JP2002137306A - Foamed composite material for interior finishing for automobile and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a foamed composite material for interior finishing for automobile having a light weight, high rigidity and excellent dimensional stability and capable of recycling and a method for manufacturing the same. SOLUTION: The method for manufacturing the foamed composite material for interior finishing the automobile comprises the steps of molding a composition for forming a foamable sheet containing a propylene resin (A) of 100 pts.wt. containing an ethylene propylene copolymer segment having a limiting viscosity of 2 to 8 dl/g of 3 to 30 wt.% and a crystalline polypropylene segment of 70 to 97 wt.% and an ethylene content of 3 to 30 mole %, a radical generating agent (B) of 0.01 to 0.1 pts.wt., a crosslinking assistant (C) of 0.1 to 5 pts.wt., and a foaming agent (D) of 2 to 5 pts.wt. in a sheet-like state at a temperature for not decomposing the agent (D), adhering and integrating a nonwoven fabric (E) containing glass fibers as a main component to and with at least one side surface of the obtained foamable sheet, then heating the sheet to a temperature for decomposing the agent (D) to form the agent, then placing a skin material before cooling and solidifying the sheet, and press molding the sheet.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foamed composite material for an automobile interior and a method for producing the same, and more particularly, to a recyclable polypropylene foam molded article which is lightweight, has high rigidity, has excellent dimensional stability, and is recyclable. The present invention relates to a foamed composite material for an automobile interior and a method for producing the same.

[0002]

BACKGROUND OF THE INVENTION Foams of propylene-based resins such as polypropylene generally have better physical properties such as heat resistance, strength and rigidity than polyethylene foams. Applications as building materials and lightweight structural materials are expanding. By the way, the existing polypropylene foam is a high foam having an expansion ratio of 15 to 40 times, and is a flexible foam mainly composed of a soft propylene random copolymer. On the other hand, a polypropylene foam as a base material (aggregate) for an automobile interior is required to be lightweight and highly rigid.

[0003] Substrates for automobile interiors, for example, base materials for automobile ceiling materials include paper corrugated cardboard, composite materials of urethane foam and glass fiber, resin felt obtained by combining fiber and thermosetting resin, and glass fiber. There are many base materials, such as a material using polyethylene or polypropylene as a binder, and Dailark ^™ using a polystyrene foam.

However, in molded ceiling materials for automobiles,
Lightweight, high rigidity, excellent dimensional stability, excellent acoustic characteristics, low cost, freedom of molding, not polluting the environment during molding, recycling What is possible (recyclability),
A wide variety of designs (designability) and easy mounting work are required, and each of the above base materials has advantages and disadvantages, and few materials satisfy all of the above requirements. In recent years, in particular, the importance of recyclability has been emphasized in view of global environmental issues. Currently, some base materials for automotive ceiling materials that satisfy recyclability are used, but these base materials are It has not yet become mainstream from problems.

[0005] Also, Japanese Patent Application Laid-Open No. 5-70621 discloses that
The following method for producing a polypropylene foam molded article has been proposed. That is, a foamable sheet-forming composition including a propylene-based resin composed of a propylene block copolymer, a radical generator, a crosslinking aid and a foaming agent is formed into a sheet at a temperature at which the foaming agent does not decompose. After laminating a backing material on one side of the foamable sheet or laminating a skin material having a function as a backing material and integrating them, the foamable sheet is irradiated with ionizing radiation to crosslink the propylene resin, and then A method for producing a foamed molded article, characterized in that the foamable sheet is heated and foamed, and simultaneously molded. According to such a manufacturing method, it is possible to obtain a composite foam molded article which is lightweight, has such strength and high rigidity that it can be used as a base material (aggregate), and is used as a base material for interior materials such as automobiles. According to the method described above, it is described in the above-mentioned publication that a trunk room material and a door trim can be specifically obtained.However, when a fluffy sheet, a velvet-raised sheet or the like is used as a skin material In this case, the raised material on the surface of the skin material falls down, and the texture of the skin surface of the foam molded product is not always satisfactory.

Therefore, it is lightweight and has high rigidity, dimensional stability, acoustic characteristics, molding environment, design, texture of the skin surface,
There has been a demand for a method capable of producing an inexpensive interior material for an automobile having excellent workability and recyclability and having a high degree of freedom in molding, and the emergence of a composite molded material thereof.

[0007]

SUMMARY OF THE INVENTION An object of the present invention is to solve the problems associated with the prior art as described above, and to provide a foam composite material for automobile interiors which is lightweight, has high rigidity, and has excellent dimensional stability, and a method for producing the same. It is intended to provide.

[0008]

SUMMARY OF THE INVENTION A method for producing a foamed composite material for automobile interiors according to the present invention comprises the following propylene resin (A): 100 parts by weight, radical generator (B): 0.01 to 0.1 parts by weight, 0.1 to 5 parts by weight of a crosslinking assistant (C) and a foaming agent (D)
The foaming sheet-forming composition containing 2 to 5 parts by weight is formed into a sheet at a temperature at which the foaming agent (D) does not decompose, and at least one surface of the obtained foamable sheet contains glass fiber as a main component. The nonwoven fabric (E) to be bonded is bonded and integrated to form a foamable sheet composite, and then the foamable sheet composite is heated to a temperature at which the foaming agent (D) is decomposed and foamed. A method for producing a foamed composite material for automobile interiors, wherein a skin material is placed on the surface of the foamed sheet composite before the composite is cooled and solidified; and a press molding process is performed; propylene-based resin (A): 135 ° C. Ethylene / propylene copolymer segments having an intrinsic viscosity [η] measured in decalin in the range of 2 to 8 dl / g are 3% by weight or more and less than 30% by weight, and crystalline polypropylene segments are more than 70% by weight and 97% by weight or less. Consists, propylene block copolymer ethylene content is less than 3 mol% to 30 mol% (A-1).

In the present invention, the propylene resin (A)
(A-2) 5 to 30% by weight of an ethylene / propylene copolymer segment having an intrinsic viscosity [η] of 2 to 8 dl / g measured in decalin at 135 ° C. and 70 to 95% by weight of a crystalline polypropylene segment % Of a propylene block copolymer having an ethylene content in the range of 10 to 30 mol%: 30 to 100 parts by weight, and (A-3)
Melt flow rate (MFR, ASTM D-1238,
L, 230 ° C, 2.16 kg load, the same applies hereinafter)
Propylene homopolymer of -20 g / 10 min: 70-0
Parts by weight (however, the total amount of the propylene block copolymer (A-2) and the propylene homopolymer (A-3) is 100 parts by weight), and the MFR is 0.5 to 20 g / 10.
Propylene resin composition (A-4) in the range of minutes.

In the present invention, the propylene block copolymer (A-2) has an (A-5) MFR of 0.5 to 10 g / 10
Propylene block copolymer having a relatively high molecular weight in the range of 10 to 100 parts by weight, and (A-6) MFR
Is in the range of 10 to 80 g / 10 minutes, a relatively low molecular weight propylene block copolymer: an amount of 0 to 90 parts by weight (provided that the propylene block copolymer (A-5) and the propylene block copolymer ( A-6) is 100 parts by weight.).

The nonwoven fabric (E) containing glass fibers as a main component includes, for example, glass fibers alone or a mixture of glass fibers and thermoplastic resin fibers.
The foamable sheet composite comprises a propylene-based resin (A) 1
The glass fiber (F) having an average fiber diameter in the range of 5 to 25 μm and a fiber length of 0.1 to 30 mm is contained, for example, in an amount of 1 to 15 parts by weight with respect to 00 parts by weight. In the foamable sheet composite, a part of the glass fibers (F) may be contained in the foamable sheet, for example, in a range not exceeding 3 parts by weight.

The foamable sheet-forming composition may further comprise, in addition to the propylene resin (A), the radical generator (B), the crosslinking assistant (C) and the foaming agent (D), an unsaturated carboxylic acid or its unsaturated carboxylic acid. Modified polypropylene (G) obtained by graft polymerization of a derivative may be contained in an amount of 1 to 10 parts by weight. In the present invention, when the nonwoven fabric (E) containing glass fiber as a main component is bonded to and integrated with the foamable sheet, a film made of a modified polypropylene obtained by graft-polymerizing an unsaturated carboxylic acid or a derivative thereof is formed by foaming. It may be interposed between the sheet and the nonwoven fabric (E) containing glass fiber as a main component.

In the present invention, the foamable sheet is heated at a decomposition temperature of the foaming agent (D) so that the propylene resin (A) is heated.
Before the step of crosslinking the propylene resin (A), a step of irradiating the foamable sheet with ionizing radiation at 2 to 10 kGy to crosslink the propylene-based resin (A) may be performed. The foamed composite material for an automobile interior according to the present invention comprises the propylene block copolymer (A-1) or the propylene composition (A-
4) The propylene resin (A) is crosslinked,
The gel fraction is 1 to the weight of the propylene resin (A).
One of a crosslinked foamed sheet composite in which a nonwoven fabric (E) containing glass fiber as a main component is bonded to at least one surface thereof, which is 10% by weight and expands mainly in the thickness direction and has a magnification of 5 to 10 times. Is characterized in that a skin material is laminated on the surface of.

The foamable sheet is prepared by adding a modified polypropylene (G) obtained by graft polymerization of an unsaturated carboxylic acid or a derivative thereof to 100 parts by weight of the propylene resin (A).
It may be included in an amount of from 10 to 10 parts by weight. Further, between the crosslinked foamed sheet and the nonwoven fabric (E) containing glass fiber as a main component, a layer made of modified polypropylene obtained by graft-polymerizing an unsaturated carboxylic acid or a derivative thereof may be provided.

[0015]

DETAILED DESCRIPTION OF THE INVENTION Hereinafter, the foamed composite material for an automobile interior according to the present invention and a method for producing the same will be specifically described. In the method for producing a foamed composite material for an automobile interior according to the present invention, the propylene resin (A) and the radical generator (B)
The composition for forming a foamable sheet, comprising a crosslinking aid (C) and a foaming agent (D), is formed into a sheet to form a foamable sheet, and the foamable sheet and glass fibers are the main components. A nonwoven fabric (E) is bonded and integrated to form a foamable sheet composite, and then the foamable sheet composite is heated and foamed, and a skin material is placed on the surface of the foamed sheet composite. And press forming.

First, the composition for forming a foamable sheet, the nonwoven fabric (E) containing glass fiber as a main component, and the skin material used in the present invention for producing the foam composite material for automobile interior will be described. Foamable sheet forming composition The foamable sheet composite used in the present invention comprises a propylene-based resin (A), a radical generator (B), and a crosslinking assistant (C).
And a foaming agent (D), if necessary, modified polypropylene (G), and further additives such as a heat stabilizer and a coloring agent in some cases.

((A) Propylene Resin) The propylene resin (A) used in the present invention may be a so-called non-polymer blend type (ie, chemical blend type) propylene block copolymer (A-1). Alternatively, it may be a polymer blend type, that is, a propylene resin composition (A-4) composed of a propylene block copolymer (A-2) and a propylene polymer (A-3).

The propylene block copolymer (A-1) used as the propylene resin (A) in the present invention
Specifically, the intrinsic viscosity [η] measured in decalin at 135 ° C. is 2 to 8 dl / g, preferably 3 to 6 dl / g.
Is a propylene block copolymer comprising 3% by weight or more and less than 30% by weight of an ethylene / propylene copolymer segment and more than 70% by weight and 97% by weight or less of a crystalline polypropylene segment. This ethylene / propylene copolymer segment has low crystallinity or rubbery properties.

The crystalline polypropylene segment comprises:
A small amount of a crystalline polyethylene component may be contained within a range that does not impair the purpose of the present invention. More specifically, this crystalline polypropylene segment is composed of 80-100% by weight of crystalline polypropylene and 0-2% of crystalline polyethylene.
0% by weight. Also, a small amount of α-olefin component units such as ethylene and propylene may be contained in the crystalline polypropylene or crystalline polyethylene. For example, crystalline polypropylene may include a small amount of ethylene component units, and crystalline polyethylene may include a small amount of propylene component units.

This propylene block copolymer (A-1)
Is 3 mol% or more and less than 30 mol%, preferably 5 mol% or more and less than 25 mol%. When a propylene block copolymer (A-1) having an ethylene content within the above range is used as the propylene resin (A), the crosslinking of the propylene resin proceeds to an appropriate degree of crosslinking. Thus, a foamable sheet-forming composition capable of providing a foamed sheet having a thickness of 3 mm or more at an expansion ratio of 5 to 10 times can be obtained.

In the present invention, the ethylene / propylene copolymer segment constituting the propylene block copolymer (A-1) is indispensable for obtaining a uniform foam. The propylene block copolymer (A-1) is obtained by polymerizing olefins in the presence of a stereoregular catalyst, preferably a catalyst comprising a transition metal component with a carrier and an organoaluminum compound. For example, propylene homopolymerization is first performed, then random copolymerization of propylene and ethylene is performed in the same polymerization system, and if necessary, a propylene block copolymer is obtained by an operation such as homopolymerization of ethylene. Can be. The block copolymer obtained by this method is a so-called non-polymer blend type copolymer, that is, a chemical blend type copolymer. That is, crystalline polypropylene, ethylene-propylene random copolymer and crystalline polyethylene are directly blended in a polymerization reaction system by a multi-stage polymerization method. The specific manufacturing method is disclosed in Japanese Patent Application Laid-Open No. 52-98045 and Japanese Patent Publication No. 57-2661 by the present applicant.
No. 3 discloses this in detail.

The propylene resin (A) used in the present invention is a propylene block copolymer (A-
The propylene resin composition (A-4) obtained by blending 2) with the propylene polymer (A-3) may be used. The propylene block copolymer (A-2) used in the propylene resin composition (A-4) specifically has an intrinsic viscosity [η] of 2 to 8 dl / g, measured in decalin at 135 ° C., preferably 5 to 30% by weight, preferably 10 to 25% by weight of ethylene / propylene copolymer segment having 3 to 6 dl / g
% By weight and the crystalline polypropylene segments 70 to 95
A propylene block copolymer comprising about 75% to about 90% by weight.

The crystalline polypropylene segment comprises:
A small amount of crystalline polyethylene may be contained within a range that does not impair the purpose of the present invention. More specifically, this crystalline polypropylene segment consists of 80-100% by weight of crystalline polypropylene and 0-20% by weight of crystalline polyethylene. Also, a small amount of α-olefin component units such as ethylene and propylene may be contained in the crystalline polypropylene or crystalline polyethylene.
For example, crystalline polypropylene may include a small amount of ethylene component units, and crystalline polyethylene may include a small amount of propylene component units.

In the present invention, the propylene block copolymer (A-2) is a relatively high molecular weight propylene block copolymer having an MFR in the range of 0.5 to 10 g / 10 min, preferably 1 to 7 g / 10 min. Polymer (A-5): an amount of 10 to 100 parts by weight, preferably 20 to 100 parts by weight, and an MFR of 1
A relatively low molecular weight propylene block copolymer (A-6) in the range of 0 to 80 g / 10 min, preferably 15 to 60 g / 10 min: 0 to 90 parts by weight, preferably 0 to 80 parts by weight (However, the total amount of the propylene block copolymer (A-5) and the propylene block copolymer (A-6) is 10
0 parts by weight. )).

This propylene block copolymer (A-2)
Is 5 to 30 mol%, preferably 10 to 25 mol%. When a propylene block copolymer having an ethylene content within the above range is used, since the crosslinking of the propylene-based resin proceeds to an appropriate degree of crosslinking, it can be mainly foamed in the thickness direction of the sheet by heating, and can be 5 to 10 times. A foamable sheet-forming composition capable of providing a foamed sheet having a thickness of 3 mm or more at an expansion ratio of can be obtained.

This propylene block copolymer (A-2)
Has an MFR of 0.5 to 20 g / 10 min, preferably 1 to 1 g
5 g / 10 min. In addition, propylene resin composition (A-4)
The MFR of the propylene polymer (A-3) used in (1) is 0.5 to 20 g / 10 min, preferably 1 to 15 g / 10 min. In the propylene resin composition (A-4), the propylene block copolymer (A-2) contains at least 30 parts by weight of 1
The propylene polymer (A-3) is used in a proportion of less than 00 parts by weight, preferably 40 parts by weight or more and less than 80 parts by weight.
Not more than 70 parts by weight, preferably more than 20 parts by weight
It is used in a proportion of not more than part by weight (provided that the total amount of the propylene block copolymer (A-2) and the propylene polymer (A-3) is 100 parts by weight).

The propylene resin (A) used in the present invention, ie, a propylene block copolymer (A-1)
And the propylene resin composition (A-4) has an MFR of 0.1.
It is in the range of 5 to 20 g / 10 min, preferably 1.0 to 15 g / 10 min. When the MFR of the propylene-based resin (A) is within the above range, kneading and extrusion is easy, and high mechanical strength can be maintained with a small amount of a crosslinking aid used.
It is suitable as a material for automotive interior materials, especially ceiling materials.

((B) Radical Generator) As the radical generator (B) used to make the foamable sheet forming composition in a crosslinked state, organic peroxides and organic peroxyesters are mainly used. The decomposition temperature at which the half-life of the radical generator indicates 1 minute (min) is preferably higher than the melting point of the propylene-based resin (A). In addition, the half-life of the radical generator (B) is 100
It is practically preferable that the decomposition temperature indicating the time (hr) is 40 ° C. or higher.

Specific examples of these organic peroxides and organic peroxyesters include 3,5,5-trimethylhexanoyl peroxide (1), octanoyl peroxide (2), decanoyl peroxide (3), and lauroyl peroxide (4 ), Succinic peroxide (5), acetyl peroxide (6), t-butylperoxy (2-ethylhexanoate) (7), m-toluoyl peroxide (8), benzoyl peroxide (9),
t-butylperoxyisobutyrate (10), 1,1-bis (t-butylperoxy) 3,5,5-trimethylcyclohexane (11), 1,1-bis (t-butylperoxy) cyclohexane (12), t-butyl peroxymaleic acid (1
3), t-butylperoxylaurate (14), t-butylperoxy-3,5,5-trimethylcyclohexanoate (15), cyclohexanone peroxide (16), t-
Butyl peroxyisopropyl carbonate (17),
2,5-dimethyl-2,5-di (benzoylperoxy) hexane (18), t-butylperoxyacetate (19),
2,2-bis (t-butylperoxy) butane (20), t-butylperoxybenzoate (21), n-butyl-4,4-
Bis (t-butylperoxy) valerate (22), di-t
-Butylperoxyisophthalate (23), methyl ethyl ketone peroxide (24), α, α'-bis (t-butylperoxyisopropyl) benzene (25), dicumyl peroxide (26), 2,5-dimethyl-2,5- Di (t-
Butylperoxy) hexane (27), t-butylcumyl peroxide (28), diisopropylbenzene hydroperoxide (29), di-t-butylperoxide (3
0), p-menthane hydroperoxide (31), 2,5-dimethyl-2,5-di (t-butylperoxy) hexyne-3 (3
2) 1,1,3,3-tetramethylbutyl hydroperoxide (33), 2,5-dimethylhexane-2,5-dihydroperoxide (34), cumene hydroperoxide (35),
t-butyl hydroperoxide (36) and the like. Among these, the compounds (12) to (36) are particularly preferred.

The radical generator (B) is added to the propylene resin (A) 10 in the composition for forming a foamable sheet.
It is present in a proportion of 0.01 to 0.1 parts by weight with respect to 0 parts by weight. When the amount of the radical generator (B) is within the above range, an appropriate increase in the melt viscoelasticity of the propylene-based resin (A) is achieved, and a foam molded article having good closed cells can be obtained.

((C) Crosslinking Aid) Examples of the crosslinking aid (C) for crosslinking the propylene-based resin (A) include p-quinone dioxime and p, p '. -Dibenzoylquinone dioxime, N-methyl-N, 4-dinitrosoaniline, nitrobenzene, diphenylguanidine, trimethylolpropane-N, N'-m-phenylenedimaleimide, divinylbenzene (DVB), triallyl cyanurate ( TAC), triallyl isocyanurate (TAI)
C), polyfunctional methacrylate monomers such as ethylene glycol dimethacrylate, diethylene glycol dimethacrylate, polyethylene glycol dimethacrylate, trimethylolpropane trimethacrylate, allyl methacrylate, and polyfunctional vinyl monomers such as vinyl butyrate or vinyl stearate. .

With the crosslinking aid (C) as described above, a uniform and mild crosslinking reaction can be expected. Particularly, in the present invention, divinylbenzene (DVB) and triallyl isocyanurate (TAIC) are preferred. This crosslinking aid (C)
Is present in the foamable sheet-forming composition in an amount of 0.1 to 5 parts by weight, preferably 0.3 to 2 parts by weight, based on 100 parts by weight of the propylene-based resin (A). When the amount of the crosslinking aid (C) is within the above range, the crosslinking reaction of the propylene-based resin (A) proceeds favorably, a desired degree of crosslinking is obtained, and the melt viscoelasticity is sufficiently improved. It is preferable because a suitable foaming is performed.

((D) Blowing agent) The blowing agent (D) used in the present invention is a chemical substance which is liquid or solid at normal temperature and decomposes by heating to generate a gas. Is not particularly limited as long as it has a decomposition temperature equal to or higher than the melting point. Such foaming agents include azodicarbonamide (ADCA), barium azodicarboxylate, N, N'-dinitrosopentamethylenetetramine, 4,4
-Oxybis (benzenesulfonylhydrazide), diphenylsulfone-3,3-disulfonylhydrazide, p-toluenesulfonylsemicarbazide, trihydrazinotriazine, biurea, zinc carbonate and the like. Among them, azodicarbonamide (ADCA), N, N-dinitrosopentamethylenetetramine, which generate a large amount of gas and whose gas generation end temperature is sufficiently lower than the thermal degradation start temperature of the propylene-based resin (A), Trihydrazinotriazine is particularly preferred.

The foaming agent (D) is present in the foamable sheet forming composition in a proportion of 2 to 5 parts by weight based on 100 parts by weight of the propylene resin (A). When the amount of the foaming agent (D) is within the above range, since the amount of generated gas is moderate, expansion of 5 to 10 times in the thickness direction is possible, and the foam has a uniform size. And uniformly dispersed. If the degree of foaming is excessively increased by increasing the degree of crosslinking, the sheet may expand in a three-dimensional direction and may not be used as a ceiling foam base material.

The composition for forming a foamable sheet may be modified, if necessary, in addition to the propylene resin (A), the radical generator (B), the crosslinking assistant (C) and the foaming agent (D). G) may be included. ((G) Modified polypropylene) The modified polypropylene (G) used as required in the present invention is a polypropylene graft-modified with an unsaturated carboxylic acid or a derivative thereof.

The polypropylene used for the modified polypropylene (G) is a homopolymer of propylene or a copolymer of propylene and an α-olefin, and has a propylene content of 60 to 100 mol%, preferably 80 to 100 mol%.
Mol% range. This polypropylene has an MFR of usually 0.1 to 50 g / 10 min, preferably 0.3 to 30 g.
/ 10 min, and the melting point (Tm) is 110-165.
° C, preferably from 120 to 165 ° C.

As the α-olefin, ethylene and α-olefins having 4 to 20 carbon atoms, specifically, 1-
Butene, 1-hexene, 4-methyl-1-pentene, 1-octene, 1-decene, 1-tetradecene, 1-octadecene, etc., and these α-olefins are used alone or in combination of two or more. be able to. Specific examples of unsaturated carboxylic acids used for modifying polypropylene include acrylic acid, methacrylic acid, maleic acid, fumaric acid, itaconic acid, citraconic acid, crotonic acid, endocis-bicyclo [2,2,1] hept -5-ene-2,3-dicarboxylic acid (Nadic acid ^™ ) and the like.

Examples of the unsaturated carboxylic acid derivatives include acid halides, esters, amides, imides, and anhydrides. Specific examples include maleimide, acrylamide, methacrylamide, glycidyl methacrylate, and maleic anhydride. Acids, citraconic anhydride, monomethyl maleate, dimethyl maleate, glycidyl maleate and the like.

These compounds are used alone or in combination of two or more. Among them, acrylic acid, methacrylic acid and maleic anhydride are preferred. The amount of the unsaturated carboxylic acid or derivative thereof grafted on the polypropylene is 0.01 to 10% by weight, preferably 0.1 to 5% by weight, based on the weight of the modified polypropylene. Further, the modified polypropylene may be obtained by diluting a modified polypropylene obtained by highly graft-polymerizing an unsaturated carboxylic acid or a derivative thereof with an unmodified polypropylene to fall within the range of the graft amount.

Modification of polypropylene can be carried out by employing conventionally known methods and conditions. This modified polypropylene (G) is obtained by mixing the propylene resin (A) 10
Usually 1 to 10 parts by weight, preferably 3 to 10 parts by weight with respect to 0 parts by weight.
It is used as needed at a ratio of 7 parts by weight.

The foamed sheet containing the modified polypropylene (G) in the above range has excellent adhesion to the nonwoven fabric (E) made of glass fiber. (Compounding Agent) The composition for forming a foamable sheet may contain various additives in addition to the components described above. For example, when kneading a radical generator (B), a crosslinking aid (C), a foaming agent (D), and if necessary, a modified polyolefin (G) together with the propylene-based resin (A), Phenolic heat stabilizers can be used.

When a phenolic heat stabilizer is added to the composition for forming an expandable sheet in an amount of 0.05 to 1% by weight, preferably 0.1 to 0.5% by weight, the concentration of polymer radicals generated can be controlled. In addition to increasing the crosslinking efficiency, it is possible to prevent the oxidative deterioration during heating and foaming of the foamable sheet-forming composition and during the thermal processing of the foam, and to enhance the heat aging resistance of the product in use. This is preferable because

Examples of such heat stabilizers include n-octadecyl-3- (4′-hydroxy-3 ′, 5′-di-t-butylphenyl) propionate and 1,1,3-tris (2 -Methyl-4-hydroxy-5-t-butylphenyl) butane, 1,3,5-
Tris (4-t-butyl-3-hydroxy-2,6-dimethylbenzyl) -s-triazine-2,4,6- (1H, 3H, 5H) trione, 1,3,
5 Trimethyl-2,4,6-tris (3,5-di-t-butyl-4-hydroxyphenyl) benzylbenzene, 1,3,5-tris (3,5-
Di-t-butyl-4'-hydroxybenzyl) -s-triazine-
2,4,6- (1H, 3H, 5H) trione, tetrakis [methylene-3
(3,5-di-t-butyl-4-hydroxyphenyl) propionate] methane, or a mixture of two or more thereof.

If an additive having a function of preventing secondary agglomeration of the foaming agent is previously mixed with the foaming agent (D), the foaming agent (D) can be dispersed in the composition for forming a foamable sheet. The foamability is improved, and a good foam without coarse cells can be obtained. Such additives include metal soaps and surfactants. Specifically, substances that are solid at the kneading temperature, such as metal stearate such as calcium stearate and stearyl monoglyceride, are preferred.

In addition, since a foam molded article generally has a white appearance, when a color such as an end of the foam molded article is conspicuous, a coloring agent such as carbon black should be added to the composition for forming an expandable sheet. Can be. Non-woven fabric containing glass fiber as a main component (E) Non-woven fabric containing glass fiber as a main component to be adhered to at least one surface of a foam sheet obtained from the above-mentioned foam sheet composition (E) Simply "non-woven fabric (E)"
There is that. ) Is, for example, a strand cut to a predetermined length, dispersed in a random direction, laminated to a uniform thickness, molded into a mat with a binder,
Examples thereof include those obtained by uniformly dispersing a mixture of a thermoplastic resin fiber and a glass fiber, and forming the mixture into a mat shape with a binder.

The glass fiber (F) and the thermoplastic resin fiber used for the nonwoven fabric (E) have an average fiber diameter of usually 5
~ 25μm, preferably 10 ~ 20μm, the fiber length is usually 0.1 ~ 30mm, preferably 0.3 ~ 20m
m. As the nonwoven fabric (E), specifically, a glass fiber having an average fiber diameter of about 10 μm and an average fiber length of about 13 mm made of paper using a urethane-based binder, or an average fiber diameter of about 10 μm and an average fiber length of 13 mm
About 70% of glass fiber mixed with polyester fiber having a fiber diameter of about 3 denier and a fiber length of about 10 mm, and making a paper using a urethane binder.

The nonwoven fabric (E) has a basis weight of 10 to 80 g / m.
² , preferably in the range of 20 to 60 g / m ² . Such a nonwoven fabric (E) has a large vertical and horizontal elongation and is excellent in a balance of vertical and horizontal elasticity because it follows the shape of a mold by a forming process such as drawing. The foamed composite material for automobile interior is required not to sag by 10 mm or more in a wet-cooling heat test at 90 ° C. to −40 ° C., and this requirement is satisfied by using the nonwoven fabric (E). Conventionally, talc is most often used at low cost as a filler for improving rigidity. However, since it is necessary to improve not only the rigidity of the ceiling material but also the heat resistance, the amount of talc used is too large to satisfy those physical properties, the weight of the obtained ceiling material becomes heavy, and foaming occurs. There is a disadvantage that the foamability of the flexible sheet is reduced. Such disadvantages of talc can be improved by using the nonwoven fabric (E) described above.

In the present invention, from the viewpoint of enhancing the adhesion between the nonwoven fabric (E) and the propylene-based resin (A), a polypropylene graft-modified with an unsaturated carboxylic acid or a derivative thereof, for example, the above-mentioned modified polypropylene (G ) May be coated on the glass fiber (F) forming the nonwoven fabric (E). As a method of coating the glass fiber (F) with the modified polypropylene, for example, a method of impregnating and adhering the modified polypropylene to the glass fiber (F) in a solution state or coating the glass fiber (F) in a molten state at the time of making a nonwoven fabric is available.

The amount of the glass fiber (F) forming the nonwoven fabric (E) is 1 to 15 with respect to 100 parts by weight of the propylene resin (A) forming the foamable sheet.
It is used in an amount of preferably at least 4 to 10 parts by weight. When the nonwoven fabric (E) is used at the above ratio, a foamed composite material for automobile interiors having high rigidity, excellent heat resistance and dimensional stability, and capable of being recycled can be obtained.

The skin material used in the present invention is, for example, a non-woven fabric such as polyester, nylon or polypropylene, a woven fabric made of polyester, nylon, polypropylene or the like.
A woven fabric made of natural fibers and the like can be given. The basis weight of the nonwoven fabric or the like is usually 100 to 300 g / m ² . Also,
A composite material obtained by laminating a foam such as a polyurethane foam, a polyethylene foam, and a polypropylene foam on these materials can also be used as the skin material. Furthermore, a composite material in which leather made of a vinyl chloride resin, a thermoplastic elastomer, or the like is lined with a woven fabric, or a composite material in which a foam such as a polyurethane foam, a polyethylene foam, or a polypropylene foam is laminated on such leather is also used as a skin. It can be used as a material.

The above-described foamable sheet is in a molten state in a foamed state, and is bonded to a woven fabric, a nonwoven fabric, and an open-cell foam by an anchor effect, and is bonded to polypropylene by heat fusion, so that the adhesive sheet is bonded. Agents are not required. Manufacturing Method Next, a method for manufacturing a foamed composite material for an automobile interior using the composition for forming an expandable sheet, the nonwoven fabric (E) and the skin material as described above will be described.

First, in order to form the foamable sheet-forming composition into a sheet to form a foamable sheet, the foamable sheet-forming composition containing each of the above components is kneaded with a Brabender or the like, A method of forming a sheet with a calender roll, a method of forming a sheet with a press forming machine, a method of kneading a composition for forming a foamable sheet with an extruder, and forming the sheet through a T die or an annular die can be employed. . Among these, the method of kneading the foamable sheet-forming composition and then extruding it from a T-die at a temperature lower than the decomposition temperature of the foaming agent (D) to form an energy consumption,
Both the required time is short and the flatness and the extruded surface of the sheet are good, which is preferable.

When the composition for forming an expandable sheet is formed into a sheet, it must be performed at a temperature at which the blowing agent (D) does not decompose as described above. Specifically, azodicarbonamide is used as the blowing agent. When (ADCA) is used, about 160 to
It is preferable to form the foamable sheet-forming composition into a sheet at 190 ° C, preferably 165 to 180 ° C. The thickness of the unfoamed foamable sheet is about 0.5 to 1 mm.

Next, the nonwoven fabric (E) is integrally lined with at least one surface of the foamable sheet obtained as described above by a conventionally known method. For example, in the present invention, the foamable sheet forming composition is extruded into a sheet,
Immediately after passing through a pair of seating rolls,
By passing the nonwoven fabric (E) through the pair of sheeting rolls, the foamable sheet and the nonwoven fabric (E) can be pressure-bonded and integrated by the sheeting roll. Such an integration method requires an adhesive in particular. Is not preferred.

In the present invention, when the nonwoven fabric (E) is lined and integrated with at least one surface of a foamable sheet, a film made of a modified polypropylene (G) obtained by graft polymerization of an unsaturated carboxylic acid or a derivative thereof (hereinafter referred to as “modified”) A polypropylene film ") may be interposed between the foamable sheet and the nonwoven fabric (E). When the modified polypropylene film is interposed between the foamable sheet and the nonwoven fabric (E), the foamable sheet and the nonwoven fabric (E) are integrated as follows.

For example, a method in which the modified polypropylene film and the nonwoven fabric (E) are fed from different rolls to the kneading roll portion and pressed simultaneously, or the modified polypropylene film is laminated on the nonwoven fabric (E) in advance and then fed to the kneading roll portion. And crimping. This modified polypropylene film is composed of the modified polypropylene (G) and has a thickness of 10 to 70 μm.
m, preferably a film of 20 to 50 μm.

This modified polypropylene film can be produced by a conventionally known method. For example, using a single screw extruder, a kneading extruder, a ram extruder, a gear extruder, or the like, the molten modified polypropylene is subjected to T-die molding. It can be formed into a film by extruding from a film. When the modified polypropylene film is interposed between the foamable sheet and the nonwoven fabric (E), the adhesive strength between the foamable sheet and the nonwoven fabric (E) is improved.

By bonding the nonwoven fabric (E) to the foamable sheet in this way, it is possible to prevent drawdown due to heat softening of the sheet, and to reduce the thickness direction of the sheet when the foamable sheet is foamed. Thus, a molded article having an expansion ratio of 3 times or more, particularly a molded article having a high expansion ratio of 5 to 10 times can be obtained.

Next, the foamable sheet composite obtained by laminating the nonwoven fabric (E) to the foamable sheet is directly heated to crosslink and foam, or is irradiated with ionizing radiation to produce a propylene-based composite. After crosslinking the resin (A),
Heat to foam. When a step of irradiating ionizing radiation to crosslink the propylene-based resin (A) is included, the ionizing radiation includes α rays, β rays, γ rays, X rays,
An electron beam, a neutron beam and the like are used. Of these, γ-rays and electron beams of cobalt-60 are preferably used. The irradiation amount of the ionizing radiation is about 2 to 10 kGy, preferably 3 to 7 kGy, and the gel fraction which is an index of the degree of crosslinking of the propylene-based resin (A) is 1 to 10% by weight, preferably It is desirable that the irradiation dose be in the range of 3 to 7% by weight.

When the irradiation amount of the ionizing radiation is within the above range, the degree of crosslinking of the propylene-based resin (A) is appropriate, and a desired degree of foaming can be obtained. In addition, the foaming sheet expands mainly in the thickness direction. It is preferred. The trimming waste of the foamed sheet having such a degree of crosslinking can be recycled. For example, the trimming waste can be effectively used by being mixed with an unused resin for an automobile molded ceiling material.

Here, the gel fraction as an index of the degree of crosslinking of the propylene-based resin (A) is obtained as follows.
3 g of a sample was taken in a # 100 mesh screen basket, and the sample was subjected to an extraction treatment with p-xylene for 3 hours using a Soxhlet extraction apparatus, and the extraction residual ratio (xylene insoluble fraction) was obtained. The fraction is defined as the gel fraction.

Next, when the foamable sheet is heated and molded into a desired shape, a polypropylene foam molded article is obtained. In this case, it is naturally necessary to heat the foaming agent (D) to a temperature higher than the decomposition temperature. There are the following methods for heating and expanding the foamable sheet. (1) A method using radiant heat from a heating element. (2) A method of heating by high-frequency induction. (3) A method of heating using an oven. (4) A method of heating with hot air.

The foamable sheet mainly foams in the thickness direction, and the foamable sheet is formed while foaming is occurring or while foaming is almost completed but the sheet is still plastic. As a processing method, a press molding method is used. Generally, a nonwoven fabric of polyester is used as the skin material. This skin material is placed on the top surface of the foam sheet before cooling and solidifying after the foam sheet is foamed, i.e., while it is in a plastic state, and the ceiling mold for top and bottom is closed and both are laminated and integrated. And shape.
The mold is provided with a cooling water groove and cooled using a chiller or the like. In the present invention, a foamable sheet may be placed on the skin material.

According to the method of the present invention, since the skin material is not heated by the heater, there is no change in the thickness and the appearance, and in particular, a fluffy sheet, a flared sheet or the like, or a fluffed sheet. Even if the sheet is used as a skin material, the hair does not fall down and a skin surface with an excellent texture can be obtained. The clearance between the upper and lower molds is preferably about 1 to 2 mm smaller than the foam thickness of the foam sheet plus the thickness of the skin material. By minimizing the clearance at the end of the foamed sheet, the foamed resin is crushed to facilitate trimming.

The foam composite material for an automobile interior according to the present invention in which the skin material, the foam sheet and the nonwoven fabric (E) obtained as described above are laminated, is lightweight, has high rigidity, and has a surface condition of the skin material. Because it is stored well, it has an excellent texture of the epidermis. According to the method described above, the propylene block copolymer (A-1) or the propylene composition (A
-4) propylene resin (A) is cross-linked,
The gel fraction is usually in the range of 1 to 10% by weight, preferably 3 to 7% by weight, based on the weight of the propylene-based resin (A), and the magnification mainly expanded in the thickness direction is usually 5 to 10 times. The foamed composite for automotive interior of the present invention comprising a crosslinked foamed sheet composite having a nonwoven fabric (E) bonded to at least one side of a crosslinked foamed sheet, preferably 6 to 8 times, and a skin material laminated on one surface of the crosslinked foamed sheet composite Wood is obtained.

The crosslinked foamed sheet is prepared by grafting a modified polypropylene (G) obtained by graft-polymerizing an unsaturated carboxylic acid or a derivative thereof with 1 to 10 parts by weight, preferably 3 to 7 parts by weight, per 100 parts by weight of the propylene resin (A). May be included. The foamed composite material for an automobile interior of the present invention has a layer made of a modified polypropylene obtained by graft-polymerizing an unsaturated carboxylic acid or a derivative thereof between the crosslinked foamed sheet and the nonwoven fabric (E), for example, the above-mentioned modified polypropylene (G). You may.

The foamed composite material for an automobile interior according to the present invention comprises 1 to 15 parts by weight of a glass fiber (F) derived from a nonwoven fabric (E) based on 100 parts by weight of a propylene resin (A) forming a crosslinked foamed sheet. Parts, preferably 4 to 10 parts by weight. When the glass fiber (F) is contained in the above proportion, it becomes a foamed composite material for automobile interiors which has high rigidity, excellent heat resistance and dimensional stability, and which can be recycled.

[0068]

According to the method for producing a foamed composite material for an automobile interior according to the present invention, a foamed composite material for an automobile interior having a low specific gravity, excellent rigidity, particularly excellent heat resistance rigidity, and an excellent balance of physical properties in the vertical and horizontal directions can be obtained. . According to the method for producing a foamed composite material for an automobile interior according to the present invention, the dimensional stability, acoustic characteristics, molding environment, design, texture of the skin surface, excellent workability and recyclability, and moreover, the molding process An automotive interior foamed composite material having a high degree of freedom can be manufactured at low cost.

The foam composite for automobile interior according to the present invention comprises:
It is lightweight, has high rigidity, is excellent in dimensional stability, acoustic characteristics, molding environment, design, installation workability, recyclability and texture of the skin surface, and has a large degree of freedom in molding and is inexpensive.

[0070]

EXAMPLES The present invention will be described below with reference to examples, but the present invention is not limited to these examples.

[0071]

Example 1 Propylene block copolymer (BPP-1)
(MFR: 2.0 g / 10 min, ethylene content: 20 mol%, ethylene / propylene copolymer segment: 10 wt%, crystalline polypropylene segment (crystalline polypropylene: 86.7 wt%, crystalline polyethylene: 1
3.3 wt%) 90 wt%, intrinsic viscosity [η] of ethylene / propylene copolymer segment [η]: 3 dl / g) 55 wt parts, and propylene homopolymer (HPP-1) having an MFR of 11.0 g / 10 min. ) 45 parts by weight and the total amount of the above propylene block copolymer and propylene homopolymer of 10
2,5-dimethyl as radical generator with respect to 0 parts by weight
-2,5-di (t-butylperoxy) hexyne-3 0.05
Parts by weight and divinylbenzene (DVB) as a crosslinking aid
1.0 parts by weight and tetrakis- [methylene-3- (3 ', 5'-di-t-butyl-4'-hydroxyphenyl) as an antioxidant
Propionate] methane [trade name Irganox 1010, manufactured by Nippon Ciba Geigy Co., Ltd.] 0.1 part by weight, 0.1 part by weight of calcium stearate, and 3.0 parts by weight of azodicarbonamide (ADCA) as a foaming agent Mixing was performed using a high-speed mixer (Henschel mixer).

Next, the mixture was screwed with a 50 mm screw.
It is melted and granulated at 170 ° C using a twin screw extruder with a diameter,
An unfoamed homogeneous mixed pellet was obtained. Then, the pellets were formed into a 1.0 mm thick unfoamed foamable sheet at a temperature of 175 ° C. using a T-die sheet forming machine having a screw diameter of 90 mm and a width of 1800 mm. Then, a nonwoven fabric obtained by mixing glass fiber and polyester fiber with a basis weight of 50 g / m ^{2 at} a weight ratio (glass fiber / polyester fiber) of 70/30 was attached to both sides of the foamable sheet to obtain a foamable sheet composite. .

Next, the foamable sheet composite was irradiated with 4 kGy of γ-ray (Co-60) to perform crosslinking. The foamable sheet portion of the crosslinked foamable sheet composite has M
The FR (230 ° C.) was 3.0 g / 10 min, and the gel fraction (xylene-insoluble fraction) determined by performing treatment with boiling p-xylene for 3 hours was 5.3%. Next, this foamable sheet composite was sized to 1500 mm × 1300 mm.
And the four sides were clamped, and the foamable sheet was heated by a far-infrared heater. As for the temperature condition of the heater, when the set temperature of the upper heater was set to 400 ° C. and the set temperature of the lower heater was set to 300 ° C., foaming occurred in 85 seconds.
The obtained foam sheet composite had a thickness of 7.2 mm and an expansion ratio of 7.2.

Next, before the obtained foamed sheet composite had been cooled and solidified, a nonwoven fabric made of polyester with a basis weight of 250 g / m ² was layered on the upper surface of the foamed sheet composite as a ceiling skin material. Was press molded. This mold is cooled by passing water. The molded ceiling material in which the foam sheet and the skin material were integrated was cooled and solidified in one minute. One minute later, the mold was opened and the molded ceiling material was taken out. In addition, since the mold clearance is set to 0 at the end surface of the ceiling material, the foamed resin is crushed and thinned,
Cutting was easy with a cutter.
Since almost no resin was present, only the skin material and the nonwoven fabric were seen from the side as viewed from the side. Also, the mold clearance of the part other than the end face is set so that the thickness is 1.5 mm less than the thickness of the foamed sheet composite and the pressed skin material, and press-molded. (Molded ceiling material) was obtained. In addition, the thickness of only the base material was 4.3 mm. Press pressure is 5kg / cm ²
It was extremely low pressure.

As described above, since the skin material was not directly heated and the pressing pressure was extremely low, the skin material had a good texture without falling down. The obtained molded ceiling material was mounted on the ceiling of a car and subjected to a moist cooling test under the following conditions. The ceiling droop was 10 mm or less, and the car passed the standards of the car manufacturer without any deformation or appearance. Met.

In this example, the physical properties of the foam sheet were measured as follows. [Thickness of foam sheet in free foam state and its foaming ratio]
After clamping the four sides of the foamable sheet, the foamable sheet was heated and foamed by the upper and lower heaters. Next, the obtained foamed sheet was forcibly cooled by an air fan and solidified. The average thickness of the central part of the foamed sheet after solidification was defined as "the thickness of the foamed sheet in a free foamed state". The value obtained by dividing the thickness of the foamed sheet by the thickness of the sheet (foamable sheet) before foaming was defined as the “expansion ratio of the foamed sheet in a free foamed state”. [Elastic gradient] The above foam sheet was press-molded at 200 ° C. to a thickness of 3.5 mm, and then a sample of 50 mm × 150 mm was prepared. The span gap was 100 mm, and the bending speed was 50 mm / mi.
The load at the time of deformation of 10 mm when performing a three-point bending test is represented by n. [Molding shrinkage] Using a metal mold with a mark of 400 mm x 300 mm. Press molding to 3.5mm thickness,
It was determined by measuring the dimensional change 24 hours after molding. [Dropping of skin-coated synthetic molded article after wet / cold heat test] Wet / cold heat test method A molded / finished ceiling material is attached to the automobile ceiling of a sheet metal model, and a wet / cold heat test is performed under the following conditions. And the position of the ceiling material after the test,
If the difference (the amount of hanging of the ceiling) was 10 mm or less, it was judged as acceptable. In addition, it was examined whether or not noticeable deformation was observed in the ceiling material after the moist cooling test, and further, whether or not the skin material was peeled or discolored.

Test conditions: 90 ° C. × 4 hours → Leave at room temperature for 0.5 hour → −40 ° C. × 7.
5 hours → Leave at room temperature for 0.5 hours → 50 ° C × 95% RH × 3
A test of 4 cycles is performed in which one cycle is a period of time → rooming at room temperature for 0.5 hour. Table 1 shows the results.

[0078]

Example 2 Example 1 except that the γ-ray irradiation step was omitted.
In the same manner as in the above, a molded composite material was prepared and tested. Table 1 shows the results.

[0079]

Example 3 Example 1 was repeated except that propylene homopolymer (HPP-1) was not used and only propylene block copolymer (BPP-1) was used in an amount of 100 parts by weight. Similarly, molded composites were prepared and tested. Table 1 shows the results.

[0080]

Example 4 In Example 1, propylene block copolymer (BPP-1) and propylene block copolymer (BPP-2) (MFR: 25 g /
10 minutes, ethylene content: 18 mol%, ethylene / propylene copolymer segment: 9 wt%, crystalline polypropylene segment (crystalline polypropylene: 88.3 wt%, crystalline polyethylene: 11.7 wt%) 91 wt% , Intrinsic viscosity [η] of ethylene-propylene copolymer:
3 dl / g) and propylene homopolymer (HPP-2)
(MFR: 2.0 g / 10 min) in the same manner as in Example 1 except that the composition ratio shown in Table 1 was used to prepare a molded composite material, and a test was conducted. Table 1 shows the results.

[0081]

Comparative Example 1 In Example 1, except that the same amount of glass fiber as the glass fiber contained in the nonwoven fabric mainly composed of glass fiber bonded to the foamable sheet was blended at the time of producing the unfoamed mixed pellet. In the same manner as in Example 1, a molded ceiling material was prepared and tested. Table 1 shows the results.

[0082]

[Table 1]

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B32B 27/12 B32B 27/32 Z 4F212 27/32 B60R 13/02 A 4F213 B60R 13/02 D06N 7/04 D06N 7/04 B29K 23:00 // B29K 23:00 B29L 31:58 B29L 31:58 B29C 67/22 (72) Inventor Yoichi Wakida 580-32 Nagaura, Sodegaura City, Chiba Prefecture Within Grand Polymer Co., Ltd. 72) Inventor Masahiro Sugi 580-32 Nagaura, Sodegaura City, Chiba Prefecture Within Grand Polymer Co., Ltd. (72) Inventor Kazuhiro Tani 148-27 Takano, Hitachinaka-shi, Ibaraki Prefecture F-term in the Katsuta Plant of Hi-Sheet Industry Co., Ltd. 3D023 BA01 BB02 BD01 BE04 BE06 BE31 4F055 AA21 BA12 CA06 CA18 EA04 EA08 EA24 FA05 GA34 HA07 4F100 AG00B AK07A AK07D AK24A AK41 AL02A AL04 A AL04D AL05A AL06D AL07A AT00C BA03 BA04 BA07 BA10A BA10C DG01B DG15B EC18 EC183 EH17 EH171 EJ02 EJ02A EJ022 EJ05 EJ05A EJ052 EJ17 EJ42 EJ422 EJ52 EJ522 A33A33 A33AA11AA11AA CB01 CB11 CB13 CB22 CB30 CN01 CN05 CN13 4F208 AA04E AA11 AA11E AA11F AA11J AA11K AA20G AA24 AA29 AB02 AB03 AB04 AC03 AD04 AD16 AH26 LW01 LW06 LW15 LW50 MA02 MA07 MB01 M11 MB11 M03 M04 MG11 MB11 M13 MG04 AA11J AA11K AB02 AB03 AB04 AC03 AD04 AD16 AG01 AG03 AG20 AH26 UA01 UA09 UA15 UB01 UB13 UB22 UC06 UG02 UG05 UH30 UN02 UN05 UN06 4F213 AA04E AA11 AA11E AA11F AA11J AA11 AB02 AA03A04 A03A04 WB11 WB22 WB28 WC02 WE02 WE06 WE07 WE25 WF05 WF06 WK01 WK03 WW01 WW06 WW15 WW33

Claims (11)

[Claims] 1. 100 parts by weight of the following propylene resin (A), 0.01 to 0.1 part by weight of a radical generator (B), 0.1 to 5 parts by weight of a crosslinking assistant (C), Blowing agent (D)
A foamable sheet-forming composition containing 2 to 5 parts by weight of the foaming agent (D) at a temperature at which the foaming agent (D) does not decompose;
A nonwoven fabric (E) containing glass fiber as a main component is bonded to at least one surface of the obtained foamable sheet to form a foamable sheet composite, and then the foamable sheet composite is foamed with a foaming agent (D). A car interior characterized in that a skin material is placed on the surface of the foam sheet composite and press-molded before the foam sheet composite is cooled and solidified after being heated to a temperature at which the foam is decomposed. Production method of foamed composite material for use; Propylene resin (A): 3 to 30% by weight of ethylene / propylene copolymer segment having intrinsic viscosity [η] of 2 to 8 dl / g measured in decalin at 135 ° C. Propylene block copolymer (A-1) comprising less than 70% by weight and less than 70% by weight and less than 97% by weight of a crystalline polypropylene segment, and having an ethylene content of 3 mol% or more and less than 30 mol%. 2. The method according to claim 1, wherein the propylene resin (A) is (A-
2) The intrinsic viscosity [η] measured in decalin at 135 ° C. is 2
A propylene block copolymer comprising 5 to 30% by weight of an ethylene / propylene copolymer segment in the range of ８8 dl / g and 70 to 95% by weight of the crystalline polypropylene segment and having an ethylene content in the range of 10 to 30% by mole. Combination: 30 to 100 parts by weight, and (A-3) melt flow rate (ASTM D-1238, L, 230 ° C, 2.
Propylene homopolymer having a load of 16 kg) of 0.5 to 20 g / 10 min: 70 to 0 parts by weight (provided that the total of propylene block copolymer (A-2) and propylene homopolymer (A-3) The amount is 100 parts by weight), and the melt flow rate (ASTM D-1238, L, 230 ° C,
2. The method for producing a foamed composite material for an automobile interior according to claim 1, wherein the propylene resin composition is a propylene resin composition (A-4) having a load of 2.16 kg) in the range of 0.5 to 20 g / 10 minutes. 3. The propylene block copolymer (A-2)
Is (A-5) melt flow rate (ASTM D-123
8, L, 230 ° C, 2.16 kg load) 0.5 to 10
g / 10 minutes relatively high molecular weight propylene block copolymer: amount of 10 to 100 parts by weight, and (A-6)
Melt flow rate (ASTM D-1238, L, 23
A relatively low molecular weight propylene block copolymer having a temperature of 0 ° C. and a load of 2.16 kg in the range of 10 to 80 g / 10 minutes: an amount of 0 to 90 parts by weight (provided that the propylene block copolymer (A-5 ) And the total amount of the propylene block copolymer (A-6) is 100 parts by weight.)
Or the method for producing a foamed composite material for an automobile interior according to 2. 4. The nonwoven fabric (E) containing glass fiber as a main component is a nonwoven fabric of glass fiber alone or a nonwoven fabric obtained by mixing glass fiber and thermoplastic resin fiber.
4. The method for producing a foamed composite material for an automobile interior according to any one of claims 3 to 3. 5. The foamable sheet composite has an average fiber diameter of 5 to 100 parts by weight of the propylene resin (A).
The foamed composite material for an automobile interior according to any one of claims 1 to 4, comprising a glass fiber (F) in a range of 25 µm and a fiber length of 0.1 to 30 mm in an amount of 1 to 15 parts by weight. Production method. 6. The foamable sheet-forming composition according to claim 1, further comprising an unsaturated carboxylic acid or an unsaturated carboxylic acid, in addition to the propylene resin (A), the radical generator (B), the crosslinking assistant (C), and the foaming agent (D). 6. A modified polypropylene (G) obtained by graft-polymerizing a derivative thereof in an amount of 1 to 10 parts by weight.
The method for producing a foamed composite material for an automobile interior according to any one of the above. 7. A film made of a modified polypropylene obtained by graft-polymerizing an unsaturated carboxylic acid or a derivative thereof when the nonwoven fabric (E) containing glass fiber as a main component is bonded to and integrated with the foamable sheet. The method for producing a foamed composite material for an automobile interior according to any one of claims 1 to 5, wherein the foamed composite material is interposed between a conductive sheet and a nonwoven fabric (E) containing glass fibers as a main component. 8. Prior to the step of heating the foamable sheet at the decomposition temperature of the foaming agent (D) to foam the propylene-based resin (A), the foamable sheet is exposed to ionizing radiation for 2 to 1 times.
Irradiation at 0 kGy to produce propylene resin (A)
The method for producing a foamed composite material for an automobile interior according to any one of claims 1 to 7, wherein a step of crosslinking is performed. 9. A propylene resin (A) which is the propylene block copolymer (A-1) according to claim 1 or the propylene composition (A-4) according to claim 2, which is crosslinked. The gel fraction is 1 to 10% by weight with respect to the weight of the propylene-based resin (A), and mainly contains glass fiber on at least one surface, which mainly expands in the thickness direction and has a magnification of 5 to 10 times. A foam composite material for automobile interiors, wherein a skin material is laminated on one surface of a crosslinked foam sheet to which a nonwoven fabric (E) is bonded. 10. The crosslinked foamed sheet contains a modified polypropylene (G) obtained by graft-polymerizing an unsaturated carboxylic acid or a derivative thereof in an amount of 1 to 10 parts by weight based on 100 parts by weight of the propylene-based resin (A). 10. The foam composite for automotive interior according to 9. 11. The foam for automobile interiors according to claim 9, further comprising a layer made of a modified polypropylene obtained by graft-polymerizing an unsaturated carboxylic acid or a derivative thereof between a crosslinked foamed sheet and a nonwoven fabric mainly composed of glass fibers. Composite materials.