure,

1 Noryl resin foam thin slice

11,1A continuous air bubbles layer

12 separated foam layers

13 non-foam layers (epidermal area)

2 hole portions

3 Noryls are resin flake

5 surface sheets

6 adhesive layers

61 tackifier

62 epidermis adhesive layers

7 skin materials

8 anti-noise materials

A automobile inside material foam sheet

B moulding product

Embodiment

(embodiment 1)

Potpourri (GE plastics society system with polyphenylene oxide and polystyrene resin, trade name " NORYL EFN4230 ", polyphenylene oxide: 70 weight %, polystyrene resin: 30 weight %) to mix and form Noryl be resin (polyphenylene oxide composition: 35 weight % to 50 weight portions and polystyrene (Japan styrene society system trade name " HRM-26 ") 50 weight portions, polystyrene resin composition: 65 weight %, glass transition temperature: 132 ℃), with this Noryl is that resin and talcum 0.65 weight portion are supplied to first extruder and carry out fusion and mix, in first extruder, be pressed into simultaneously volatile foaming agent 3.9 weight portions of forming by isobutane 35 weight % and normal butane 65 weight %, and under 300 ℃, carry out fusion and mix, in second extruder that the top with above-mentioned first extruder is connected, supply with molten resin continuously then and resin temperature is adjusted into 206 ℃, extrude molten resin and foam with cylindric from the round metal pattern (temperature: 155 ℃) that is installed in the second extruder top afterwards.By being extruded direction along it, these cylindric foams cut, launch to obtain unprocessed Noryl resin foam thin slice between the outside within it continuously.In the froth bed of this unprocessed Noryl resin foam thin slice, on a face of the continuous air bubbles layer 11 that mainly constitutes, be formed with the separated foam layer 12a that mainly constitutes, on another face of continuous air bubbles layer 11, be formed with the separated foam layer 12b that mainly constitutes by separated foam by separated foam by continuous air bubbles.In addition, on separated foam layer 12a, 12b surface whole, be formed with non-foam layer (epidermal area) 13,13.

Then, prepare on a face, to embed the flat board that is provided with a plurality of nails, and nail that should flat board is pricked into from the separated foam layer 12a side of above-mentioned unprocessed Noryl resin foam thin slice.So, only on a face of Noryl resin foam thin slice, with the form in the surperficial 1a arrival continuous air bubbles layer 11 of foam sheet, form openend and be a plurality of hole portion 2 of planar rondure, promptly the form that is positioned at continuous air bubbles layer 11 according to surperficial 1a opening and bottom 21 at foam sheet forms a plurality of hole portion 2 that openend is a planar rondure, has obtained automobile inside material foam sheet A thus.

In addition, the automobile inside material that formation obtains is 3.6mm with the thickness of the continuous air bubbles layer 11 of the Noryl resin foam thin slice of processing through the hole 1 of foam sheet A, the thickness of separated foam layer 12a is 0.6mm, and the thickness of separated foam layer 12b is 1.0mm, and order is paid and is 250g/m ²

In addition, the density of the above-mentioned Noryl resin foam thin slice of processing through the hole 1 is 0.048g/cm ³, whole continuous air bubbles rate is 61.3%, and the ratio of the continuous air bubbles that contains in continuous air bubbles layer 11 is 93.0%, and the ratio of the separated foam that contains in the separated foam layer 12 is 85%, and mean air bubble diameter is 0.54mm.

In addition, through the hole portion 2 of the Noryl resin foam thin slice 1 of hole processing as shown in Figure 9, adequate relief becomes black and white sub-box shape, and the openend area of each hole portion 2 is 3.14mm ², the degree of depth is 3.7mm, and total aperture area of hole portion 2 is 9.8% with respect to the automobile inside material with the ratio on foam sheet A surface, and the length d of the square frame part 42 of imaginary grid 4 is 8mm.

(embodiment 2)

Will be by potpourri (the GE plastics society system trade name " NORYL EFN4230 " of polyphenylene oxide and polystyrene resin, polyphenylene oxide: 70 weight %, polystyrene resin: 30 weight %), the Noryl that polystyrene (Japan styrene society system trade name " HRM-26 ") and high impact polystyrene (Japan styrene society system trade name " E641N ") are formed be resin (glass transition temperature Tg:116 ℃) and as the black masterbatch (mastre batch) of colorant (the big Japan society that refines makes trade name " PS-M SSC 98H822A ", carbon black: 40 weight %) mix, so that the polyphenylene oxide composition is 20 weight %, the phenylethylene resin series composition is 77.6 weight %, rubber constituent is 2 weight %, carbon black is 0.4 weight %, simultaneously the resin that mixes is supplied to two extruders respectively.

Afterwards, with soon the Noryl of molten state after just being extruded by an extruder in two extruders is resin flake, be layered in by on the face that just launches unprocessed Noryl resin foam thin slice soon made from embodiment 1 same procedure and make it carry out thermal welding and integrated, soon the Noryl of molten state is that resin flake is layered on another face of above-mentioned unprocessed Noryl resin foam thin slice and makes it carry out thermal welding and integrated after will just having been extruded by another extruder simultaneously, and directly the stacked Noryl that is colored as the thick 95 μ m of black by carbon black on its whole thickness direction is a resin flake 3 by thermal welding on two faces of unprocessed Noryl resin foam thin slice, 3 and make it integrated.

Then, be adjusted into 2.54mm except openend area with hole portion 2 ²In addition, according to the method identical with embodiment 1, only be laminated with Noryl resin foam thin slice on two faces and carrying out on the face of incorporate unprocessed Noryl resin foam thin slice, be formed on a plurality of hole portion 2 that the surperficial upper shed of Noryl resin foam thin slice and bottom 21 are positioned at continuous air bubbles layer 11, and obtained automobile inside material foam sheet A thus.In addition, the openend of hole portion 2 is planar rondure.

In addition, the automobile inside material of acquisition is 5.1mm with the thickness of the Noryl resin foam thin slice of processing through the hole 1 of foam sheet A, and order is paid and is 450g/m ², the thickness of continuous air bubbles layer 11 is 3.5mm, and the thickness of a separated foam layer 12a is 0.6mm, and the thickness of another separated foam layer 12b is 1.0mm, and density is 0.088g/cm ³, the continuous air bubbles rate is 73.3%, and the ratio of the continuous air bubbles that contains in continuous air bubbles layer 11 is 94.6%, and the ratio of the separated foam that contains in the separated foam layer 12 is 85%, and mean air bubble diameter is 0.54mm.

In addition, the hole portion 2 of Noryl resin foam thin slice 1 adequate relief as shown in Figure 9 becomes black and white sub-box shape, and the openend area of each hole portion 2 is 2.54mm ², the degree of depth is 3.7mm, and hole portion 2 total aperture areas are 7.9% with respect to the automobile inside material with the ratio on foam sheet A surface, and the length d of the square frame part 42 of imaginary grid 4 is 8mm.

(embodiment 3)

Will be by potpourri (the GE plastics society system trade name " NORYL EFN4230 " of polyphenylene oxide and polystyrene resin, polyphenylene oxide: 70 weight %, polystyrene resin: 30 weight %), the Noryl that polystyrene (Japan styrene society system trade name " HRM-26 ") and high impact polystyrene (Japan styrene society system trade name " E641N ") are formed be resin (glass transition temperature Tg:113 ℃) and as the black masterbatch of colorant (the big Japan society that refines makes trade name " PS-M SSC 98H822A ", carbon black: 40 weight %) mix, so that the polyphenylene oxide composition is 16.8 weight %, the phenylethylene resin series composition is 81.2 weight %, rubber constituent is 2.6 weight %, carbon black is 0.4 weight %, simultaneously the resin that mixes is supplied to two extruders respectively.

On the other hand, except being decided to be 3.5 weight portions, the volatile foaming agent gauge replaces 3.9 weight portions, in second extruder, resin temperature is adjusted into 203 ℃ and replaces 206 ℃, the temperature of circular metal mould is defined as 180 ℃ replaces beyond 155 ℃, extrude molten resin and foam with cylindric by the circular metal mould that is installed in the second extruder top according to the method identical with embodiment 1.These cylindric foams are extruded direction along it to cut, launches between the outside within it continuously.Afterwards, on the face of the unprocessed Noryl resin foam thin slice after just launching, stacked just pushed by an above-mentioned extruder after soon the Noryl of molten state be resin flake and make it carry out thermal welding and integrated, soon the Noryl of molten state is that resin flake is layered on another face of above-mentioned unprocessed Noryl resin foam thin slice and makes it carry out thermal welding and integrated after will just having been pushed by above-mentioned another extruder simultaneously, and directly the stacked Noryl that is colored as the thick 95 μ m of black by carbon black on whole thickness direction is a resin flake 3 by thermal welding on two faces of unprocessed Noryl resin foam thin slice, 3 and finished integrated.

Then, be adjusted into 0.50mm except openend area with hole portion 2 ²The length d of the square frame part 42 of imaginary grid 4 is adjusted into beyond the 4mm, according to the method identical with embodiment 1, only carry out on the face of incorporate Noryl resin foam thin slice at stacked Noryl resin foam thin slice on two faces, formed in the surperficial upper shed of Noryl resin foam thin slice and arrived a plurality of hole portion 2 in the continuous air bubbles layer of Noryl resin foam thin slice, and obtained automobile inside material foam sheet A thus.

In addition, the automobile inside material that obtains only is made up of the continuous air bubbles layer 1A that mainly is made of continuous air bubbles with the froth bed of the Noryl resin foam thin slice of processing through the hole 1 of foam sheet A, and being formed with thickness on two faces of this continuous air bubbles layer 1A is the non-foam layer 13 of 0.1mm.In addition, the thickness of the Noryl resin foam thin slice of processing through the hole 1 is 5.3mm, and order is paid and is 500g/m ², density is 0.094g/cm ³, the continuous air bubbles rate of foam sheet integral body is 79.6%, and the continuous air bubbles rate of continuous air bubbles layer 1A is 92.2%, and mean air bubble diameter is 0.49mm.

In addition, the hole portion 2 of the Noryl resin foam thin slice of processing through the hole 1 adequate relief as shown in Figure 9 becomes black and white sub-box (plover grid) shape, and each hole portion 2 openend area is 0.50mm ², be 4.0mm deeply, hole portion 2 total aperture areas are 6.3% with respect to the automobile inside material with the ratio on foam sheet A surface, the length d of the square frame part 42 of imaginary grid 4 is 4mm.

(embodiment 4)

Except making hole portion 2 adequate reliefs through the planar rondure of the Noryl resin foam thin slice 1 of hole processing become clathrate, the length d of the square frame part 42 of imaginary grid 4 is adjusted into the 5.3mm, obtained automobile inside material foam sheet A in the same manner with embodiment 3.

In addition, the thickness of the Noryl resin foam thin slice of processing through the hole 1 is 5.3mm, and order is paid and is 500g/m ², density is 0.094g/cm ³, the continuous air bubbles rate of foam sheet integral body is 79.2%, and the continuous air bubbles rate of continuous air bubbles layer 1A is 92.0%, and mean air bubble diameter is 0.49mm.

In addition, each hole portion 2 openend area is 0.50mm ², be 4.0mm deeply, hole portion 2 total aperture areas are 3.6% with respect to the automobile inside material with the ratio on foam sheet A surface, the length d of the square frame part 42 of imaginary grid 4 is 5.3mm.

(embodiment 5)

Except as Noryl being potpourri (the GE plastics society system trade name " NORYL EFN4230 " of resin use with polyphenylene oxide and polystyrene resin, polyphenylene oxide: 70 weight %, polystyrene resin: 57.1 weight portions 30 weight %), and polystyrene (Japan styrene society system trade name " HRM-26 ") 42.9 weight portions mix and the Noryl that forms is a resin (polyphenylene oxide composition: 40 weight %, polystyrene resin composition: 60 weight %, glass transition temperature Tg:137 ℃), the volatile foaming agent gauge is decided to be 3.5 weight portions replaces 3.9 weight portions, in second extruder, resin temperature is adjusted into 208 ℃ and replaces 206 ℃, the temperature of circular metal mould is defined as 185 ℃ to be replaced beyond 155 ℃, according to the method identical, extrude molten resin and foam with cylindric by the circular metal mould that is installed in the second extruder top with embodiment 1.These cylindric foams are extruded direction along it to cut, launches between the outside within it continuously.Then, on two faces of the unprocessed Noryl resin foam thin slice after just launching, directly be that resin flake carries out thermal welding and integrated with Noryl according to the method identical with embodiment 3.In addition, on unprocessed Noryl resin foam thin slice, form hole portion according to the method identical and obtained automobile inside material foam sheet A with embodiment 3.

In addition, the automobile inside material that obtains only is made up of the continuous air bubbles layer 1A that mainly is made of continuous air bubbles with the froth bed of the Noryl resin foam thin slice of processing through the hole 1 of foam sheet A, is formed with thick non-foam layer 13 for 0.1mm on two faces of this continuous air bubbles layer 1A.In addition, the thickness of the Noryl resin foam thin slice of processing through the hole is 5.4mm, and order is paid and is 500g/m ², density is 0.093g/cm ³, the continuous air bubbles rate of foam sheet integral body is 79.6%, and the continuous air bubbles rate of continuous air bubbles layer 1A is 92.6%, and mean air bubble diameter is 0.55mm.

In addition, the hole portion 2 of the Noryl resin foam thin slice of processing through the hole 1 adequate relief as shown in Figure 9 becomes black and white sub-box shape, and each hole portion 2 openend area is 0.50mm ², be 4.0mm deeply, hole portion 2 total aperture areas are 6.3% with respect to the automobile inside material with the ratio on foam sheet A surface, the length d of the square frame part 42 of imaginary grid 4 is 4mm.

(embodiment 6)

Except to carry out incorporate Noryl on two faces of unprocessed Noryl resin foam thin slice be that the thick gauge of resin flake is decided to be 119 μ m and replaces having obtained automobile inside material foam sheet in the same manner with embodiment 5 the 95 μ m being layered in.

(embodiment 7)

Except as Noryl being potpourri (the GE plastics society system trade name " NORYL EFN4230 " of resin use with polyphenylene oxide and polystyrene resin, polyphenylene oxide: 70 weight %, polystyrene resin: 64.3 weight portions 30 weight %), and polystyrene (Japan styrene society system trade name " HRM-26 ") 35.7 weight portions mix and the Noryl that forms is a resin (polyphenylene oxide composition: 45 weight %, polystyrene resin composition: 55 weight %, glass transition temperature Tg:142 ℃), the volatile foaming agent gauge is decided to be 3.5 weight portions replaces 3.9 weight portions, in second extruder, resin temperature is adjusted into 212 ℃ and replaces 206 ℃, the temperature of circular metal mould is defined as 189 ℃ to be replaced beyond 155 ℃, according to the method identical, extrude molten resin and foam with cylindric by the circular metal mould that is installed in the second extruder top with embodiment 1.These cylindric foams are extruded direction along it to cut, launches between the outside within it continuously.Then, on two faces of the unprocessed Noryl resin foam thin slice after just launching, directly be that resin flake carries out thermal welding and integrated with Noryl according to the method identical with embodiment 3.In addition, on unprocessed Noryl resin foam thin slice, form hole portion according to the method identical and obtained automobile inside material foam sheet A with embodiment 3.

In addition, the automobile inside material that obtains only is made up of the continuous air bubbles layer 1A that mainly is made of continuous air bubbles with the froth bed of the Noryl resin foam thin slice of processing through the hole 1 of foam sheet A, is formed with thick non-foam layer 13 for 0.1mm on two faces of this continuous air bubbles layer 1A.In addition, the thickness of the Noryl resin foam thin slice of processing through the hole 1 is 5.4mm, and order is paid and is 500g/m ², density is 0.093g/cm ³, the continuous air bubbles rate of foam sheet integral body is 78.6%, and the continuous air bubbles rate of continuous air bubbles layer 1A is 92.7%, and mean air bubble diameter is 0.49mm.

In addition, the hole portion 2 of the Noryl resin foam thin slice of processing through the hole 1 adequate relief as shown in Figure 9 becomes black and white sub-box shape, and each hole portion 2 openend area is 0.50mm ², be 4.0mm deeply, hole portion 2 total aperture areas are 6.3% with respect to the automobile inside material with the ratio on foam sheet A surface, the length d of the square frame part 42 of imaginary grid 4 is 4mm.

(embodiment 8)

(ケ レ Ha テ Star ケ society system order is paid 130g/m to the skin material 7 that constitutes at the nonwoven fabrics of being made up of dacron fibre ²) a face on, according to 30g/m ²Amount evenly to disperse pulverous ethylene-vinyl acetate copolymer be heat sealing adhesive (fusing point: 97 ℃).

Then, skin material 7 is heated to the temperature more than the fusing point of heat sealing adhesive, hold under the arm with the pressure of 0.7MPa by the two sides afterwards and press skin material 7, thereby heat sealing adhesive is anchored on the face of skin material 7 with the state that its part is immersed in the skin material 7.

Then, above-mentioned skin material 7 is overlapped the automobile inside material that is obtained by embodiment 3 uses the hole portion 2 of foam sheet A to form on the face, make this moment its tackifier set face be positioned at automobile inside material foam sheet A side, afterwards the automobile inside material is heated to foam sheet A more than the fusing point of heat sealing adhesive, then push the automobile inside material with foam sheet A and skin material 7 it to be carried out integrated from both sides.In addition, avoided the automobile inside material to be stopped up by heat sealing adhesive through adjustment with the hole portion 2 of foam sheet A.

(embodiment 9)

Obtained unprocessed Noryl resin foam thin slice 1 according to the method identical with embodiment 1.In the froth bed of this Noryl resin foam thin slice 1, on a face of the continuous air bubbles layer 11 of the thick 3.6mm that mainly constitutes, be formed with mainly the separated foam layer 12a of the thick 1.0mm that constitutes by separated foam by continuous air bubbles, be formed with mainly the separated foam layer 12b of the thick 0.6mm that is made of separated foam on another face of continuous air bubbles layer 11, order is paid and is 265g/m ²In addition, on separated foam layer 12a, 12b surface whole, be formed with non-foam layer 13,13.

In addition, the thickness of unprocessed Noryl resin foam thin slice 1 is 5.2mm, and density is 0.051g/cm ³, the continuous air bubbles rate is 61.3%, and the ratio of the continuous air bubbles that contains in continuous air bubbles layer 11 is 93%, and the ratio of the separated foam that contains in the separated foam layer 12 is 85%, and mean air bubble diameter is 0.54mm.

Then, prepared on a face, to embed the flat board that is provided with a plurality of nails, and nail that should flat board is pricked into from the separated foam layer 12a side of unprocessed Noryl resin foam thin slice 1, according to the form in the surperficial 1a arrival continuous air bubbles layer 11 of foam sheet 1, on a face of Noryl resin foam thin slice 1, formed a plurality of hole portion 2 of a plurality of planar rondures, promptly form a plurality of hole portion 2 of a plurality of planar rondures that are positioned at continuous air bubbles layer 11 in the surperficial 1a upper shed and the bottom 21 of foam sheet 1, and obtained automobile inside material foam sheet A thus.

In addition, the automobile inside material that formation obtains is 3.6mm with the thickness of the continuous air bubbles layer 11 of the Noryl resin foam thin slice of processing through the hole 1 of foam sheet A, the thickness of separated foam layer 12a is 1.0mm, and the thickness of separated foam layer 12b is 0.6mm, and order is paid and is 265g/m ²

In addition, the density of the above-mentioned Noryl resin foam thin slice of processing through the hole 1 is 0.051g/cm ³, whole continuous air bubbles rate is 62.5%, and the ratio of the continuous air bubbles that contains in continuous air bubbles layer 11 is 94%, and the ratio of the separated foam that contains in the separated foam layer 12 is 84%, and mean air bubble diameter is 0.54mm.

In addition, the hole portion 2 of the Noryl resin foam thin slice of processing through the hole 1 adequate relief as shown in Figure 9 becomes black and white sub-box shape, and each hole portion 2 openend area is 2.27mm ², be 4.7mm deeply, hole portion 2 total aperture areas are 7.1% with respect to the ratio on Noryl resin foam thin slice 1 surface, the length d of the square frame part 32 of imaginary grid 3 is 8mm.

On the other hand, as the nonwoven fabrics that constitutes surface sheets, two have been prepared by sisal fiber, with core be polyethylene terephthalate and sheath portion be poly core-sheath-type synthetic resin fiber form pass through nonwoven fabrics (the sisal fiber diameter: 150-250 μ m that wet type is copied the thickness constant of slurry manufactured, sisal fiber is long: 25mm, constitute the fusing point of the polyethylene terephthalate of core in the core-sheath-type synthetic resin fiber: 250 ℃, constitute the poly fusing point of sheath portion: 80 ℃, core-sheath-type synthetic resin fiber diameter: 2 dawn, the core-sheath-type synthetic resin fiber is long: 5mm, sisal fiber: core-sheath-type synthetic resin fiber (weight ratio)=40: 60, order is paid: 85g/m ², thick: 0.33mm).In addition, sisal fiber roughly is distributed in the nonwoven fabrics equably.

Then, on the face (hole portion form face 1a) of automobile inside material with foam sheet A, (Wu Yu テ Star ケ society system trade name " ゲ イ Na テ Star ケ LNS8050 ", order is paid: 50g/m by getting involved the shape sheet of being made up of heat sealing adhesive (polyamide-based tackifier) ²), above-mentioned nonwoven fabrics is stacked as surface sheets, on automobile inside material another face with foam sheet A, (ケ ラ ボ ウ society system trade name " X-2200 ", order is paid: 24g/m by getting involved the film of being made up of heat sealing adhesive (polyolefin tackifier) simultaneously ²), above-mentioned nonwoven fabrics is stacked as surface sheets, thus the stacked thin slice of nonwoven fabrics made.

Then, between the opposite face of the belt up and down (temperature: 135-145 ℃) of the teflon system that keeps predetermined distance on the direction up and down and stand facing each other, supply with the stacked thin slice of above-mentioned nonwoven fabrics, make the heat sealing adhesive fusing of the stacked thin slice of nonwoven fabrics on one side, one side is difference compressive surface thin slice on two faces of automobile inside material usefulness foam sheet A, thereby it is stacked integrated on two faces of automobile inside material with foam sheet A surface sheets to be carried out.In addition, the automobile inside material is 5.9mm with the thickness of foam sheet A integral body, and whole order is paid and is 509g/m ²

(embodiment 10)

(order is paid: 180g/m to have prepared the nonwoven fabrics be made up of dacron fibre as skin material ², thick: 1.0mm).Then, carrying out on the stacked incorporate surface sheets with the formation face 1a side of the hole portion among the foam sheet A according to automobile inside material with the making of embodiment 9 same procedure, (Wu Yu テ Star Network society system trade name " ゲ イ Na テ Star ケ LNS8050 ", order is paid: 50g/m by getting involved the shape sheet of being made up of heat sealing adhesive (polyamide-based tackifier) ²), stacked above-mentioned skin material.

Then, between the opposite face of the belt up and down (temperature: 135-145 ℃) of the teflon system that keeps predetermined distance on the direction up and down and stand facing each other, supply with automobile inside material foam sheet A, make the heat sealing adhesive fusing on one side, on one side at the face upper edge thickness direction extruding skin material of automobile inside material with foam sheet A, thus the automobile inside material with the face of foam sheet A on stacked skin material carried out integrated.The automobile inside material is 6.9mm with the thickness of foam sheet A, and order is paid and is 739g/m ²The automobile inside material has gas penetration potential with the hole portion 2 of foam sheet A with ambient atmosphere.

(embodiment 11)

Replace 3.9 weight portions except volatile foaming agent being defined as 3.5 weight portions, in second extruder, resin temperature is adjusted into 205 ℃ and replaces 206 ℃, the temperature of circular metal mould is defined as 180 ℃ replaces beyond 155 ℃, obtained unprocessed Noryl resin foam thin slice in the same manner with embodiment 1.

In addition, the thickness of unprocessed Noryl resin foam thin slice is 5.0mm, and density is 0.060g/cm ³, the continuous air bubbles rate is 81.4%, and mean air bubble diameter is 0.57mm, and order is paid and is 300g/m ²

In addition, the continuous air bubbles layer 1A that the froth bed of unprocessed Noryl resin foam thin slice 1 is 4.8mm by the main thickness that is made of continuous air bubbles only forms, and a whole respectively ground is formed with thick non-foam layer 13,13 for 0.1mm on two faces of this continuous air bubbles layer 1A.Then, on a face of unprocessed Noryl resin foam thin slice 1, form hole portion 2 according to the method identical, thereby obtained automobile inside material foam sheet A with embodiment 9.

In addition, the thickness of the Noryl resin foam thin slice of processing through the hole 1 is 5.0mm, and order is paid and is 300g/m ², density is 0.060g/cm ³, the continuous air bubbles rate of foam sheet integral body is 82.5%, mean air bubble diameter is 0.57mm.

In addition, the hole portion 2 of the Noryl resin foam thin slice of processing through the hole 1 adequate relief as shown in Figure 9 becomes black and white sub-box shape, and each hole portion 2 openend area is 0.64mm ², be 4.0mm deeply, hole portion 2 total aperture areas are 3.5% with respect to the ratio on Noryl resin foam thin slice 1 surface, the length d of the square frame part 32 of imaginary grid 3 is 6mm.

On the other hand, the core-sheath-type synthetic resin fiber that mestha (kenaf) fiber and core and sheath portion are polyethylene terephthalate is supplied to carding machine and makes fleece (web), make styrene-butylene copolymer (SBR resin) impregnated in this fleece and make its drying, thereby two nonwoven fabrics (kenaf diameters: 50-130 μ m that become surface sheets have been made, kenaf is long: 76mm, constitute the fusing point of the polyethylene terephthalate of core in the core-sheath-type synthetic resin fiber: 255 ℃, constitute the fusing point of the polyethylene terephthalate of sheath portion: 110 ℃, core-sheath-type synthetic resin fiber diameter: 2 dawn, the core-sheath-type synthetic resin fiber is long: 51mm, kenaf: core-sheath-type synthetic resin fiber (weight ratio)=80: 20, order is paid: 78g/m ², thick: 0.45mm, styrene-butylene copolymer content: 8.3g/m ²).

Afterwards, on whole an of face of nonwoven fabrics, to make EVA be heat sealing adhesive powder (potpourri of ethylene-vinyl acetate copolymer and straight-chain low density polyethylene, fusing point: 100 ℃) according to being 35.5 weight portion (27.7g/m with respect to nonwoven fabrics 100 weight portions ²) ratio evenly disperse.

Then, be that the nonwoven fabrics of heat sealing adhesive powder is heated to 120 ℃ with being dispersed with EVA, this nonwoven fabrics is supplied between a pair of chill roll compresses afterwards, thereby heat sealing adhesive be impregnated in whole of nonwoven fabrics along thickness direction.

Then, the stacked respectively nonwoven fabrics that has flooded heat sealing adhesive has been made the stacked thin slice of nonwoven fabrics as surface sheets on two faces of Noryl resin foam thin slice 1.Then, supply with the stacked thin slice of above-mentioned nonwoven fabrics between the opposite face of the belt up and down (temperature: 135-145 ℃) of the teflon system that keeps predetermined distance on the direction up and down and stand facing each other, make the heat sealing adhesive fusing in the surface sheets in the stacked thin slice of nonwoven fabrics on one side, one side is difference compressive surface thin slice on two faces of automobile inside material usefulness foam sheet A, thereby it is stacked integrated on two faces of foam sheet surface sheets to be carried out.In addition, the automobile inside material is 5.9mm with the thickness of foam sheet A integral body, and whole order is paid and is 528g/m ²

(comparative example 1)

Except the resin temperature in second extruder is adjusted into 202 ℃, the volatile foaming agent gauge is decided to be beyond 3.3 weight portions, obtained unprocessed Noryl resin foam thin slice 1 in the same manner with embodiment 1.In the froth bed of this unprocessed Noryl resin foam thin slice, on a face of the continuous air bubbles layer 11 that mainly constitutes by continuous air bubbles, be formed with the separated foam layer 12a that mainly constitutes by separated foam, on another face of continuous air bubbles layer 11, be formed with the separated foam layer 12b that mainly constitutes by separated foam.In addition, on separated foam layer 12a, 12b surface whole, be formed with non-foam layer 13,13.Then, on this unprocessed Noryl resin foam thin slice, formed a plurality of hole portion 2 according to the method identical, thereby obtained automobile inside material foam sheet A with embodiment 1.

In addition, the automobile inside material that formation obtains is 1.8mm with the thickness of the continuous air bubbles layer 11 of the Noryl resin foam thin slice of processing through the hole 1 of foam sheet A, and the thickness of separated foam layer 12a is 1.0mm, and the thickness of separated foam layer 12b is 1.2mm.

In addition, the thickness of the above-mentioned Noryl resin foam thin slice of processing through the hole 1 is 4.0mm, and order is paid and is 210g/m ², density is 0.053g/cm ³, whole continuous air bubbles rate is 48.1%, and the ratio of the continuous air bubbles that contains in continuous air bubbles layer 11 is 90.6%, and the ratio of the separated foam that contains in separated foam layer 12 is 81%, and mean air bubble diameter is 0.49mm.

(comparative example 2)

Except the resin temperature in second extruder is adjusted into 202 ℃, the volatile foaming agent gauge is decided to be 3.3 weight portions, the temperature of circular metal mould is defined as beyond 157 ℃, has obtained unprocessed Noryl resin foam thin slice 1 in the same manner with embodiment 1.

In addition, in the froth bed of the unprocessed Noryl resin foam thin slice 1 that obtains, on a face of the continuous air bubbles layer 11 of the thick 1.8mm that mainly constitutes by continuous air bubbles, be formed with mainly the separated foam layer 12a of the thick 1.0mm that constitutes by separated foam, on another face of continuous air bubbles layer 11, be formed with mainly the separated foam layer 12b of the thick 1.2mm that constitutes by separated foam.

In addition, the thickness of above-mentioned unprocessed Noryl resin foam thin slice 1 is 4.0mm, and order is paid and is 210g/m ², density is 0.053g/cm ³, the continuous air bubbles rate is 48.1%, and the ratio of the continuous air bubbles that contains in continuous air bubbles layer 11 is 90.6%, and the ratio of the separated foam that contains in separated foam layer 12 is 81%, and mean air bubble diameter is 0.49mm.

Then, on a face of unprocessed Noryl resin foam thin slice 1, formed hole portion 2 according to the method identical, thereby obtained automobile inside material foam sheet A with embodiment 1.In addition, the hole portion 2 of Noryl resin foam thin slice 1 adequate relief as shown in Figure 9 becomes black and white sub-box shape, and each hole portion 2 openend area is 3.14mm ², be 3.7mm deeply, hole portion 2 total aperture areas are 9.8% with respect to the ratio on Noryl resin foam thin slice 1 surface, the length d of the square frame part 32 of imaginary grid 3 is 8mm.

Then, it is stacked integrated according to the method identical with embodiment 11 surface sheets to be carried out at the automobile inside material respectively on two faces of foam sheet A.In addition, the automobile inside material is 4.9mm with the integral thickness of foam sheet A, and whole order is paid and is 438g/m ²

With foam sheet with make the automobile inside material carry out second time of foaming with foam sheet and the sound absorption properties and the automobile inside material of the secondary frothing forming product that obtain are measured according to following method with the formability of foam sheet, it the results are shown in shows among 1-6 and Figure 20-23 to the automobile inside material that obtains as described above.In addition, measured the linear expansivity of the automobile inside material of embodiment 2,9-11 and comparative example 2 with foam sheet A.Wherein, the automobile inside material of embodiment 2 is 48.20 * 10 with the linear expansivity of foam sheet ⁶/ ℃.

(sound absorption properties)

For the secondary frothing forming product that the automobile inside material obtains with making the automobile inside material carry out second time of foaming with foam sheet A with foam sheet A,, measured sound absorption properties by the transmission coefficient method of testing based on the vertical incidence acoustic absorptivity of ASTM E1050.Being specially, under the condition of no back air space, is that the sound wave of 500-6300Hz is injected the automobile inside material with having measured the vertical incidence acoustic absorptivity foam sheet A and the secondary frothing forming product from hole portion 2 open side with frequency.In addition, the automobile inside material with the sound absorption properties of foam sheet A be shown in table 1,3 and Figure 20,22 in, the sound absorption properties of secondary frothing forming product be shown in table 2,4 and Figure 21,23 in.

In addition, the secondary frothing forming product have been obtained by following method.That is, the automobile inside material is heated to its surface temperature with foam sheet A reaches table 5, the temperature shown in 6 and make it freely carry out second time of foaming.When the automobile inside material reaches table 5 with the surface temperature of foam sheet A, during temperature shown in 6, finish the thickness of the automobile inside material behind the second time of foaming with foam sheet A has been measured in the heating of automobile inside material with foam sheet A.Repeat 3 times aforesaid operations, the arithmetic mean of the thickness of three blocks of automobile inside materials after with foam sheet A second time of foaming is defined as thickness behind the second time of foaming.

Then, it is table 5 that the automobile inside material is heated to its surface temperature with foam sheet A, the temperature shown in 6.Then, this automobile inside material is configured in opposite face with foam sheet A to form between the pair of plates shape metal pattern of even surface, clamp the tabular metal pattern afterwards, the automobile inside material is carried out compression molding with foam sheet A along thickness direction, the thickness that has the foam sheet A of separated foam layer in froth bed reaches 90% of thickness behind the second time of foaming, and the thickness of the foam sheet A that froth bed only is made up of the continuous air bubbles layer reaches 95% of thickness behind the second time of foaming, cools off simultaneously.When the automobile inside material is the glass transition temperature Tg of resin also during low 50 ℃ temperature with the surface temperature of foam sheet A than the Noryl that constitutes foam sheet 1, open pair of plates shape metal pattern, thereby obtain the secondary frothing forming product.In addition, in above-mentioned method,, measured the temperature of the one side that is not laminated with surfacing 7 for the automobile inside material foam sheet A of embodiment 8,10.

At table 5, the integral thickness of secondary frothing forming product, the thickness of continuous air bubbles layer, the thickness of separated foam layer (comprising non-foam layer), the long d of square frame part, the total aperture area of openend area and the hole portion ratio surperficial with respect to the secondary frothing forming product of hole portion have been shown in 6.

In addition, when the secondary frothing forming product are measured above-mentioned assessment item, according to carrying out with the identical method of the measuring method in the foam sheet with the automobile inside material, in the table 5,6, the thickness of separated foam layer is according to the order record of separated foam layer 12a, separated foam layer 12b.In addition, in embodiment 8-11, when carrying out the measurement about hole portion, with skin material 7 and surface sheets 5 from secondary frothing forming product sur-face peeling, remove and carried out the measurement of above-mentioned project after hole portion is exposed.

(formability)

(ケ レ Ha テ Star ケ society system order is paid 130g/m to the skin material 7 that constitutes at the nonwoven fabrics of being made up of dacron fibre ²) a face on according to 30g/m ²Amount evenly to disperse pulverous ethylene-vinyl acetate copolymer be heat sealing adhesive (fusing point: 97 ℃).

Then, skin material 7 is heated to the temperature more than the fusing point of heat sealing adhesive, hold pressure skin material 7 under the arm from the two sides with the pressure of 0.7MPa afterwards, thereby heat sealing adhesive is anchored on the face of skin material 7 with the states that its part is submerged in the skin material 7.

Then, above-mentioned skin material 7 is overlapped on the hole portion 2 formation faces of automobile inside material with foam sheet A, make this moment its tackifier set face be positioned at automobile inside material foam sheet A side, simultaneously on automobile inside material another face with foam sheet A, the stacked anti-noise material 8 that constitutes by nonwoven fabrics (forming) (Japan weaving society system trade name " エ ケ-レ 6151A ") by dacron fibre, this moment the heat sealing adhesive powder that on whole of these anti-noise material 8 single faces, roughly evenly adheres to relative with automobile inside material usefulness foam sheet A to, thereby made duplexer.In addition, for the automobile inside material foam sheet A of embodiment 8,10, only on another face, make anti-noise material 8 carry out the stacked duplexer of having made according to the method described above.

Then, above-mentioned duplexer is supplied between a pair of belt of teflon system that surface temperature remains 135-145 ℃, this duplexer is added hot compression from its two sides along thickness direction, thereby stacked skin material 7 carries out integratedly on the face of automobile inside material with foam sheet A, and stacked noise control sound material 8 has carried out integrated on another face.

Intercept the test film of stipulating shape with foam sheet A from skin material 7 and the stacked as described above incorporate automobile inside material of anti-noise material 8, and heat this test film, so that the surface temperature on its two sides reaches table 5, temperature shown in 6, thus the moulding product B of the shape that hat brim part as shown in Figure 19 prolongs to outside direction from the circumference along continuous straight runs of upper end-face edge that the bottom tube-like body is arranged obtained.Then, the detect by an unaided eye outward appearance of moulding product B and estimate according to following standard.In addition, being positioned at inboard mode according to the automobile inside material with the skin material 7 of foam sheet A forms.In Figure 19, omitted the detailed layer structure of moulding product B.

Zero ... moulding product B do not break and thickness also roughly even.

* ... it is in uneven thickness that moulding product B produces the while of breaking.

[table 1]

Frequency (Hz)	Embodiment 1	Embodiment 2	Embodiment 3	Embodiment 4	Embodiment 5	Embodiment 6	Embodiment 7	Embodiment 8	Comparative example 1
										500	0.061	0.063	0.053	0.059	0.050	0.046	0.048	0.067	0.033
630	0.068	0.071	0.087	0.083	0.072	0.067	0.068	0.087	0.036
										800	0.089	0.095	0.101	0.105	0.085	0.079	0.083	0.115	0.040
1000	0.105	0.124	0.134	0.145	0.117	0.105	0.113	0.163	0.040
										1250	0.137	0.179	0.188	0.207	0.166	0.147	0.161	0.232	0.050
1600	0.175	0.266	0.271	0.303	0.247	0.217	0.244	0.350	0.055
										2000	0.228	0.390	0.396	0.424	0.378	0.331	0.379	0.492	0.057
2500	0.299	0.496	0.572	0.535	0.589	0.526	0.598	0.595	0.065
										3150	0.387	0.489	0.705	0.555	0.808	0.766	0.815	0.564	0.075
4000	0.480	0.398	0.672	0.556	0.778	0.809	0.759	0.609	0.088
										5000	0.557	0.311	0.770	0.687	0.707	0.789	0.673	0.592	0.090
6300	0.593	0.400	0.501	0.575	0.620	0.699	0.692	0.393	0.012

[table 2]

Frequency (Hz)	Embodiment 1	Embodiment 2	Embodiment 3	Embodiment 4	Embodiment 5	Embodiment 6	Embodiment 7	Embodiment 8	Comparative example 1
										500	0.060	0.038	0.045	0.049	0.050	0.050	0.048	0.069	0.033
630	0.064	0.047	0.047	0.058	0.058	0.067	0.066	0.079	0.036
										800	0.083	0.060	0.064	0.073	0.075	0.086	0.079	0.105	0.040
1000	0.097	0.076	0.084	0.096	0.090	0.113	0.108	0.133	0.035
										1250	0.123	0.111	0.106	0.128	0.124	0.160	0.142	0.177	0.043
1600	0.145	0.146	0.141	0.180	0.171	0.233	0.196	0.238	0.046
										2000	0.170	0.190	0.189	0.257	0.245	0.340	0.282	0.328	0.048
2500	0.204	0.262	0.278	0.401	0.378	0.511	0.442	0.441	0.051
										3150	0.254	0.370	0.462	0.663	0.618	0.726	0.710	0.522	0.056
4000	0.339	0.499	0.774	0.876	0.876	0.794	0.911	0.609	0.078
										5000	0.485	0.623	0.987	0.858	0.934	0.821	0.866	0.659	0.070
6300	0.623	0.862	0.894	0.746	0.767	0.690	0.743	0.574	0.009

[table 3]

Frequency (Hz)	Embodiment 9	Embodiment 11	Comparative example 2
				500	0.06	0.05	0.03
630	0.07	0.05	0.04
				800	0.09	0.07	0.04
1000	0.12	0.10	0.04
				1250	0.18	0.15	0.05
1600	0.26	0.22	0.06
				2000	0.40	0.33	0.06
2500	0.57	0.55	0.07
				3150	0.60	0.82	0.08
4000	0.47	0.81	0.09
				5000	0.46	0.63	0.09
6300	0.73	0.53	0.01

[table 4]

Frequency (Hz)	Embodiment 9	Embodiment 10	Embodiment 11	Comparative example 2
					500	0.06	0.08	0.05	0.03
630	0.07	0.10	0.06	0.04
					800	0.11	0.13	0.07	0.04
1000	0.16	0.16	0.09	0.04
					1250	0.21	0.19	0.13	0.04
1600	0.24	0.20	0.17	0.05
					2000	0.29	0.22	0.25	0.05
2500	0.36	0.23	0.42	0.05
					3150	0.44	0.28	0.67	0.06
4000	0.61	0.50	0.81	0.08
					5000	0.64	0.35	0.76	0.07
6300	0.49	0.34	0.70	0.01

[table 5]

	Embodiment 1	Embodiment 2	Embodiment 3	Embodiment 4	Embodiment 5	Embodiment 6	Embodiment 7	Embodiment 8	Comparative example 1
										Surface temperature (℃)	140	140	132	132	132	130	130	130	140
Integral thickness (mm)	5.7	4.8	5.4	5.5	5.9	5.8	5.9	5.6	4.8
										The thickness of continuous air bubbles layer (mm)	3.6	3.0	5.2	5.3	5.7	5.6	5.7	4.8	1.7
The thickness of separated foam layer (mm)	0.8/1.3	0.6/ 1.2	-	-	-	-	-	-	1.4/ 1.7
										Square frame partial-length d (mm)	8	8	4	5.3	4	4	4	4	8
Openend area (the mm of hole portion 2)	3.46	6.15	0.97	1.18	1.01	0.92	0.96	0.97	3.46
										Total aperture area ratio (%)	10.8	19.2	12.2	8.4	12.6	11.5	12.1	12.2	10.8
Formability	○	○	○	○	○	○	○	○	○

[table 6]

	Embodiment 9	Embodiment 10	Embodiment 11	Comparative example
					Surface temperature (℃)	140	140	140	140
Integral thickness (mm)	6.5	7.2	5.7	5.6
					The thickness of continuous air bubbles layer (mm)	3.5	3.0	4.7	1.4
The thickness of separated foam layer (mm)	1.3/0.9	1.3/0.8	-	1.6/1.8
					Square frame partial-length d (mm)	8	8	6	8
Openend area (the mm of hole portion 2)	2.54	2.54	1.27	3.46
					Total aperture area ratio (%) of hole portion	7.9	7.9	7.0	10.8
Formability	○	○	○	○
					Linear expansivity (* 10 6/℃)	9.54	9.01	12.20	13.10

Industrial utilizability

Sheet for interior material of the present invention uses foam sheet applicable to sheet for interior material purposes such as roof of the vehicle material, door members.

Claims (17)

1. automobile inside material foam sheet, it is characterized in that, be to be stacked integrated formation of resin flake with non-foam Noryl on two faces of the Noryl resin foam thin slice more than 50% in the continuous air bubbles rate, the froth bed of above-mentioned Noryl resin foam thin slice has the continuous air bubbles layer that mainly is made of continuous air bubbles, the Noryl that hole portion is opened on an above-mentioned side is on the surface of resin flake, and above-mentioned hole portion extends to the continuous air bubbles layer.

2. automobile inside material foam sheet as claimed in claim 1, it is characterized in that, on the face of automobile inside material, stacked and integrated by the surface sheets of forming by the nonwoven fabrics that contains form maintenance fiber and thermoplastic resin fibre with the porose portion of formation in the foam sheet.

3. automobile inside material foam sheet as claimed in claim 1 is characterized in that, the froth bed of Noryl resin foam thin slice only is made up of the continuous air bubbles layer that mainly is made of continuous air bubbles.

4. automobile inside material foam sheet as claimed in claim 1, it is characterized in that, in the froth bed of Noryl resin foam thin slice, on two faces of the continuous air bubbles layer that mainly constitutes, be formed with the separated foam layer that mainly constitutes by separated foam by continuous air bubbles.

5. automobile inside material foam sheet as claimed in claim 1 is characterized in that the continuous air bubbles rate is 60-90%.

6. automobile inside material foam sheet as claimed in claim 4 is characterized in that the thickness of separated foam layer is the 1-25% of Noryl resin foam sheet thickness.

7. automobile inside material foam sheet as claimed in claim 1 is characterized in that, total aperture area of hole portion is 2-50% with respect to the automobile inside material with the ratio on foam sheet surface.

8. automobile inside material foam sheet as claimed in claim 1 is characterized in that the openend area of hole portion is 0.2-40mm ²

9. automobile inside material foam sheet as claimed in claim 1 is characterized in that, the Noryl that constitutes Noryl resin foam thin slice is in the resin, and the phenylate composition is that 15-60 weight % and styrene composition are 40-85 weight %.

10. automobile inside material foam sheet as claimed in claim 1 is characterized in that, the Noryl that constitutes non-foam Noryl and be resin flake is in the resin, and the phenylate composition is that 10-50 weight % and styrene composition are 50-90 weight %.

11. automobile inside material foam sheet as claimed in claim 1 is characterized in that, is to contain rubber constituent in the resin flake at non-foam Noryl.

12. automobile inside material foam sheet as claimed in claim 2, it is characterized in that, it is at least a fiber that is selected from glass fibre, carbon fiber, basalt fibre and the natural fiber that form keeps fiber, the Noryl of while thermoplastic resin fibre's fusing point Tm and formation Noryl resin foam thin slice is that the glass transition temperature Tg of resin satisfies following formula

Tg-65℃≤Tm≤Tg+40℃。

13. automobile inside material foam sheet as claimed in claim 2 is characterized in that, and is by getting involved adhesive layer that the automobile inside material is integrated with foam sheet and surface sheets.

14. automobile inside material foam sheet as claimed in claim 13 is characterized in that, the tackifier that constitutes adhesive layer is submerged in the whole surface sheets.

15. automobile inside material foam sheet as claimed in claim 1, it is characterized in that, above-mentioned automobile inside material with a face of foam sheet on stacked skin material carry out the incorporate while, stacked noise control sound material and carry out integrated and form on above-mentioned automobile inside material another face with foam sheet.

16. an automobile inside material is characterized in that, by each described automobile inside material among the claim 1-15 is formed with the foam sheet thermoforming.

17. automobile inside material as claimed in claim 16 is characterized in that, the automobile inside material is the roof of the vehicle material.

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