PURPOSE: To provide a method for producing the black base material of a car interior material in which a white or other nonwoven fabric except a black one is used as a raw material and a pre-process for dyeing this nonwoven fabric in black is not necessary.
CONSTITUTION: A white spin-bond nonwoven fabric 2 (100%, 30 to 50g/m2 of polyester) is fed by a roller 3 to a solution tank 1 in which 99% of water, soluble phenol resin is mixed with 1% of azo dye. The nonwoven fabric is impregnated with the mixed solution of the amount of impregnation 50g/m2. The obtained impregnated nonwoven fabric 2A is fed to a drying furnace 5 by a roller 4, and dried for 80 seconds by using steam at temperature of 130°C to have a volatile component of 8 to 10%. The dried nonwoven fabric 2B is cut to a predetermined size by a cutter 6. A three-layer plate 8 formed by providing the two cut nonwoven fabrics 2C and 2C on the upper and lower sides of a rock fiber 7 is placed in a forming die 9 with the prescribed form of a car interior material and thermally pressed. The azo dye with which the cut nonwoven fabrics 2C and 2C are impregnated becomes black and the water soluble phenol resin is cured owing to heating at this time, so that the black base material 10 of the car interior material with the prescribed form can be obtained.
ISHIHAMA HIDENORI
ISHIDA MASANOBU
KATO YOSHIAKI
ISHIDA KK
AICA KOGYO CO LTD