AU6669900A - Laminate and materials for the same - Google Patents

Laminate and materials for the same Download PDF

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Publication number
AU6669900A
AU6669900A AU66699/00A AU6669900A AU6669900A AU 6669900 A AU6669900 A AU 6669900A AU 66699/00 A AU66699/00 A AU 66699/00A AU 6669900 A AU6669900 A AU 6669900A AU 6669900 A AU6669900 A AU 6669900A
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AU
Australia
Prior art keywords
thermoplastic resin
woven fabric
layer
natural vegetable
fibers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
AU66699/00A
Inventor
Takeo Kitayama
Yoshinori Ohmura
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sumika Plastech Co Ltd
Sumitomo Chemical Co Ltd
Original Assignee
Sumika Plastech Co Ltd
Sumitomo Chemical Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP30412899A external-priority patent/JP2001122046A/en
Priority claimed from JP30412599A external-priority patent/JP2001122986A/en
Priority claimed from JP30412799A external-priority patent/JP2001121651A/en
Priority claimed from JP30412699A external-priority patent/JP4410887B2/en
Priority claimed from JP30412499A external-priority patent/JP2001131854A/en
Application filed by Sumika Plastech Co Ltd, Sumitomo Chemical Co Ltd filed Critical Sumika Plastech Co Ltd
Publication of AU6669900A publication Critical patent/AU6669900A/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/088—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/12—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/504—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/20—Fibres of continuous length in the form of a non-woven mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B32B2307/734—Dimensional stability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/10—Polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)

Description

a a a. a a
AUSTRALIA
PATENTS ACT 1990 COMPLETE SPECIFICATION NAME OF APPLICANT(S): Sumitomo Chemical Company, Limited AND Sumika Plastech Co., Ltd.
ADDRESS FOR SERVICE: DAVIES COLLISON CAVE Patent Attorneys 1 Little Collins Street, Melbourne, 3000.
INVENTION TITLE: Laminate and materials for the same The following statement is a full description of this invention, including the best method of performing it known to me/us:- BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminate useful as a material of interior members for vehicles, particularly a laminate which can exhibit characteristics required for interior members of vehicles to have through using, as one of the elements of a interior member, a thermoplastic resin sheet layer which is allowed to contain natural vegetable cellulose-based fibers therein; a thermoplastic resin sheet useful as a material (processed material) of interior members of vehicles; a non-woven fabric laminate useful as a material (another processed material) of interior members of vehicles, particularly a non-woven fabric laminate which can exhibit characteristics which have not been heretofore obtained, through using a non-woven fabric containing fibers made of different materials; a composite non-woven fabric useful as a material (material for processing) of interior members of vehicles, particularly a composite non-woven fabric which can exhibit characteristics which have not been heretofore obtained, through using fibers made of different materials; and the like.
2. Description of the Related Art As interior members of vehicles such as a ceiling material of an It I vehicle, those made of a thermoplastic resin have been widely used. In order to improve quality of design, touch feeling and high-quality image of such interior members of vehicles, various kinds of skin materials are sometimes laminated as a layer on surfaces of interior members made of a thermoplastic resin. As materials for such skin materials, various materials are known such as woven fabric or knitted fabric such as moquette and tricot, non-woven fabric, metallic foil and a sheet or film made of a thermoplastic resin or thermoplastic elastomer.
Incidentally, interior members made of a thermoplastic resin including interior members of vehicles are often required to have characteristics such as a high rigidity, a small coefficient of linear expansion and a light weight.
The interior members made of a thermoplastic resin can relatively easily achieve the characteristics and but as for the reduction of a coefficient of linear expansion no desired value has been achieved yet.
Namely, temperature inside a vehicle varies greatly as a season changes. The temperature change is as much as 100 0 C. Interior members of vehicles are required to have such characteristics that the members do not deflect even if such a temperature change takes place.
An important factor for interior members of vehicles to meet such a requirement is that the interior members have a low coefficient of linear expansion, but actually speaking, any interior member of vehicles made of only a thermoplastic resin can not satisfy such a requirement enough.
Under such circumstances, many technologies for attaining a low coefficient of linear expansion of interior members made of a thermoplastic resin, especially those of vehicles, have been proposed.
The most typical technology ever known is a laminate in which a mat comprising glass fibers is laminated on a surface of a layer comprising a thermoplastic resin. Such a thermoplastic resin laminate has a relatively low coefficient of linear expansion due to a relatively low coefficient of linear expansion of the glass fibers.
Mats comprising glass fibers, however, have poor touch feeling and are not suitable as interior members of vehicles. Moreover, they have heavy weight and may inhibit the aforementioned characteristic Furthermore, glass fibers impair a working environment in the production of laminates and are not easy to be recycled, causing a problem in disposal thereof. In addition, it has been pointed out that glass fibers are relatively expensive and therefore the above-mentioned laminate requires a relatively high cost.
••go SUMMARY OF THE INVENTION The present invention has been made under such circumstances and its object is to provide an interior member made of a thermoplastic resin and its materials, the interior member being able to solve problems with interior members made of a thermoplastic resin using a conventional glass fiber mat, being able to attain a low coefficient of linear expansion that is the most important characteristic which interior members of vehicles are required to have, having a high rigidity, and being light weight.
The present inventors have studied from various angles to attain the above object and they first directed their attention particularly to natural vegetable cellulose-based fibers as a raw material of the laminate, thermoplastic resin sheet, non-woven fabric laminate and composite non-woven fabric of the present invention having the aforementioned characteristics. Furthermore, they turned their attention particularly to hemp fiber that has excellent natural feeling, a high Young's modulus and a low coefficient of linear expansion.
As a result, they have reached the present invention through finding that to obtain desired laminates, particularly interior members of vehicles, with making use of the characteristics of such natural vegetable cellulose-based fibers, laminates that fit the purpose described above can be realized by laminating at least one thermoplastic resin sheet layer containing from 50 to 10% by weight of a thermoplastic resin and from to 90% by weight of natural vegetable cellulose-based fibers and at least ••go one layer comprising a thermoplastic resin.
Further scope of applicability of the present invention will become oo-* apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integer or step.
BRIEF DESCRIPTION OF THE DRAWING Fig. 1 is a schematic explanatory view for illustrating a process for producing the non-woven fabric laminate of the present invention.
DETAILED DESCRIPTION OF THE INVENTION First, the present invention provides a laminate comprising at least one natural vegetable cellulose-based fiber-containing thermoplastic resin sheet layer comprising both of a thermoplastic resin and (a-ii) natural vegetable cellulose-based fibers and at least ego.
:.one layer comprising a thermoplastic resin, wherein a content of the natural vegetable cellulose-based fibers (a-ii) in the at least one natural vegetable cellulose-based fiber-containing thermoplastic resin sheet layer is from 50 to 90% by weight.
As described previously, natural vegetable cellulose-based fiber, especially hemp fiber, has such characteristics as it is excellent in natural feeling, it has a high Young's modulus, it has a low coefficient of linear expansion, it is lightweight, it is waterabsorbable and it has an antistatic effect. A laminate in which a thermoplastic resin sheet comprising a thermoplastic resin and (a-ii) such natural vegetable cellulose-based fibers and a layer-structured material comprising a thermoplastic resin are laminated can reflect the characteristics of the natural vegetable cellulose-based fiber, satisfying the characteristics from through that are characteristics which interior members of vehicles are required to have. Such a laminate also has a surface of good touch feeling. Furthermore, since natural vegetable cellulose-based fiber is a natural material, it causes no problems in its recycling and is relatively inexpensive, achieving a relatively low cost of the laminate.
Although the interior member of vehicles according to the present invention can be used through forming the above-mentioned laminate into a predetermined shape, a skin material (as a layer) may be bonded or welded to one side or both sides of the laminate before or after the formation of the laminate as needed.
The natural vegetable cellulose-based fiber-containing thermoplastic resin sheet in the laminate of the present invention may be produced, for example, by once forming a composite non-woven fabric using thermoplastic resin fibers and natural vegetable cellulose-based fibers together and hot-pressing the composite non-woven fabric with rolls under a predetermined pressure to form it into a sheet. As described earlier, the composite non-woven fabric herein used comprises a thermoplastic resin fibers and natural vegetable cellulose-based fibers and a content of the natural vegetable cellulose-based fibers in the composite non-woven fabric is preferably set to from 50 to 90% by weight.
When the content of the natural vegetable cellulose-based fibers is less than 50% by weight, laminates reflecting the characteristics through caused by the natural vegetable cellulose-based fibers or composite non-woven fabrics reflecting the characteristics and may not be realized easily. When the content of the natural vegetable cellulosebased fibers in the composite non-woven fabric exceeds 90% by weight, a ratio of the thermoplastic resin becomes relatively low (less than 10% by weight). As a result, fibers will soon loosen and it becomes difficult for the fibers to maintain a predetermined shape and to be formed into a sheet.
The thermoplastic resin sheet may be used preferably as a material of interior members of vehicles and may also be used preferably as an expansion-inhibiting material of a synthetic "tatami" containing a thermoplastic resin foam therein as a core.
The aforementioned layer comprising a thermoplastic resin may be either a non-foamed layer or a foamed layer.
S. In general, a non-foamed layer is the preferable choice for applications where rigidity and strength are required and a foamed layer is also the preferable choice for applications where weight reduction is required. When a foamed polyolefin is used, its expansion ratio is preferably about three times or more from the viewpoint of weight reduction and about 20 times or less since too high expansion ratio results in lowering of strength.
The production of the laminate of the present invention may be conducted in the following manner. First, a surface of a thermoplastic resin sheet produced in the aforementioned manner is heated with a heater to melt the thermoplastic resin in the sheet. At the same time, a surface of a layer-structured material comprising a thermoplastic resin is heated to melt the surface. Then both materials are introduced to 7 between hot rolls and pressed under heating. By doing this, the molten surfaces (heated surfaces) are welded to produce a laminate in which the thermoplastic resin sheet layer and the layer-structured material are laminated together. By using such a method, laminates having at least one thermoplastic resin sheet layer and at least one layer comprising a thermoplastic resin may be produced.
When the thermoplastic resin sheet and/or the layer comprising a thermoplastic resin is made of polyolefin, the application of a halogenated polyolefin onto a surface of the thermoplastic resin sheet and/or the layer comprising a thermoplastic resin may improve adhesive strength between the layers. The halogenated polyolefin may be selected depending upon the materials forming the thermoplastic resin sheet and/or the layer *"ocomprising a thermoplastic resin. For example, chlorinated polypropylene and chlorinated polyethylene may be employed.
S
A process for the production of the laminate of the present invention is not limited to that described above. For example, the laminate may also be produced by piling at least one thermoplastic resin sheet and at least one layer comprising a thermoplastic resin in an appropriate order and bonding them by an adhesive. The adhesive to be used here may be an epoxy resin-based adhesive and a polyester resinbased adhesive.
By finally forming the laminate into a predetermined shape such as a ceiling material by means of a stamping molding machine or the like may be produce the interior member of vehicles according to the present invention. If necessary, bonding or welding a skin material (as a layer) selected from those of various kinds onto one side or both sides of the laminate before or after its formation is also useful for the improvement of quality of design, touch feeling and high-quality image. The bonding or welding may be conducted in the same manner as that described above in which the laminate is produced. The skin material layer (as a layer) is preferably bonded or welded to one surface or both surfaces of the laminate, the surface or each of the surfaces being a surface of a natural vegetable cellulose-based fiber-containing thermoplastic resin sheet layer.
The interior member of vehicles according to the present invention obtained in the above-described manner is excellent in characteristics which interior members of vehicles are required to have such as (1) rigidity, a coefficient of linear expansion and light weight. The desired values of these characteristics required for interior member of vehicles are as follows: Rigidity: 30 N/50 mm or more in terms of maximum flexural load and 80 N/50 mm/cm or more in terms of flexural modulus Coefficient of linear expansion: 3X 10-5 /C or less Light weight: 700 g/m 2 or less in terms of weight per unit area Examples of the thermoplastic resin or its fibers used in the thermoplastic resin sheet of the present invention include various resins or their fibers, for example, conventional thermoplastic resins or their fibers including polyolefins such as polypropylene and polyethylene, an acrylonitrile-styrene-butadiene block copolymer, polystyrene, polyamides such as nylon, polyesters, poly(vinyl chloride), polycarbonate, acrylic resins and a styrene-butadiene copolymer, thermoplastic elastomers or their fibers such as EPM (ethylene-propylene copolymer) and EPDM (ethylene-propylene-diene copolymer), mixtures of these resins or their fibers, and polymer alloys or their fibers using these resins. Among them, polyolefins and thermoplastic elastomers such as polypropylene, polyethylene, EPM and EPDM or their fibers may be preferably employed with consideration given to processability to sheets. More preferred is polypropylene or its fiber which has good heat resistance.
In order to bond the polyolefins or their fibers to the natural vegetable cellulose-based fibers well to achieve greater strength, it is preferable that the polyolefins or their fibers are polyolefins modified with unsaturated acids or unsaturated acid anhydrides, that is, modified polyolefins or their fibers. Common unsaturated acids and unsaturated acid anhydrides include unsaturated carboxylic acids and unsaturated carboxylic acid anhydrides. Examples thereof include acrylic acid, methacrylic acid, maleic acid, maleic anhydride, fumaric acid, itaconic acid, itaconic anhydride, mesaconic acid, citraconic acid, crotonic acid, isocrotonic acid and angelic acid. Preferable modified polyolefins or their fibers include maleic anhydride-modified polypropylene or its fiber.
Examples of the natural vegetable cellulose-based fiber used in the thermoplastic resin sheet of the present invention include cotton fiber, hemp fiber, palm fiber and bamboo fiber. Although any of these fibers may be used, hemp fiber is the most desirable as a material of the composite non-woven fabric of the present invention. Among the abovelisted natural vegetable cellulose-based fibers, hemp fiber is the best in moisture-absorbing property and moisture-desorbing property. Further, hemp fiber is stronger than other natural vegetable cellulose-based fibers.
In addition, it is excellent in touch feeling due to its fresh cool feeling and fresh touch feeling.
Among the natural vegetable cellulose-based fiber used in the thermoplastic resin sheet of the present invention, the hemp fiber may be flax (linen), ramie, jute, Manila hemp (abaca), sisal, kenaf and the like.
Any of these hemp fibers may be used. Among them, it is preferable to use jute, kenaf or flax since these are annual and are relatively easy obtained.
0000 The diameter thickness) and length of the natural vegetable cellulose-based fibers used in the present invention may vary depending 0o on the kind of the fibers and are not limited as long as the fibers can form non-woven fabric, but standards for some fibers are as follows.
0000 As for diameter of natural vegetable cellulose-based fiber, a proper diameter varies depending on the kind of fiber, but one having a diameter of approximately from 1 to 50 deniers is preferably used. Accordingly, a fiber having a desirable diameter may be selected and used depending on the type of fiber. For example, in the case of cotton fiber, those having a diameter of approximately from 1 to 4 deniers are preferably used. In the case of hemp fiber, those having a diameter of approximately from 5 to deniers are preferably used. Those having a diameter of approximately from 5 to 20 deniers are more desirable.
As for the length of the natural vegetable cellulose-based fiber, when cotton fiber is used preferable length thereof is approximately from to 45 mm. In the case where hemp fiber is used the length thereof is usually from about 10 to about 60 mm, preferably from about 20 to about mm, still more preferably from about 40 to about 60 mm.
The present invention provides a composite non-woven fabric comprising thermoplastic resin fibers and (ii) natural vegetable cellulose-based fibers.
As a method for the production of the composite non-woven fabric, various methods are known including wet method, dry method and spunbond method. The dry method includes needle punch method, stitch bond method and adhesion method. Although all of these .,.methods may be adopted as a method for the production of the composite non-woven fabric of the present invention, using the needle punch method, which is a kind of the dry method, is the best choice from the viewpoint of obtaining a composite non-woven fabric in which the characteristics of the natural vegetable cellulose-based fiber used as a raw material are reflected and because of the convenience in the production. The needle punch method is a method in which fibers are formed into a sheet-like web by means of a card for spinning and the like and the web is stuck with many needles many times so that the fibers in the web are entangled up and down. This method hardly deteriorates the natural vegetable cellulose-based fibers as a raw material and may leave the soft feeling and touch feeling of the natural vegetable cellulose-based fiber as they are after the formation of the thermoplastic resin sheet or non-woven fabric laminate.
Examples of the thermoplastic resin fibers used in the composite non-woven fabric of the present invention include various resin fibers, for example, fibers made of conventional thermoplastic resins including polyolefins such as polypropylene and polyethylene, an acrylonitrilestyrene-butadiene block copolymer, polystyrene, polyamides such as nylon, polyesters, poly(vinyl chloride), polycarbonate, acrylic resins and a styrene-butadiene copolymer, thermoplastic elastomers or their fibers such as EPM (ethylene-propylene copolymer) and EPDM (ethylenepropylene-diene copolymer), mixtures of these resins, and polymer alloys.
Among them, polyolefin fibers and thermoplastic elastomer fibers such as *ft polypropylene, polyethylene, EPM and EPDM fibers may be preferably employed with consideration given to processability to sheets. More preferred is polypropylene fiber which has good heat resistance.
In order to bond the polyolefin fibers to the natural vegetable cellulose-based fibers well to achieve greater strength, it is preferable t that the polyolefin fibers are polyolefin fibers modified with unsaturated acids or unsaturated acid anhydrides, that is, modified polyolefin fibers.
Common unsaturated acids and unsaturated acid anhydrides include unsaturated carboxylic acids and unsaturated carboxylic acid anhydrides.
Examples thereof include acrylic acid, methacrylic acid, maleic acid, maleic anhydride, fumaric acid, itaconic acid, itaconic anhydride, mesaconic acid, citraconic acid, crotonic acid, isocrotonic acid and angelic acid. Preferable modified polyolefin fibers include maleic anhydridemodified polypropylene fiber.
Examples of the natural vegetable cellulose-based fiber used in the composite non-woven fabric of the present invention include cotton fiber, hemp fiber, palm fiber and bamboo fiber. Although any of these fibers may be used, hemp fiber is the most desirable as a material of the composite non-woven fabric of the present invention. Among the abovelisted natural vegetable cellulose-based fibers, hemp fiber is the best in moisture-absorbing property and moisture-desorbing property. Further, hemp fiber is stronger than other natural vegetable cellulose-based fibers.
In addition, it is excellent in touch feeling due to its fresh cool feeling and fresh touch feeling.
Among the natural vegetable cellulose-based fiber used in the composite non-woven fabric of the present invention, the hemp fiber may be flax (linen), ramie, jute, Manila hemp (abaca), sisal, kenaf and the like.
Any of these hemp fibers may be used. Among them, it is preferable to use jute, kenaf or flax since these are annual and are relatively easy obtained.
The diameter thickness) and length of the natural vegetable cellulose-based fibers used in the present invention may vary depending on the kind of the fibers and are not limited as long as the fibers can form non-woven fabric, but standards for some fibers are as follows.
As for diameter of natural vegetable cellulose-based fiber, a proper diameter varies depending on the kind of fiber, but one having a diameter of approximately from 1 to 50 deniers is preferably used. Accordingly, a fiber having a desirable diameter may be selected and used depending on the type of fiber. For example, in the case of cotton fiber, those having a diameter of approximately from 1 to 4 deniers are preferably used. In the case of hemp fiber, those having a diameter of approximately from 5 to deniers are preferably used. Those having a diameter of approximately from 5 to 20 deniers are more desirable.
As for the length of the natural vegetable cellulose-based fiber, when cotton fiber is used preferable length thereof is approximately from to 45 mm. In the case where hemp fiber is used the length thereof is usually from about 10 to about 60 mm, preferably from about 20 to about mm, still more preferably from about 40 to about 60 mm.
~The present invention provides a non-woven fabric laminate comprising both of a layer comprising a thermoplastic resin and a layer comprising a composite non-woven fabric laminated on one side or both sides of the layer comprising a thermoplastic resin the composite non-woven fabric comprising thermoplastic resin fibers and (b-ii) •fT "natural vegetable cellulose-based fibers wherein a content of the natural Svegetable cellulose-based fibers (b-ii) in the layer comprising the composite non-woven fabric is from 50 to 90% by weight.
A process for the production of the non-woven fabric laminate of the present invention will be described with reference to the drawing.
Fig. 1 is a schematic explanatory view for illustrating a process for producing the non-woven fabric laminate of the present invention. The numerals 1, la, 2, 3, 4, and 5a and 5b denote a roll of a sheet-like composite non-woven fabric, the sheet-like composite non-woven fabric, a preheater, a thermoplastic resin sheet (or board), a heater, and a pair of hot rolls, respectively.
In the production of the non-woven fabric laminate of the present invention, the sheet-like composite non-woven fabric la rolled into the form of a roll 1 is heated with a preheater 2 to melt the thermoplastic resin fibers in the composite non-woven fabric la. At the same time, a surface of the thermoplastic resin sheet 3 (the layer comprising a thermoplastic resin) is heated with a heater 4 to melt the surface. Then both of the materials are introduced to between the hot rolls 5a and and pressed under heating to be welded. This produces a non-woven fabric laminate in which a composite non-woven fabric is laminated on ne side of the thermoplastic resin sheet 3 (the layer comprising a thermoplastic resin). Moreover, by using such a method, a non-woven fabric laminate in which composite non-woven fabrics are laminated on both sides of a layer comprising a thermoplastic resin.
Although in Fig. 1 is illustrated a case in which both the composite non-woven fabric la and the thermoplastic resin sheet 3 (the layer comprising a thermoplastic resin) are heated, it is also possible .o to eliminate either the preheater 2 or the heater 4 and heat either the composite non-woven fabric la or the thermoplastic resin sheet 3 (the layer comprising a thermoplastic resin) and then lead them to between the hot rolls 5a and 5b to press them under heating. In order to weld the composite non-woven fabric la and the thermoplastic resin sheet 3 (the layer comprising a thermoplastic resin) well even when such a case is adopted and only the composite non-woven fabric 1 is heated, it is necessary to set the content of the thermoplastic resin fibers in the composite non-woven fabric to 10% by weight or more.
A process for the production of the non-woven fabric laminate of the present invention is not limited to that illustrated in Fig. 1 and other 16 processes may be adopted. For example, a non-woven fabric laminate in which a composite non-woven fabrics are laminated on both sides of a layer comprising a thermoplastic resin may be produced by supplying a composite non-woven fabric to between a pair of female and male mold members, supplying a layer comprising a thermoplastic resin whose surfaces are in a molten state to between the composite non-woven fabric and one of the mold members, and clamping the mold members to press 00 0the composite non-woven fabric and the layer comprising the thermoplastic resin.
p Alternatively, a non-woven fabric laminate in which two •o composite two non-woven fabrics are laminated on both sides of a layer *006 comprising a thermoplastic resin may be obtained by using two composite 0000 ***non-woven fabrics, supplying a layer comprising a thermoplastic resin whose surfaces are in a molten state to between the two non-woven :fabrics and clamping the mold members to press the two composite nonwoven fabric and the layer comprising the thermoplastic resin. However, when this method is adopted, it is necessary to proper weight of a composite non-woven fabric so that the layer comprising a thermoplastic resin in the molten state does not penetrate through the composite nonwoven fabric completely.
Moreover, in the case where the thermoplastic resin in the composite non-woven fabric and/or the thermoplastic resin in the layer comprising a thermoplastic resin is polyolefin, the application of halogenated polyolefin to a surface of the composite non-woven fabric and/or the layer comprising a thermoplastic resin may improve adhesion 17 strength between the layers. The halogenated polyolefin may be selected depending on materials of the composite non-woven fabric and/or the layer comprising a thermoplastic resin, and chlorinated polyolefin, chlorinated polyethylene and the like may be used.
In addition, bonding a composite non-woven fabric and a layer comprising a thermoplastic resin may produce the non-woven fabric laminate of the present invention by an adhesive. The adhesion to be used here may be an epoxy resin-based adhesive, a polyester resin-based .*0 adhesive and the like.
$oo The aforementioned layer comprising a thermoplastic resin may be either a non-foamed layer or a foamed layer.
In general, a non-foamed layer is the preferable choice for applications where rigidity and strength are required and a foamed layer is also the preferable choice for applications where weight reduction is required. When a foamed polyolefin is used, its expansion ratio is •preferably about three times or more from the viewpoint of weight reduction and about 20 times or less since too high expansion ratio results in lowering of strength.
Examples of the thermoplastic resin or its fibers used in the nonwoven fabric laminate of the present invention include various resins or their fibers, for example, conventional thermoplastic resins or their fibers including polyolefins such as polypropylene and polyethylene, an acrylonitrile-styrene-butadiene block copolymer, polystyrene, polyamides such as nylon, polyesters, poly(vinyl chloride), polycarbonate, acrylic resins and a styrene-butadiene copolymer, thermoplastic elastomers or 18 their fibers such as EPM (ethylene-propylene copolymer) and EPDM (ethylene-propylene-diene copolymer), mixtures of these resins or their fibers, and polymer alloys or their fibers using these resins. Among them, polyolefins and thermoplastic elastomers such as polypropylene, polyethylene, EPM and EPDM or their fibers may be preferably employed with consideration given to processability to sheets. More preferred is polypropylene or its fiber which has good heat resistance.
In order to bond the polyolefins or their fibers to the natural .vegetable cellulose-based fibers well to achieve greater strength, it is preferable that the polyolefins or their fibers are polyolefins modified with unsaturated acids or unsaturated acid anhydrides, that is, modified polyolefins or their fibers. Common unsaturated acids and unsaturated acid anhydrides include unsaturated carboxylic acids and unsaturated carboxylic acid anhydrides. Examples thereof include acrylic acid, methacrylic acid, maleic acid, maleic anhydride, fumaric acid, itaconic acid, itaconic anhydride, mesaconic acid, citraconic acid, crotonic acid, isocrotonic acid and angelic acid. Preferable modified polyolefins or their fibers include maleic anhydride-modified polypropylene or its fiber.
Examples of the natural vegetable cellulose-based fiber used in the non-woven fabric laminate of the present invention include cotton fiber, hemp fiber, palm fiber and bamboo fiber. Although any of these fibers may be used, hemp fiber is the most desirable as a material of the composite non-woven fabric of the present invention. Among the abovelisted natural vegetable cellulose-based fibers, hemp fiber is the best in moisture-absorbing property and moisture-desorbing property. Further, hemp fiber is stronger than other natural vegetable cellulose-based fibers.
In addition, it is excellent in touch feeling due to its fresh cool feeling and fresh touch feeling.
Among the natural vegetable cellulose-based fiber used in the non-woven fabric laminate of the present invention, the hemp fiber may be flax (linen), ramie, jute, Manila hemp (abaca), sisal, kenaf and the like.
Any of these hemp fibers may be used. Among them, it is preferable to use jute, kenaf or flax since these are annual and are relatively easy obtained.
The diameter thickness) and length of the natural vegetable cellulose-based fibers used in the present invention may vary depending on the kind of the fibers and are not limited as long as the fibers can form non-woven fabric, but standards for some fibers are as follows.
As for diameter of natural vegetable cellulose-based fiber, a proper diameter varies depending on the kind of fiber, but one having a diameter of approximately from 1 to 50 deniers is preferably used. Accordingly, a fiber having a desirable diameter may be selected and used depending on the type of fiber. For example, in the case of cotton fiber, those having a diameter of approximately from 1 to 4 deniers are preferably used. In the case of hemp fiber, those having a diameter of approximately from 5 to deniers are preferably used. Those having a diameter of approximately from 5 to 20 deniers are more desirable.
As for the length of the natural vegetable cellulose-based fiber, when cotton fiber is used preferable length thereof is approximately from to 45 mm. In the case where hemp fiber is used the length thereof is usually from about 10 to about 60 mm, preferably from about 20 to about mm, still more preferably from about 40 to about 60 mm.
The present invention will be concretely described by means of the following Examples, which do not intend to limit the scope of the invention. Modifications in the light of the objects described above and below are contained in the technical scope of the present invention.
EXAMPLES
Example 1 (Production of composite non-woven fabric, thermoplastic resin sheet and laminate) A web having a weight per unit area of 150 g/m 2 was prepared by uniformly mixing jute fibers (diameter: 16 to 21 deniers; length: 30 to mm) and polypropylene fibers (diameter: 5 deniers; length: 51 mm) "i in a weight ratio (jute fiber:polypropylene fiber) of 80:20. This web was subjected to needle-punching in a density of 200 needles/m 2 to yield a :needle-punched non-woven fabric 3 mm in thickness. The non-woven fabric was pressed between hot rolls at 180°C defining a 0.3 mm clearance therebetween to produce a thermoplastic resin sheet 0.3 mm in thickness.
Two thermoplastic resin sheets prepared in the manner described above were applied with a chlorinated polypropylene solution in toluene to their single surfaces and then heated with hot air at 250 0 C. On the other hand, a polypropylene sheet having an expansion ratio of 8 times (coefficient of linear expansion: 1 X 10-4 C; flexural modulus: 118 MPa; maximum flexural load: 7.8 N/50 mm) was applied with a chlorinated polyproptylene solution in toluene on its both surfaces and heated with hot air at 250°C. The polypropylene sheet was inserted to between the two thermoplastic resin sheets so that their chlorinated polypropylene-applied surfaces faced one another and the sheets were laminated. The laminated sheets were pressed between hot rolls at 120'C defining a clearance of 3 mm therebetween to yield a two-kind •three-layer laminate.
The laminate obtained had a coefficient of linear expansion of 3 X 10-5 0 C, a flexural modulus of 1079 MPa and a maximum flexural load of 19.6 N/50 mm. The values of the coefficient of linear expansion, flexural modulus and maximum flexural load were determined by the following measuring methods.
*00 <Coefficient of linear expansion> Three specimens sized 150 mm by 20 mm were taken from a product along its longitudinal direction. Other three specimens were also taken from the product along its cross direction. These specimens were left in a thermostatic oven at 85- 2°C for 24 hours and then taken out to be cooled spontaneously. The specimens were provided with 130mm marks and measured their size.
Next, the specimens were left in a thermostatic oven at 80± 2°C for six hours, and then taken out and measured their size immediately.
Further, the specimens were cooled spontaneously and left in a thermostatic oven at 0+±2C for six hours. They were then taken out of the oven and measured their size immediately 22 A coefficient of linear expansion of each specimen was calculated from the following equation. Of the mean value of the coefficients of linear expansion of the specimens along the longitudinal direction and that of the coefficients of linear expansion of the specimens along the cross direction, the larger one was considered to be the coefficient of linear expansion of the product.
Coefficient of linear expansion [Standard length at 80 0
C
Standard length at 0°C Standard length at 0°C (mm) X Temperature difference at the time of standard length measurement] <Flexural modulus and Maximum flexural load> A 50 mm by 150 mm specimen was supported at two points at a 100 mm interval and weight was put on the specimen at the center between the supported points at a rate of 50 mm/minute. From the relationship between displacement and load, a flexural modulus and a maximum flexural load were determined.
Example 2 (Production of non-woven fabric laminate) A web having a weight per unit area of 100 g/m 2 was prepared by uniformly mixing 60% by weight of jute fibers (diameter: 16 to 21 deniers; length: 30 to 50mm) and 40% by weight of polypropylene fibers (diameter: 5 deniers; length: 51 mm). The web was subjected to needle punching in a density of 200 needles/m 2 to yield a needle-punched non-woven fabric. The non-woven fabric was heated from its one side by means of an infrared heater so that the temperature 23 of the heated surface reached about 150'C. The heated surface was then brought into contact with a 180 0 C bar heater, thereby melting the polypropylene fibers in the vicinity of the heated surface. On the other hand, a 3-mm-thick polypropylene sheet was heated from its one side by means of an infrared heater so that the temperature of the heated surface reached about 140-C.
The composite non-woven fabric and the polypropylene sheet were laminated with making their heated surfaces face one another and then pressed between hot rolls at 160C at a pressure of 0.29 MPa. This yielded a non-woven fabric laminate in which the composite non-woven fabric was laminated to a surface of the polypropylene sheet.
oo The present invention is composed in the manner described above.
By forming interior members made of a thermoplastic resin, particularly interior members of vehicles, from a laminate in which a thermoplastic resin sheet comprising a thermoplastic resin and natural vegetable cellulose-based fibers and a layer comprising a thermoplastic resin are laminated, problems with interior members made of a thermoplastic resin, particularly interior members of vehicles, made of conventional laminates using glass fiber mats can be solved. At the same time, the reduction of a coefficient of linear expansion, which is the most important characteristic that interior members of vehicles are required to have, can be achieved and interior members made of a thermoplastic resin, particularly interior members of vehicles, having a high rigidity and a light weight have been realized.
Moreover, the thermoplastic resin sheet, non-woven fabric laminate and composite non-woven fabric of the present invention can exhibit characteristics which have not been heretofore obtained, through using fibers made of different materials and are useful as materials of interior members for vehicles.
Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that that prior art forms part of the common general knowledge **in Australia.
o oooo

Claims (24)

1. A laminate comprising at least one natural vegetable cellulose-based fiber-containing thermoplastic resin sheet layer comprising both of a thermoplastic resin and (a-ii) natural vegetable cellulose-based fibers and at least one layer comprising a thermoplastic resin, wherein a content of the natural vegetable cellulose-based fibers (a-ii) in the at least one natural vegetable cellulose-based fiber-containing thermoplastic resin sheet layer is from 50 to 90% by weight.
2. The laminate according to claim 1, wherein the thermoplastic resin in the at least one natural vegetable cellulose-based fiber- *containing thermoplastic resin sheet layer is polyolefin.
3. The laminate according to claim 1, wherein the thermoplastic resin in the natural vegetable cellulose-based fiber-containing thermoplastic resin sheet layer is polypropylene.
4. The laminate according to claim 1, wherein the natural vegetable cellulose-based fiber (a-ii) is hemp fiber. The laminate according to claim 4, wherein the hemp fiber is jute, flax or kenaf.
6. The laminate according to claim 1, wherein the at least one layer comprising a thermoplastic resin is a foamed polyolefin layer.
7. The laminate according to claim 6, wherein the foamed polyolefin layer has an expansion ratio of 3 times or more.
8. A laminate comprising the laminate of claim 1 and a skin material layer bonded or welded on one side or both sides of the laminate.
9. A thermoplastic resin sheet comprising both of a thermoplastic resin and (ii) natural vegetable cellulose-based fibers, wherein a content of the natural vegetable cellulose-based fibers (ii) in the thermoplastic resin sheet is from 50 to 90% by weight. A thermoplastic resin sheet comprising both of a thermoplastic resin and (ii) hemp fibers, wherein a content of the hemp fibers (ii) in the thermoplastic resin sheet is from 50 to 90% by weight.
11. The thermoplastic resin sheet according to claim 9, wherein the thermoplastic resin is polyolefin.
12. The thermoplastic resin sheet according to claim 9, wherein the thermoplastic resin is polypropylene.
13. The thermoplastic resin sheet according to claim 10, wherein the hemp fiber is jute, flax or kenaf. S: 14. A non-woven fabric laminate comprising both of a layer comprising a thermoplastic resin and a layer comprising a composite non-woven fabric laminated on one side or both sides of the layer comprising a thermoplastic resin the composite non-woven fabric comprising thermoplastic resin fibers and (b-ii) natural vegetable cellulose-based fibers wherein a content of the natural vegetable cellulose-based fibers (b-ii) in the layer comprising the composite non-woven fabric is from 50 to 90% by weight. The non-woven fabric laminate according to claim 14, wherein the natural vegetable cellulose-based fiber (b-ii) is hemp fiber.
16. The non-woven fabric laminate according to claim 14, wherein the thermoplastic resin fiber is polyolefin fiber. 27
17. The non-woven fabric laminate according to claim 14, wherein the layer of a thermoplastic resin is made up of polyolefin.
18. A composite non-woven fabric comprising thermoplastic resin fibers and (ii) natural vegetable cellulose-based fibers.
19. The composite non-woven fabric according to claim 18, wherein a content of the natural vegetable cellulose-based fibers (ii) in the composite non-woven fabric is from 50 to 90% by weight.
20. The composite non-woven fabric according to claim 18 or 19, wherein a diameter of the natural vegetable cellulose-based fibers (ii) is from 1 to 50 deniers. s, 21. The composite non-woven fabric according to claim 18, wherein the natural vegetable cellulose-based fiber (ii) is hemp fiber.
22. The composite non-woven fabric according to claim 18, wherein the thermoplastic resin fiber is polyolefin fiber.
23. Use of the laminate of claim 1 as an interior member of go vehicles.
24. Use of the thermoplastic resin sheet of claim 9 as a material of interior members of vehicles. Use of the non-woven fabric laminate of claim 14 as a material of interior members of vehicles.
26. Use of the composite non-woven fabric of claim 18 as a material of interior members of vehicles.
27. A process for producing a thermoplastic resin sheet comprising both of a thermoplastic resin and (ii) natural vegetable cellulose-based fibers, the process comprising steps of once forming the 28 0 1 composite non-woven fabric of claim 18 and hot-pressing said composite non-woven fabric with rolls under a predetermined pressure to form it into a sheet.
28. A process for producing a laminate comprising at least one natural vegetable cellulose-based fiber-containing thermoplastic resin sheet layer comprising both of a thermoplastic resin and (a-ii) natural vegetable cellulose-based fibers and at least one layer S" •comprising a thermoplastic resin wherein a content of the natural vegetable cellulose-based fibers (a-ii) in the at least one natural vegetable cellulose-based fiber-containing thermoplastic resin sheet layer is from 50 to 90% by weight, the process comprising steps of heating a surface of the thermoplastic resin sheet of claim 9 with a heater to melt the thermoplastic resin in said thermoplastic resin sheet, heating a surface of a layer-structured material comprising a thermoplastic resin with a heater to melt the surface, and introducing said thermoplastic resin sheet and said layer-structured material to between hot rolls to press them under heating to weld their molten surfaces.
29. A process for producing a non-woven fabric laminate comprising both of a layer comprising a thermoplastic resin and a layer comprising a composite non-woven fabric laminated on one side or both sides of the layer comprising a thermoplastic resin, the composite non-woven fabric comprising thermoplastic resin fibers and (b-ii) natural vegetable cellulose-based fibers wherein a content of the natural vegetable cellulose-based fibers (b-ii) in the layer comprising the composite non-woven fabric is from 50 to 90% by weight, the process comprising steps once forming the composite non-woven fabric of claim 18, heating a surface of said composite non-woven fabric with a heater to melt the thermoplastic resin in said composite non-woven fabric, heating a surface of a layer-structured thermoplastic resin with a heater to melt the surface, and introducing said layer-structured material and said composite non-woven fabric to between hot rolls to press them under heating to weld their molten surfaces. a a. oooo o o*o *°o B 31 A laminate, resin sheet, fabric and/or a process for producing a resin sheet and/or laminate substantially as hereinbefore described with reference to the drawings and/or Examples.
31. The steps, features, compositions and compounds disclosed herein or referred to or indicated in the specification and/or claims of this application, Sindividually or collectively, and any and all combinations of any two or more of said steps or features. ,o DATED this TWENTY FOURTH day of OCTOBER 2000 Sumitomo Chemical Company, Limited AND Sumika Plastech Co., Ltd. DATED this TWENTY FOURTH day of OCTOBER 2000 Sumitomo Chemical Company, Limited AND Sumika Plastech Co., Ltd. 09 by DAVIES COLLISON CAVE Patent Attorneys for the applicant(s)
AU66699/00A 1999-10-26 2000-10-24 Laminate and materials for the same Abandoned AU6669900A (en)

Applications Claiming Priority (10)

Application Number Priority Date Filing Date Title
JP30412899A JP2001122046A (en) 1999-10-26 1999-10-26 Interior material for automobile
JP11-304127 1999-10-26
JP11-304126 1999-10-26
JP30412599A JP2001122986A (en) 1999-10-26 1999-10-26 Thermoplastic resin sheet
JP30412799A JP2001121651A (en) 1999-10-26 1999-10-26 Laminate
JP11-304124 1999-10-26
JP11-304125 1999-10-26
JP11-304128 1999-10-26
JP30412699A JP4410887B2 (en) 1999-10-26 1999-10-26 Method for producing nonwoven fabric laminate
JP30412499A JP2001131854A (en) 1999-10-26 1999-10-26 Composite nonwoven fabric

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