WO2010110312A1

WO2010110312A1 - Laminate for vehicular exterior trim, process for producing same, and vehicular exterior trim

Info

Publication number: WO2010110312A1
Application number: PCT/JP2010/055076
Authority: WO
Inventors: 幸弘杉江; 一人西澤; 和夫下村
Original assignee: 積水化学工業株式会社
Priority date: 2009-03-24
Filing date: 2010-03-24
Publication date: 2010-09-30
Also published as: JPWO2010110312A1; JP5374506B2; CN102341296B; CN102341296A; DE112010001365T5

Abstract

A laminate for vehicular exterior trims is provided from which a vehicular exterior trim can be obtained by thermoforming, the trim having substantially no rumples in the surface, having excellent surface smoothness, and suffering no damage such as breakage even if a flying stone or the like hits thereagainst. The laminate (A) for vehicular exterior trims is characterized by being obtained by: superposing a synthetic-resin film (2,2) on at least one surface of a fibrous mat (1) obtained by mixing inorganic fibers, heat-resistant organic fibers having a melting point of 200ºC or higher, and binder resin fibers for binding the inorganic fibers and the heat-resistant organic fibers, the synthetic-resin film (2,2) comprising a binder resin capable of binding the inorganic fibers and the heat-resistant organic fibers; and melting the binder resin fibers and the binder resin contained in the synthetic-resin film to infiltrate the melted binder resin from the synthetic-resin film into the fibrous mat and bind the inorganic fibers and the heat-resistant organic fibers together.

Description

Laminate for vehicle exterior material, manufacturing method thereof, and vehicle exterior material

The present invention relates to a laminate for a vehicle exterior material, a manufacturing method thereof, and a vehicle exterior material.

A vehicle under cover is attached to the bottom of the vehicle, such as an automobile, to reduce the air resistance by covering the uneven shape of the bottom of the vehicle, to prevent noise from outside the vehicle, and to prevent damage to the bottom of the vehicle body due to stepping stones. It is required to be lightweight.

However, since the conventional vehicle undercover is manufactured by injection molding, it has a problem of being heavy and poor in sound absorption.

Therefore, instead of the vehicle undercover manufactured by injection molding, for example, Patent Document 1 discloses a core material obtained by mixing a reinforcing material such as glass fiber and an olefin resin, and an olefin on one side or both sides of the core material. A sound-absorbing undercover in which a reinforcing layer made of resin or the like is laminated and integrated has been proposed.

However, the sound-absorbing type undercover has a problem that when a stepping stone collides during traveling, the surface is more easily damaged than a vehicle undercover manufactured by injection molding.

Also, the vehicle under cover is provided with an uneven shape that matches the bottom of the vehicle body. However, the sound-absorbing type undercover has a problem that wrinkles are generated on the uneven surface and the base of the uneven shape when the flat material is heat formed into the uneven shape.

JP 2006-240408 A

The present invention relates to a laminate for a vehicle exterior material capable of obtaining a vehicle exterior material that is hardly flawed on the surface even when it is thermoformed and is not easily torn even when a stepping stone collides, a method for manufacturing the same, and a vehicle exterior material I will provide a.

The laminate for a vehicle exterior material of the present invention includes a fiber mat 1 in which inorganic fibers and heat-resistant organic fibers having a melting point of 200 ° C. or higher are bound by molten binder resin fibers, and at least the fiber mat 1. The synthetic resin film 2 is laminated and integrated on one surface, and a part of the synthetic resin film 2 is melted and impregnated in the fiber mat. FIG. 1 shows a laminate A for a vehicle exterior material in which synthetic resin films 2 are laminated and integrated on both surfaces of a fiber mat.

Examples of the inorganic fiber constituting the fiber mat 1 include glass fiber, rock wool, metal fiber, and carbon fiber. Inorganic fibers are preferably glass fibers and rock wool because they are easy to handle, and glass fibers are more preferable. In addition, an inorganic fiber may be used independently or 2 or more types may be used together.

The length of the inorganic fiber is preferably 5 to 250 mm, more preferably 30 to 150 mm. The thickness of the inorganic fiber is preferably 3 to 30 μm, more preferably 5 to 20 μm, and more preferably 6 to 15 μm.

The content of inorganic fibers in the fiber mat 1 is preferably 15 to 60% by weight because a vehicle exterior material having a light weight and sufficient mechanical strength can be obtained.

Further, the heat-resistant organic fiber constituting the fiber mat 1 may be maintained in a form without melting during the manufacturing process, and specifically, the melting point needs to be 200 ° C. or higher. Examples of the resin used for the heat-resistant organic fiber include synthetic resin fibers such as polyethylene terephthalate fiber, polybutylene terephthalate fiber, polyamide fiber, aramid fiber, and polyurethane fiber, and natural fibers such as cotton, hemp, kenaf, and wool. . In addition, melting | fusing point of a heat resistant organic fiber means what was measured based on JISK7121. The heat-resistant organic fibers may be used alone or in combination of two or more.

The length of the heat resistant organic fiber is preferably 5 to 250 mm, more preferably 30 to 150 mm. The content of the heat-resistant organic fiber having a length of 30 to 150 mm in the heat-resistant organic fiber is preferably 25% by weight or more, and more preferably 26 to 100% by weight because sufficient strength can be given to the fiber mat. The fineness of the heat-resistant organic fiber is preferably 2 to 50 dtex, more preferably 5 to 30 dtex because the fibers can be mixed and dispersed uniformly.

The content of the heat resistant organic fiber in the fiber mat 1 is preferably 5 to 60% by weight, and more preferably 10 to 40% by weight. If the content of the heat-resistant organic fiber is small, the impact resistance of the vehicle exterior material may be lowered. When the content of the heat-resistant organic fiber is large, the mechanical strength of the vehicle exterior material may be lowered.

The fiber mat 1 contains binder resin fibers, and the inorganic resin and heat-resistant organic fibers having a melting point of 200 ° C. or higher are bound by the binder resin fibers. Examples of the synthetic resin constituting the binder resin fiber include polyolefin resins such as polyethylene resins and polypropylene resins.

The form of the binder resin fiber may be a fiber having a core-sheath structure in addition to a fiber formed from a single synthetic resin. In the case of a fiber having a core-sheath structure, the inorganic fiber and the heat-resistant organic fiber having a melting point of 200 ° C. or higher are bound by the synthetic resin constituting the fiber surface.

When the melting point of the fiber formed from a single synthetic resin and the melting point of the synthetic resin constituting the surface of the core-sheath structure fiber are low, the heat resistance may be lowered. 70 to 170 ° C. is preferable because the heat-resistant organic fibers having a temperature higher than or equal to 0 ° C. may be insufficiently bonded and the strength of the vehicle exterior material may be lowered. In the present invention, the melting point of the synthetic resin refers to a value measured according to JIS K7121.

The length of the binder resin fiber is preferably 5 to 250 mm, more preferably 30 to 150 mm. The fineness of the binder resin fiber is preferably 2 to 50 dtex, more preferably 5 to 30 dtex because it can be easily dispersed in the fiber and is easy to handle.

The content of the binder resin fiber in the fiber mat 1 is preferably 10 to 40% by weight. By adjusting the content of the binder resin fiber, the mechanical strength of the vehicle exterior material can be sufficiently expressed.

Basis weight of the fiber mat 1, because it is easy to achieve both weight and mechanical strength, preferably 100 ~ 1500g / m ^2, more preferably 300 ~ 1000g / m ^2.

The synthetic resin film 2 is laminated and integrated on at least one surface, preferably both surfaces, of the fiber mat 1, and a part of the synthetic resin film 2 is melted and impregnated in the fiber mat 1.

The synthetic resin constituting the synthetic resin film 2 contains a binder resin that can be impregnated into the fiber mat 1 to bind inorganic fibers and heat-resistant organic fibers having a melting point of 200 ° C. or higher. . Examples of such binder resins include polyethylene resins, polypropylene resins, ethylene-vinyl acetate copolymers, polyethylene terephthalate, polyethylene terephthalate copolymer resins, and maleic anhydride-modified polyethylene. The synthetic resin constituting the synthetic resin film 2 is preferably made of a binder resin. If the content of the binder resin in the synthetic resin constituting the synthetic resin film 2 is small, the mechanical strength of the fiber mat may be lowered. Therefore, the content is preferably 50% by weight or more, and 80% by weight or more. More preferred. The synthetic resin may contain a synthetic resin other than the binder resin as long as the binding between the inorganic fiber and the heat-resistant organic fiber is not inhibited. Examples of the synthetic resin other than the binder resin include polystyrene resin and polyvinyl chloride resin. In addition, the synthetic resin which comprises the synthetic resin film 2 may be used independently, or 2 or more types may be used together.

The melt flow rate of the synthetic resin constituting the synthetic resin film 2 is preferably 0.1 to 25 g / 10 minutes, and more preferably 0.3 to 15 g / 10 minutes. If the melt flow rate of the synthetic resin is low, it may take time until the molten resin is sufficiently impregnated into the fiber mat. When the melt flow rate of the synthetic resin is high, it becomes difficult to accurately adjust the amount of molten resin impregnated in the fiber mat. In the present invention, the melt flow rate of the synthetic resin refers to that measured in accordance with JIS K 7210.

In the above description, the case where the synthetic resin film 2 is a single layer has been described. However, as shown in FIG. 2, the synthetic resin film 2 is composed of a plurality of

synthetic resin layers

21, 21. It may be a film. In this case, among the synthetic resin films 2, the innermost synthetic resin layer 21a, that is, the synthetic resin layer 21a in contact with the fiber mat 1, is the same as the synthetic resin constituting the single-layer synthetic resin film 2. These synthetic resins are used. In addition, when the synthetic resin film 2 is laminated and integrated on both surfaces of the fiber mat 1, even if only one of the synthetic resin films 2 is a multilayer synthetic resin film, or both synthetic resin films 2 May be a multilayer synthetic resin film. In addition, in FIG. 2, the case where one synthetic resin film 2 was a multilayer synthetic resin film was shown.

The at least one synthetic resin layer other than the innermost layer is preferably a heat resistant synthetic resin layer composed of a heat resistant synthetic resin having a melting point of 200 ° C. or higher, and the outermost synthetic resin layer 21b has a melting point. Is more preferably a heat-resistant synthetic resin layer composed of a heat-resistant synthetic resin at 200 ° C. or higher.

In this way, by forming at least one synthetic resin layer 21 from a heat-resistant synthetic resin, the synthetic resin layer 21 remains thick on the surface of the fiber mat 1 even after the laminated body for vehicle exterior materials is thermoformed. Thus, a vehicle exterior material excellent in mechanical strength, particularly in impact resistance can be obtained.

In particular, when the outermost synthetic resin layer 21b of the synthetic resin film 2 is made of a heat resistant synthetic resin, the outermost layer does not melt during the manufacturing process of the laminated body for vehicle exterior materials or during the thermoforming of the laminated body for vehicle exterior materials. Therefore, the surface of the vehicle exterior material can be a smooth surface that is difficult to be iced. Therefore, the vehicle exterior material has excellent impact resistance, and it is possible to prevent the vehicle exterior material from icing when used in a cold region.

Examples of such heat-resistant synthetic resins include polyethylene terephthalate, polybutylene terephthalate, polyamide, aromatic polyamide, and modified resins thereof.

The melting point of the heat resistant synthetic resin is preferably 30 ° C. or higher, more preferably 50 ° C. or higher than the melting point of the synthetic resin constituting the innermost synthetic resin layer 21a. If the difference between the melting point of the heat-resistant synthetic resin and the melting point of the synthetic resin constituting the innermost synthetic resin layer 21a is small, the laminate for the vehicle exterior material or the laminate for the vehicle exterior material The synthetic resin layer formed from the heat resistant synthetic resin may be melted by the heat applied at the time of thermoforming.

Further, the melt flow rate of the synthetic resin constituting at least one synthetic resin layer other than the innermost layer is ½ or less of the melt flow rate of the synthetic resin constituting the innermost synthetic resin film layer 21a. Preferably there is. By comprising in this way, a synthetic resin layer can be reliably formed in the surface of a fiber mat, and the impact resistance of the surface of a vehicle exterior material can be improved.

The total thickness of the single layer or multilayer synthetic resin film 2 is preferably 30 to 500 μm, and more preferably 100 to 400 μm. When the thickness of the synthetic resin film 2 is thin, it is difficult to obtain a vehicle exterior material having high impact resistance, and the surface smoothness of the vehicle exterior material is lowered, and it may be easy to form ice when used in a cold region. When the thickness of the synthetic resin film 2 is thick, it may be difficult to form the vehicle exterior material.

Next, the manufacturing method of the laminated body for vehicle exterior materials of this invention is demonstrated. First, the manufacturing method of the fiber mat 1 is demonstrated. As a manufacturing method of the fiber mat 1, for example, after a mixed fiber formed by mixing inorganic fibers, a heat-resistant organic fiber having a melting point of 200 ° C. or more, and a binder resin fiber is supplied to a card machine to form a mat. And a method of producing a fiber mat by entanglement of fibers.

Examples of the method for entanglement of fibers include a needle punch method in which a needle punch is applied to a mat, and a water entanglement method in which a water flow collides with a mat. When needle punching is performed on the mat, the needle punch is preferably 1 to 150 locations per 1 cm ^{2 and} more preferably 10 to 100 locations.

The fiber mat may contain a thermoplastic resin powder capable of binding the inorganic fiber and the heat-resistant organic fiber in order to improve the binding property between the inorganic fiber and the heat-resistant organic fiber. Examples of the thermoplastic resin constituting such a thermoplastic resin powder include polyethylene resins, polypropylene resins, ethylene-vinyl acetate copolymers, polyethylene terephthalate, and maleic anhydride-modified polyethylene.

Next, a synthetic resin film is directly laminated on one side or both sides of the fiber mat to form a laminated sheet. In addition, when laminating the synthetic resin film on the fiber mat, the synthetic resin film in a molten state immediately after being extruded from the extruder is continuously supplied onto the fiber mat, and the synthetic resin film is laminated on the fiber mat. Also good.

When the synthetic resin film is composed of a plurality of synthetic resin layers, the synthetic resin film laminated on the fiber mat may bind inorganic fibers and heat-resistant organic fibers having a melting point of 200 ° C. or higher. It is necessary to laminate so that the synthetic resin layer containing the binder resin that can be brought into direct contact with the fiber mat.

Further, instead of the synthetic resin film composed of a plurality of synthetic resin layers, a plurality of synthetic resin films may be laminated on the fiber mat. In this case, the synthetic resin film that is in direct contact with the fiber mat contains a binder resin that can bind the inorganic fibers of the fiber mat 1 and heat-resistant organic fibers having a melting point of 200 ° C. or higher. There is a need.

After that, for example, while the laminated sheet is supplied and conveyed between the pair of conveying belts, the binder resin fiber in the fiber mat of the laminated sheet and the binder resin of the synthetic resin film are melted and The heat-resistant organic fiber is heated to a temperature at which it does not melt, the laminated sheet is compressed in the thickness direction, preferably 0.5 to 3 mm, and the binder resin is impregnated into the fiber mat from the synthetic resin film. In addition, when the heat resistant synthetic resin layer is formed in the synthetic resin film, it is necessary to set to a temperature at which the heat resistant synthetic resin does not melt.

Next, when the pressure applied to the laminated sheet is removed, the laminated sheet expands in the thickness direction due to the restoring force of the entangled inorganic fibers in the laminated sheet fiber mat, and numerous voids are formed in the laminated sheet fiber mat. Thus, a lightweight laminated sheet is obtained.

At this time, when the laminated sheet is supplied between the pair of conveying belts, the laminated sheet is sucked through the conveying belt, and is laminated by widening the interval between the pair of conveying belts with the laminated sheet adsorbed on the conveying belt. The sheet may be forcibly expanded in the thickness direction.

Since both weight reduction and mechanical strength can be achieved, it is preferable to adjust the porosity of the laminated body for vehicle exterior materials to be 30 to 90%.

Then, the laminated body for vehicle exterior materials can be obtained by cooling the laminated sheet. The binder resin fibers in the fiber mat of the obtained laminate for vehicle exterior materials are melted to bind inorganic fibers and heat-resistant organic fibers having a melting point of 200 ° C. or higher, and to bind the synthetic resin film. Part of the adhesive resin is impregnated into the fiber mat to bind the inorganic fiber and the heat-resistant organic fiber having a melting point of 200 ° C. or higher. In particular, the binder resin of the synthetic resin film impregnated in the fiber mat is concentrated on the surface portion of the fiber mat, and the surface portion of the fiber mat 1 is reinforced.

Therefore, the surface portion of the laminate for vehicle exterior materials is superior in mechanical strength such as impact resistance compared to the central portion in the thickness direction, and the laminate for vehicle exterior materials is torn by collision with stepping stones, etc. Is less likely to break.

A vehicle exterior material can be obtained by thermoforming the laminate for a vehicle exterior material. Examples of the vehicle exterior material include a vehicle under cover, a vehicle fender cover, a tire housing, and the like. The vehicle undercover is used to cover the bottom of the vehicle completely or partially to reduce air resistance at the bottom of the vehicle or to protect the bottom of the vehicle.

In addition, when the pressure is removed during the production of the laminated body for the vehicle exterior material, the entangled inorganic fibers in the fiber mat recover the thickness of the fiber mat by its own restoring force. The laminate for a vehicle exterior material whose thickness has been recovered by such an action can be heat-molded into a vehicle exterior material having a complicated shape.

Therefore, the obtained vehicle exterior material is very light with many voids formed inside the fiber mat. Furthermore, if the vehicle exterior material has an appropriate thickness, specifically, preferably 2 mm or more, more preferably 3 mm or more, the vehicle exterior material has excellent elasticity and is not easily damaged by a collision with a stepping stone or the like.

The synthetic resin constituting the laminate for vehicle exterior materials may contain a pigment such as carbon black, an antioxidant, a slip agent, a crystallization nucleating agent, and the like as necessary.

The laminate for a vehicle exterior material of the present invention has the above-described configuration, and has excellent mechanical strength because the fiber mat contains inorganic fibers and heat-resistant organic fibers. Furthermore, the laminated body for vehicle exterior materials is provided with excellent elasticity by the heat-resistant organic fiber, and effectively absorbs the impact caused by the collision of the stepping stones and is not easily broken.

In the laminate for vehicle exterior materials, a synthetic resin film is laminated and integrated on at least one surface of the fiber mat, and a part of the synthetic resin film is impregnated into the fiber mat to increase the mechanical strength of the fiber mat surface portion. It is improving. Therefore, the laminated body for vehicle exterior materials is particularly excellent in mechanical strength on the surface thereof, and is hardly broken by an impact caused by a stepping stone collision or the like due to a synergistic effect with the impact absorbing effect by the fiber mat described above.

Further, in the laminated body for vehicle exterior materials, when at least one synthetic resin layer other than the innermost layer is a heat-resistant synthetic resin layer having a melting point of 200 ° C. or higher, it is thick on the surface of the fiber mat even after thermoforming. Since the synthetic resin layer can remain, the mechanical strength on the surface of the vehicle exterior material can be further improved.

It is the longitudinal cross-sectional view which showed the laminated body for vehicle exterior materials of this invention. It is the longitudinal cross-sectional view which showed another example of the laminated body for vehicle exterior materials of this invention. It is the model side view which showed the manufacturing apparatus of the laminated body for vehicle exterior materials of this invention.

Example 1
Glass fiber having a length of 40 to 75 mm and a diameter of 9 μm, polypropylene fiber having a fineness of 6.6 dtex and a length of 64 mm (melting point: 160 ° C.), polyethylene terephthalate having a fineness of 17 dtex and a length of 64 mm Fibers (melting point: 255 ° C.) were mixed so as to have the basis weight shown in Table 1, respectively, supplied to a card machine, defibrated and mixed to obtain a long mat. The resulting mat was hit with 20 needle punches per 1 cm ² to entangle the fibers to obtain a long fiber mat 1 having a basis weight of 700 g / m ² .

Next, a thickness of 160 μm (weight per unit area: 144 g / m ² ) made of high-density polyethylene (melting point: 135 ° C., melt flow rate: 5.0 g / 10 min) is formed on each of the upper and lower surfaces of the long fiber mat 1. The long

synthetic resin films

2 and 2 are continuously laminated to obtain a laminated sheet B having a thickness of 8 mm.

As shown in FIG. 3, a pair of upper and lower

endless conveyor belts

3 and 3 whose surfaces were coated with polytetrafluoroethylene were prepared. A laminated sheet was continuously supplied between the pair of conveying

belts

3 and 3, and the laminated sheet B was passed through a 200 ° C. hot air heating furnace 4 and heated for 5 minutes.

Subsequently, the laminated sheet B is supplied between a pair of flat plate presses 5 and 5 heated to 200 ° C., and the laminated sheet B is compressed so that its thickness becomes 1.5 mm and held for 5 seconds, A portion of the high-density polyethylene constituting the synthetic resin film was impregnated into the fiber mat, and the polypropylene fiber was melted.

Next, the laminated sheet B is supplied between the flat plate-like upper and lower

vacuum expansion devices

6 and 6, and the laminated sheet B is vacuum-sucked through the pair of conveying

belts

3 and 3 to bring the laminated sheet B in the thickness direction After spreading, the laminated sheet B was supplied into the cooling device 7 and cooled to obtain a laminated body for a vehicle exterior material having a thickness of 4.5 mm and a basis weight of 1000 g / m ² .

The resulting laminate for vehicle exterior materials had a synthetic resin film made of high-density polyethylene laminated and integrated on both sides of the fiber mat. The glass fiber and polyethylene terephthalate fiber of the fiber mat are partially bound by polypropylene, and the surface portion of the fiber mat is impregnated with part of the high-density polyethylene constituting the synthetic resin film. The fibers were bound together. A void was formed in the fiber mat of the laminate for a vehicle exterior material, and the void ratio was 82%.

(Example 2)
As a synthetic resin film laminated on the upper surface of the fiber mat, two synthetic resin films made of high-density polyethylene (melting point: 135 ° C., melt flow rate: 5.0 g / 10 min) are laminated and integrated. A laminated body for vehicle exterior materials having a basis weight of 1130 g / m ² was obtained in the same manner as in Example 1 except that (thickness: 320 μm, basis weight: 288 g / m ² ) was used.

The resulting laminate for vehicle exterior materials had a synthetic resin film made of high-density polyethylene laminated and integrated on both sides of the fiber mat. The glass fibers of the fiber mat are partly bound by polypropylene, and the fiber mat surfaces are impregnated with a part of the high density polyethylene constituting the synthetic resin film to bind the fibers of the fiber mat. I was wearing it. A void was formed in the fiber mat of the laminate for a vehicle exterior material, and the void ratio was 78%.

(Example 3)
As a synthetic resin film laminated on the upper surface of the fiber mat, a polyethylene terephthalate copolymer resin (Bell Polyester Products Co., Ltd.) having a melting point of 150 ° C. and a melt flow rate of 2.9 g / 10 min with respect to a polyethylene terephthalate film having a melting point of 255 ° C. A synthetic resin film (thickness: 160 μm, basis weight: 203 g / m ² ) in which layers composed of a product name “Belpet E-02” are laminated and integrated, Conducted except that a synthetic resin film was laminated so that the polyethylene terephthalate copolymer resin layer was in contact, and a film similar to the synthetic resin film (thickness = 160 μm) made of high-density polyethylene used in Example 1 was used on the lower surface. In the same manner as in Example 1, a laminate for vehicle exterior materials having a basis weight of 1050 g / m ² was obtained.

The resulting laminate for vehicle exterior materials had a synthetic resin film laminated and integrated on both sides of the fiber mat. The glass fiber of the fiber mat and the polyethylene terephthalate fiber are partially bound by polypropylene, and on the surface layer of the fiber mat, a part of the high-density polyethylene constituting the synthetic resin film has a melting point of 150 ° C. and a melt flow rate. Part of the 2.9 g / 10 min polyethylene terephthalate copolymer resin was impregnated to bind the fibers of the fiber mat. A void was formed in the fiber mat of the laminate for a vehicle exterior material, and the void ratio was 82%.

(Comparative Example 1)
A laminated body for vehicle exterior materials having a basis weight of 1000 g / m ² was obtained in the same manner as in Example 1 except that a fiber mat was made of the same glass fiber and polypropylene fiber as in Example 1.

The resulting laminate for vehicle exterior materials had a synthetic resin film laminated and integrated on both sides of the fiber mat. The glass fiber of the fiber mat is partially bound by polypropylene, and the surface portion of the fiber mat is impregnated with a part of the high density polyethylene constituting the synthetic resin film so that the fibers of the fiber mat are interleaved. I was bound. Gaps were formed in the fiber mat of the laminate for vehicle exterior materials, and the porosity was 83%.

For the obtained laminate for vehicle exterior materials, a stepping stone test and a molding flaw test were conducted as follows. Moreover, the high temperature elongation rate was measured in the following manner. The results are shown in Table 1.

(Stepping stone test)
A test piece was cut out from a laminate for a vehicle exterior material into a rectangular shape having a length of 220 mm and a width of 290 mm, and the test piece was fixed in a metal frame. Next, a synthetic resin ball having a diameter of 6 mm was caused to collide with the center of the test piece using a commercially available model gun. In addition, about the laminated body for vehicle exterior materials of Example 3, the ball | bowl made from a synthetic resin was made to collide with the surface in which the synthetic resin film of the two-layer structure was formed.

The synthetic resin ball was repeatedly collided 30 times with the same part of the test piece, and the maximum depth of the dent of the test piece formed by colliding the synthetic resin ball was measured with a caliper.

In the laminated body for vehicle exterior materials obtained in Examples 1 to 3, no crack was generated in the recessed portion of the test piece, but in the laminated body for vehicle exterior material obtained in Comparative Example 1, Cracks have occurred.

(High temperature elongation)
A test piece was cut out from the laminate for a vehicle exterior material, and the test piece was fixed with a pair of chucks at a distance between chucks of 100 mm. In this state, the test piece was supplied into a thermostat kept at 190 ° C. and heated for 5 minutes.

When the surface temperature of the test piece reached 170 ° C., the test piece was pulled by increasing the distance between chucks, and an SS curve was recorded on the chart. The elongation Lmm of the test piece at the time when the maximum tensile load was generated from the chart was measured. The high temperature elongation rate was calculated based on the following formula.
High temperature elongation (%) = (L / 100) × 100

(Molding test)
A male mold having a frustoconical convex portion having a round shape with a bottom surface of 80 mm in diameter and a circular shape with a top surface of 40 mm in diameter, and a female die having a concave portion corresponding to the convex portion of the male mold A mold was prepared.

Next, a test piece is cut out from the laminated body for vehicle exterior materials into a rectangle of 500 mm in length and 600 mm in width, and this test piece is attached to a metal frame with a needle installed at equal intervals around it, and a far infrared heater is used. The test piece was heated so that the surface temperature was 180 ° C. Subsequently, after placing the test piece between the male and female molds, the male and female molds were clamped and held for 30 seconds, and then the mold was opened to obtain a molded product.

The periphery of the convex part of the obtained molded product was visually observed to determine whether wrinkles were generated on the molded product, and judged based on the following criteria.
Good: no wrinkle around the convex part Bad: there is a wrinkle around the convex part

Since the laminated body for vehicle exterior materials of the present invention has excellent mechanical strength and excellent elasticity, it effectively absorbs impact caused by collision of stepping stones, is not easily torn, and is formed by heat molding. It can be suitably used for vehicle exterior materials such as an undercover, a vehicle fender cover, a tire housing, and an engine cover.

1 Fiber mat 2 Synthetic resin film
21, 21a, 21b Synthetic resin layer 3 Conveyor belt 4 Hot-air heating furnace 5 Flat plate press 6 Vertical vacuum expansion device 7 Cooling device A Laminate for vehicle exterior materials

Claims

On the surface of at least one of a fiber mat formed by mixing inorganic fibers, a heat-resistant organic fiber having a melting point of 200 ° C. or higher, and the inorganic fiber and a binder resin fiber that binds the heat-resistant organic fiber, A synthetic resin film containing a binder resin capable of binding fibers and the heat-resistant organic fiber is laminated, the binder resin fiber and the binder resin contained in the synthetic resin film are melted, and the synthetic resin film A laminate for a vehicle exterior material obtained by impregnating a molten binder resin into a fiber mat and binding the inorganic fibers and the heat-resistant organic fibers.
The synthetic resin film comprises a plurality of synthetic resin layers, and at least one synthetic resin layer excluding the innermost synthetic resin layer comprises a heat resistant synthetic resin having a melting point of 200 ° C or higher. The laminated body for vehicle exterior materials of description.
The laminated body for vehicle exterior materials according to claim 2, wherein the outermost synthetic resin layer of the synthetic resin film is made of a heat-resistant synthetic resin having a melting point of 200 ° C or higher.
On the surface of at least one of a fiber mat formed by mixing inorganic fibers, a heat-resistant organic fiber having a melting point of 200 ° C. or higher, and the inorganic fiber and a binder resin fiber that binds the heat-resistant organic fiber, A laminated sheet is produced by laminating a fiber and a synthetic resin film containing a binder resin capable of binding the heat-resistant organic fiber, and the laminated sheet is heated while melting the binder resin fiber and the synthetic resin film. A method for producing a laminate for a vehicle exterior material, wherein the fiber mat is impregnated with a binder resin that has been compressed in the thickness direction and melted from the synthetic resin film, the pressure is removed, and cooling is performed.
The synthetic resin film comprises a plurality of synthetic resin layers, and at least one synthetic resin layer excluding the innermost synthetic resin layer comprises a heat-resistant synthetic resin having a melting point of 200 ° C. or higher. The manufacturing method of the laminated body for vehicle exterior materials of description.
The method for producing a laminate for a vehicle exterior material according to claim 5, wherein the outermost synthetic resin layer of the synthetic resin film is made of a heat-resistant synthetic resin having a melting point of 200 ° C or higher.
The vehicle exterior material characterized by heat-molding the laminated body for vehicle exterior materials of any one of Claim 1 thru | or 3.