Automobile interior headliner molding or forming member and automobile interior headliner member using the same

Abstract

This invention is to provide an automobile interior headliner molding or forming member which has high rigidity, being excellent in heat resistance and size stability, and having excellent moldability or formability. An automobile interior headliner molding or forming member is produced using a seven-layer polypropylene foam laminate obtained by stacking, over both sides of a foamed polypropylene sheet, a glass fiber sheet laminate, which has been obtained by laminating a polypropylene sheet with both sides of a glass fiber sheet.

What is claimed is:  
     
         1 . An automobile interior headliner molding or forming member comprising a seven-layer polypropylene foam laminate formed by laminating a foamed polypropylene sheet, on both sides thereof, with a glass fiber sheet laminate having a glass fiber sheet laminated on both sides thereof with a polypropylene sheet.  
     
     
         2 . An automobile interior headliner molding or forming member of  claim 1 , wherein the foamed polypropylene sheet constituting the seven-layer polypropylene foam laminate has an expansion ratio of 5 to 50 times and a thickness of 2 to 6 mm, 
 the glass fiber sheet is composed mainly of glass fibers and has a mass per unit area of 20 to 150 g/m 2 , and    the polypropylene sheet laminated with the glass fiber sheet on both sides thereof has a thickness of 20 to 300 μm.    
     
     
         3 . An automobile interior headliner molding or forming member of  claim 1 , wherein the glass fiber sheet contains 90 to 30% by mass of glass fibers and 10 to 70% by mass of olefin resin fibers such as polypropylene fibers.  
     
     
         4 . An automobile interior headliner molding or forming member of  claim 1 , wherein the polypropylene sheet laminated with the glass fiber sheet on both sides thereof has a melt flow rate, as measured at a testing temperature of 230° C. under a test load of 21.18N, of 3 to 40 g/10 min, and contains a filler such as mica or talc in an amount of 5 to 10% by mass.  
     
     
         5 . An automobile interior headliner molding or forming member of  claim 1 , wherein a back treating material is adhered to the back side of the seven-layer polypropylene foam laminate.  
     
     
         6 . An automobile interior headliner molding or forming member of  claim 5 , wherein the back treating material is a nonwoven fabric composed mainly of polyester fibers.  
     
     
         7 . An automobile interior headliner member obtained by molding or forming of an automobile interior headliner molding or forming member as claimed in  claim 1 .  
     
     
         8 . An automobile interior headliner member of  claim 7 , wherein the seven-layer polypropylene foam laminate has a reinforced portion formed by partially laminating a glass fiber sheet, which has been laminated with a polypropylene sheet on the side of the back treating material, to the outer surface of the back treating material adhered to the back side of the polypropylene foam laminate.  
     
     
         9 . An automobile interior headliner member of  claim 8 , wherein the glass fiber sheet and polypropylene sheet laminated with the outer surface of the back treating material on the back side of the seven-layer polypropylene foam laminate have been formed of the same materials as those used for the glass fiber sheet laminate constituting the seven-layer polypropylene foam laminate.  
     
     
         10 . An automobile interior headliner molding or forming member of  claim 1 , wherein an absolute shrinkage percentage of the automobile interior headliner molding or forming member, as tested by a method which will be described later, is 0.05% or less.  
     
     
         11 . An automobile interior headliner member of  claim 7 , wherein an absolute shrinkage percentage of the automobile interior headliner member, as tested by a method which will be described later, is 0.05% or less.