CN102471968A - 发泡成型用非织造布层叠体 - Google Patents

发泡成型用非织造布层叠体 Download PDF

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Publication number
CN102471968A
CN102471968A CN2011800029930A CN201180002993A CN102471968A CN 102471968 A CN102471968 A CN 102471968A CN 2011800029930 A CN2011800029930 A CN 2011800029930A CN 201180002993 A CN201180002993 A CN 201180002993A CN 102471968 A CN102471968 A CN 102471968A
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China
Prior art keywords
nonwoven fabric
foaming
layer
compacted zone
range
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Granted
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CN2011800029930A
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English (en)
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CN102471968B (zh
Inventor
市川太郎
小林是则
吉泽秀宪
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Mitsui Chemical Asahi Living Materials Co ltd
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Mitsui Chemical Industry Co Ltd
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    • B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
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Abstract

本发明目的在于获得一种层间的耐剥离性优异，并且表面无粉尘，具有增强效果和聚氨酯渗出防止性能的发泡成型用层叠体。本发明提供一种发泡成型用非织造布层叠体，其为在致密层的至少一面层叠增强层而形成的发泡成型用非织造布层叠体，其特征在于，致密层是在熔喷非织造布层(A)的两侧层叠纺粘非织造布层(B)、并且将该熔喷非织造布层(A)和纺粘非织造布层(B)进行部分热压接而形成的。

Description

发泡成型用非织造布层叠体
技术领域
本发明涉及层间的耐剥离性优异且具有增强效果和聚氨酯渗出防止性能的发泡成型用非织造布层叠体，尤其涉及设置于聚氨酯等的发泡成型品底部的发泡成型用非织造布层叠体。
背景技术
作为车辆用座椅等的缓冲材料，使用的是软质的发泡聚氨酯等的发泡成型品。出于提高发泡聚氨酯成型品的刚性的目的以及为了使聚氨酯在背面不渗出，在这种发泡成型品的底部设置有增强用基布。作为增强用基布，使用维多利亚细布(cheesecloth)和厚片聚氨酯(slab urethane)的组合、或粗毛布等，但存在聚氨酯成型品的刚性改善不充分，或者不能充分防止聚氨酯渗到背面的可能。
作为改良所述缺点的方法，提出了以下各种方法：使用将目付10～30g/m2的薄且致密的层与目付40～100g/m2的粗且体积大的层一体化而成的非织造布作为增强用基布的方法(日本实公昭62-26193号公报：专利文献1)；使用目付110～800g/m2、纤维直径1～16d的高目付非织造布作为增强用基布的方法(日本特开平2-258332号公报：专利文献2)；或者，使用纤维直径为10μm以下的熔喷非织造布作为致密层的方法(日本特开2004-353153号公报：专利文献3)等。
然而，专利文献1中记载的发泡成型用增强材基布由于致密层的目付低，因此有无法有效阻止聚氨酯渗出的可能。另外，专利文献2中记载的发泡成型用增强材基布虽然能够阻止聚氨酯渗出，但由于基布的目付过大，因此聚氨酯过度浸渍，有缓冲性下降和聚氨酯密度下降引起的强度下降、原材料自身的重量上升引起的经济性下降等可能。
另一方面，专利文献3中记载了使用目付为40g/m2以下、更优选为15～20g/m2且纤维直径为10μm以下的熔喷非织造布作为致密层。但是，利用针刺(needle punch)将纤维直径细的熔喷非织造布层和纺粘非织造布层进行接合时，可能是由于形成熔喷非织造布层的纤维和形成纺粘非织造布层的纤维的纤维直径差异过大，因此纤维彼此的缠结少，存在层间剥离的可能，另外，用针可切断熔喷非织造布层的纤维，从而有在发泡成型用非织造布的表面产生粉尘的可能。
现有技术文献
专利文献
专利文献1：日本实公昭62-26193号公报
专利文献2：日本特开平2-258332号公报
专利文献3：日本特开2004-353153号公报
发明内容
发明要解决的课题
本发明目的在于获得一种层间的剥离性优异，并且即使在使用针刺进行层叠(交织)时，在熔喷非织造布层的纤维屑表面也没有粉尘，具有增强效果和聚氨酯渗出防止性能的发泡成型用非织造布层叠体。
解决课题的方法
本发明提供一种发泡成型用非织造布层叠体，其是在致密层的至少一侧(也称单面。)[以下，使用“一侧”。]层叠增强层而形成的发泡成型用非织造布层叠体，其特征在于，致密层是在熔喷非织造布层(A)的两侧(也称两面。)[以下，使用“两侧”。]层叠纺粘非织造布层(B)、并且将该熔喷非织造布层(A)和纺粘非织造布层(B)进行部分热压接而形成的。
本发明还提供一种在上述发泡成型用非织造布层叠体的增强层侧进一步层叠发泡聚氨酯而形成的发泡成型用非织造布层叠体。
本发明还提供一种含有在上述发泡成型用非织造布层叠体的增强层侧层叠了发泡聚氨酯的发泡成型用非织造布层叠体的车辆用座椅或椅子。
发明效果
就本发明的发泡成型用非织造布层叠体而言，由于致密层是将熔喷非织造布层和纺粘非织造布层进行部分热压接而形成的，因此即使在设置在聚氨酯等的发泡成型操作中的成型用金属模的内侧的场合，也能够中途阻止发泡成型用树脂液的浸透，例如在汽车座椅的场合，能够有效防止金属部件与发泡聚氨酯的摩擦所引起的异常声响。
另外，由于包含作为致密层的、将熔喷非织造布层和纺粘非织造布层进行部分热压接而形成的层叠体，因此，例如进行针刺时，与增强层的纤维的交织变得强韧，即使在将发泡成型用树脂液浸渍在增强层中时或其后使用时，也不用担心无层间剥离等，对于形成致密的发泡层、提高刚性是有效的，而且在熔喷非织造布层的纤维屑的表面也无粉尘。
具体实施方式
<热塑性树脂>
作为形成本发明的致密层和增强层的非织造布的原料的热塑性树脂，只要是能形成非织造布的热塑性树脂，就没有特别限定，可例示各种公知的热塑性树脂，具体而言为，乙烯、丙烯、1-丁烯、1-己烯、4-甲基-1-戊烯和1-辛烯等α-烯烃的均聚物或共聚物、即高压法低密度聚乙烯、线型低密度聚乙烯(所谓的LLDPE)、高密度聚乙烯(所谓的HDPE)、聚丙烯(丙烯均聚物)、聚丙烯无规共聚物、聚1-丁烯、聚4-甲基-1-戊烯、乙烯·丙烯无规共聚物、乙烯·1-丁烯无规共聚物、丙烯·1-丁烯无规共聚物等聚烯烃，聚酯(聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯、聚萘二甲酸乙二醇酯等)，聚酰胺(尼龙-6、尼龙-66、聚己二酰间苯二甲胺等)，聚氯乙烯，聚酰亚胺，乙烯·乙酸乙烯酯共聚物，乙烯·乙酸乙烯酯·乙烯醇共聚物，乙烯·(甲基)丙烯酸共聚物，乙烯-丙烯酸酯-一氧化碳共聚物，聚丙烯腈，聚碳酸酯，聚苯乙烯、离子交联聚合物(ionomer)或者它们的混合物等。在这些物质之中，更优选高压法低密度聚乙烯、线型低密度聚乙烯(所谓的LLDPE)和高密度聚乙烯等乙烯系聚合物、聚丙烯和聚丙烯无规共聚物等丙烯系聚合物、或者聚对苯二甲酸乙二醇酯、聚酰胺等。
可以在不损害本发明的目的的范围内在本发明的热塑性树脂中加入抗氧化剂、耐候稳定剂、耐光稳定剂、抗粘连剂、润滑剂、成核剂、颜料、柔软剂、亲水剂、助剂、拒水剂、填料、抗菌剂等各种公知的添加剂。
这些热塑性树脂中，从成型时的纺丝稳定性、非织造布的加工性以及透气性、柔软性、轻量性、耐热性的观点出发，优选聚烯烃，特别优选丙烯系聚合物。
<丙烯系聚合物>
作为本发明的丙烯系聚合物，通常优选熔点(Tm)为125℃以上、优选为130～165℃范围内的丙烯的均聚物或丙烯与极少量的乙烯、1-丁烯、1-戊烯、1-己烯、1-辛烯、4-甲基-1-戊烯等碳原子数2以上(但不包括碳原子数3)、优选为2～8(但不包括碳原子数3)的1种或2种以上的α-烯烃的共聚物。
对于丙烯系聚合物而言，只要能够熔融纺丝，熔体流动速率(MFR：ASTMD-1238，230℃，载荷2160g)就没有特别限定，但在用于构成致密层的熔喷非织造布时，通常为10～3000g/10分钟，优选为50～2000g/10分钟，进一步优选为100～1000g/10分钟的范围，在用于构成致密层的纺粘非织造布以及增强层时，通常为1～500g/10分钟，优选为5～200g/10分钟，进一步优选为10～100g/10分钟的范围。
<熔喷非织造布层(A)>
构成本发明的致密层的熔喷非织造布层(A)是由上述热塑性树脂形成的非织造布层，纤维直径通常为0.1～5μm，优选为0.5～3μm，目付通常为0.1～5g/m2，优选为1～3g/m2的范围。
如果熔喷非织造布层(A)的纤维直径和目付在上述范围内，则用作座椅增强用基布时，可以防止聚氨酯液或发泡聚氨酯(以下有时并称为“聚氨酯”。)渗出，且即使利用针刺将致密层和基材层进行接合，熔喷非织造布层(A)的纤维也很少有被针切断的情况，而且可实现所得发泡成型用非织造布层叠体的轻量化。
熔喷非织造布层的目付超过上述范围时，由于对于聚氨酯的渗出防止，在上述范围内已经达到了改善效果的上限，因此不会有更好的效果。另一方面，如果目付超过上述范围，则与基材层层叠时，利用针刺法进行处理时形成熔喷非织造布层的纤维被大量切断而产生粉尘的可能性有可能升高的可能。另外，由于熔喷非织造布层对所得的发泡成型用非织造布层叠体的强度、利用针刺法的交织强度等的改善效果比较有限，因此从所得发泡成型用非织造布层叠体的轻量化的观点出发，优选为上述范围内。
<纺粘非织造布层(B)>
构成本发明的致密层的纺粘非织造布层(B)是由上述热塑性树脂形成的非织造布层，纤维直径通常为10～40μm，优选为10～20μm，目付通常为10～50g/m2，优选为10～20g/m2的范围。
如果纺粘非织造布层(B)的纤维直径和目付在上述范围内，则利用针刺法将致密层和基材层进行接合时，能够使致密层和基材层的纤维强韧地交织，且可以防止聚氨酯渗出，同时可实现所得发泡成型用非织造布层叠体的轻量化。
<致密层>
构成本发明的发泡成型用非织造布层叠体的致密层是在上述熔喷非织造布层(A)的两侧层叠上述纺粘非织造布层(B)，且将该熔喷非织造布层(A)和纺粘非织造布层(B)进行部分热压接而形成的。作为热压接的方法，可使用如后所述的各种方法，可以优选使用轧纹加工。另外，本发明中的“部分”是指以面积率计为5～30％、优选为5～20％的范围。
本发明的致密层优选体积密度为0.05～0.5g/cm3、优选0.05～0.3g/cm3的范围。体积密度在上述范围内时，交织后也可以保持纤维的致密性，对于防止聚氨酯的渗出有良好的效果，因此优选。
本发明的致密层的目付(层叠上述熔喷非织造布层(A)和上述纺粘非织造布层(B)后的合计目付)通常为10～60g/m2、优选为10～35g/m2、更优选为10～25g/m2的范围。
本发明的致密层可通过并用各种公知的熔喷非织造布的制造方法和纺粘非织造布的制造方法来制造。
具体而言，例如可通过如下方法制造：预先从纺丝喷丝板将上述热塑性树脂进行纺丝，利用冷却流体等冷却纺出的长纤维纤丝，通过拉伸空气对纤丝施加张力而达到规定的纤度，在移动的捕集带上收集所得的纤丝从而得到纺粘非织造布层(B)后，将上述热塑性树脂熔融挤出到该纺粘非织造布层(B)上，将从熔喷喷丝头纺成的纤维通过高温高速的气体纺成极细纤维流，用捕集装置制成极细纤维网，从而形成熔喷非织造布层(A)，接着在该熔喷非织造布层(A)上层叠纺粘非织造布层(B)，然后进行部分热压接。
将熔喷非织造布层(A)和纺粘非织造布层(B)进行部分热压接的方法没有特别限定，可采用各种公知的方法。其中，利用轧纹加工等对致密层进行热压接时，容易将所得的致密层的体积密度调整至上述范围，而且致密层的刚性提高，不产生松弛，容易向金属模中安装，操作速度也提高。另外，从可以防止聚氨酯液通过的方面考虑也是优选的。
通过热轧纹加工进行热熔合时，通常轧纹面积率为5～30％、优选5～20％的范围。刻印形状可以例示圆形、椭圆形、长圆形、正方形、菱形、长方形、四边形、褶形、方格形、六角形或以这些形状作为基础的连续形状。
就本发明的致密层而言，通过使与形成熔喷非织造布层(A)的纤维直径相比、纤维直径粗的纺粘非织造布层(B)层叠在(A)的两侧，从而更有效地发挥作为熔喷非织造布层(A)的增强材的作用。
<发泡成型用非织造布层叠体>
本发明的发泡成型用非织造布层叠体是在上述致密层的至少一侧、优选在两侧层叠增强层而形成的。
本发明的发泡成型用非织造布层叠体中，仅在一侧层叠增强层时，层叠有增强层的一侧为聚氨酯侧，即成为发泡聚氨酯/增强层/致密层的层构成。
另外，在上述致密层上层叠的增强层可以是单层，也可以是两层以上。
本发明的发泡成型用非织造布层叠体可以通过各种公知的方法，具体而言，例如热轧纹加工或超声波熔合等热熔合法、针刺或水刺等机械交织法、利用热熔粘接剂或聚氨酯系粘接剂等粘接剂的方法、挤出层压等，将上述致密层和增强层进行层叠而成，可以优选通过针刺机械地接合或通过加热处理进行熔合的方法。其中，从对所得发泡成型用非织造布层叠体赋予适当的透气性、使聚氨酯发泡时产生的气体通过、可以控制聚氨酯液的浸渍的观点出发，优选针刺法。
另外，利用针刺进行层叠(交织)时，出于减少针刺时的断丝或者减少发泡体与金属部件的异常声响的目的，在不损害本发明的效果的范围内可以对非织造布揉入或涂布柔软剂、滑爽剂等油剂。
就以往的在熔喷非织造布层上直接层叠增强层而形成的层叠体而言，例如在通过针刺法进行接合时，由于作为细纤维的熔喷非织造布层的纤维断裂或者与增强层的纤维的缠结少，因此接合面的强度弱，与之相比，就本发明的发泡成型用非织造布层叠体而言，由于致密层如上所述是利用热压接在熔喷非织造布层(A)的两面层叠纺粘非织造布层(B)而形成的，因此即使是例如通过针刺法接合致密层和增强层时，形成纺粘非织造布层(B)的纤维和形成增强层的纤维也不会同时断裂，而且缠结增多，因此具有致密层与增强层间的接合面强度增强的特征，同时即使熔喷非织造布层(A)的纤维被针切断，也不必担心其切屑会漏出到发泡成型用非织造布层叠体的表面上。
本发明的发泡成型用非织造布层叠体优选透气度为25～160cm3/cm2/秒、优选25～110cm3/cm2/秒的范围。透气度为上述范围时，聚氨酯的渗出防止性更加良好。且由于作为结果可致密地形成发泡层，因此对提高发泡体的刚性是有效的。
本发明的发泡成型用非织造布层叠体优选目付为20～160g/m2、更优选为25～120g/m2、进一步优选为30～100g/m2的范围。
构成本发明的发泡成型用非织造布层叠体的增强层没有特别限定，可以列举各种公知的非织造布，例如纺粘非织造布、熔喷非织造布等长纤维非织造布，湿式非织造布、干式非织造布、干式浆粕非织造布(dry type pulp nonwovenfabrics)、闪蒸纺丝非织造布、开纤非织造布(split yarn nonwoven)等短纤维非织造布等各种公知的非织造布。
这些非织造布中，特别是从所得发泡成型用非织造布层叠体的强度的观点出发，优选为纺粘非织造布层(C)。
本发明的纺粘非织造布层(C)是由上述热塑性树脂形成的非织造布层，纤维直径通常为12～50μm、优选为15～40μm，目付通常为10～50g/m2、优选为15～35g/m2的范围。
本发明的纺粘非织造布层(C)优选：与构成构成上述致密层的纺粘非织造布层(B)的纤维相比，优选纤维直径粗的。通过使用纤维直径粗的纺粘非织造布层(C)，通过针刺法进行接合时的交织性优异、断丝也少，所得的发泡成型用非织造布层叠体可以在确保聚氨酯的快速浸渍性的同时确保与致密层的交织强度和拉伸强度，因此优选。
形成本发明的纺粘非织造布层(C)的纤维可以是单纤维，也可以是并列(Side-by-Side)型或芯鞘型(sheath-core)的复合纤维，或者还可以是卷曲纤维。另外，纤维的截面形状除了圆型以外，还可以是V字型、十字型、T字型等异型截面。作为同芯型的纤维，还可以在芯部或鞘部中进行添加。
本发明的纺粘非织造布层(C)可以是由单一的纤维形成的非织造布，也可以是将含有两种以上不同的热塑性树脂的纤维混合而成的混纤纤维或者将形状不同的两种以上纤维混合而成的混纤纤维。
本发明的发泡成型用非织造布层叠体可以在不损害本发明的效果的范围内与其它层层叠而使用。
与本发明的非织造布层叠的其它层具体可以举出例如针织布、机织布、非织造布、膜、纸制品等。在将本发明的非织造布与其它层层叠(贴合)时，可以采用以热轧纹加工、超声波熔合等热熔合法，针刺、水刺等机械交织法，使用热熔粘接剂、聚氨酯系粘接剂等粘接剂的方法，挤出层压等为首的各种公知方法。
本发明的发泡成型用非织造布层叠体可以在不损害本发明的目的的范围内实施齿轮加工、印刷、涂布、层压、热处理、赋型加工等二次加工而使用。
实施例
以下基于实施例对本发明进一步进行具体说明，但本发明并不限定于这些实施例。
实施例和比较例中的物性值等通过以下的方法进行测定。
(1)目付(g/m2)
从非织造布中以机械方向(MD)100mm×横向(CD)100mm选取10点。算出平均值。
(2)厚度(mm)
测定上述目付测定用试样的中央、四角5点。算出50点的平均值。使用载荷为2g/cm2(载荷面积4g/cm2)的厚度计。
(3)体积密度(g/cm3)
非织造布的体积密度使用通过上述(1)和(2)所得的目付和厚度、由下式求出。
体积密度＝目付(g/m2)/(上述厚度(mm)/10×100×100)
(4)强度(N/50mm)
依据JIS L1906进行测定。从发泡成型用非织造布层叠体中选取200mm(MD)×50mm(CD)的试验片，使用拉伸试验机(岛津制作所制：AutographAGS-J)，在夹盘间距100mm、机头速度100mm/min的条件下测定MD：5点、CD：5点，算出平均值，作为强度。
(5)透气度(cm3/cm2/秒)
从发泡成型用非织造布层叠体中选取200mm(MD)×50mm(CD)的试验片，通过依据JISL1096的弗雷泽(frazier)透气度测定机进行。
(6)聚氨酯渗出评价
向发泡釜中安装发泡成型用非织造布层叠体(400mm(MD)×400mm(CD))，根据以下基准目视评价聚氨酯的渗出。
未观察到：◎
几乎观察不到：○
观察到少许：△
观察到相当多：×
另外，发泡成型使用作为树脂材料的聚氨酯以及汽车座席座椅形状的发泡釜来进行。
(7)针刺时的丝粉尘产生
根据以下基准来评价在利用针刺得到的发泡成型用非织造布层叠体的表面是否有可通过目视确认的0.5～3mm左右的粉尘。
未观察到：◎
几乎观察不到：○
观察到少许：△
观察到相当多：×
(8)基材层与致密层的纤维的交织
通过扫描电子显微镜((株)日立制作所制S-3500N型)、以35倍的倍率对利用针刺得到的发泡成型用非织造布层叠体的截面进行拍照。根据以下基准来评价由拍照后的照片是否可以观察到致密层的纤维与基材层的纤维的交织。
未观察到：×
几乎观察不到：△
观察到少许：○
观察到相当多：◎
[实施例1]
<致密层的制造>
使用MFR为60g/10分钟的丙烯均聚物、在230℃进行熔融纺丝，使所得的纤维堆积在捕集面上，从而制造目付量为5.9g/m2的纺粘非织造布层(B-1)(纤维直径15μm)。
接着，在280℃使用挤出机将MFR为400g/10分钟的丙烯均聚物熔融，将所得的熔融物从喷丝头吐出，同时通过在吐出孔出口吹280℃的加热空气的熔喷法使纤维直径3μm的纤维堆积在前述纺粘非织造布(B-1)上，形成目付量1.2g/m2的熔喷非织造布层(A-1)，再在其上层叠与前述纺粘非织造布(B-1)同样的纺粘非织造布(B-2)，使用刻印面积率18％的热轧纹辊将3层一体化而得到由SMS非织造布构成的致密层。致密层的合计目付为13g/m2。
<增强层的制造>
使用MFR为60g/10分钟的丙烯均聚物、在230℃进行熔融纺丝，使所得的纤维堆积在捕集面上，从而制造目付量为35g/m2的纺粘非织造布(C-1)(纤维直径21μm)。
<发泡成型用非织造布层叠体的制造>
在通过前述方法获得的致密层的两侧层叠纺粘非织造布层(C-2)，利用针刺进行接合，得到发泡成型用非织造布层叠体。通过上述记载的方法测定所得的发泡成型用非织造布层叠体的物性。结果示于表1。
[实施例2～5]
除了将致密层所用的熔喷非织造布层和纺粘非织造布层的目付换成表1所示的目付以外，与实施例1同样地得到发泡成型用非织造布层叠体。通过上述记载的方法测定所得的发泡成型用非织造布层叠体的物性。结果示于表1。
[实施例6]
得到与实施例2同样的致密层后，将该致密层层叠相同的2层，再与实施例1同样地在该致密层的两侧层叠纺粘非织造布层，得到发泡成型用非织造布层叠体。通过上述记载的方法测定所得的发泡成型用非织造布层叠体的物性。结果示于表1。
[实施例7]
得到与实施例3同样的致密层后，将该致密层层叠相同的3层，再与实施例1同样地在该致密层的两侧层叠纺粘非织造布层，得到发泡成型用非织造布层叠体。通过上述记载的方法测定所得的发泡成型用非织造布层叠体的物性。结果示于表1。
表1
Figure BDA0000132942820000111
[实施例8]
得到与实施例3同样的致密层后，将该致密层层叠相同的2层，并使在致密层的两侧层叠的纺粘非织造布层的目付量为50g/m2、纤维直径为35μm，除此以外，与实施例1同样地得到发泡成型用非织造布层叠体。通过上述记载的方法测定所得的发泡成型用非织造布层叠体的物性。结果示于表2。
[实施例9]
得到与实施例3同样的致密层后，将该致密层层叠相同的3层，并使在致密层的两侧层叠的纺粘非织造布层的目付量为50g/m2、纤维直径为35μm，除此以外，与实施例1同样地得到发泡成型用非织造布层叠体。通过上述记载的方法测定所得的发泡成型用非织造布层叠体的物性。结果示于表2。
[实施例10]
将致密层所用的熔喷非织造布层和纺粘非织造布层的目付换成表1所示的目付，并使在两侧层叠的纺粘非织造布层的目付量为25g/m2、纤维直径为20μm，除此以外，与实施例1同样地得到发泡成型用非织造布层叠体。通过上述记载的方法测定所得的发泡成型用非织造布层叠体的物性。结果示于表2。
[实施例11]
得到与实施例3同样的致密层后，使在两侧层叠的纺粘非织造布层的目付量为25g/m2、纤维直径为20μm，除此以外，与实施例1同样地得到发泡成型用非织造布层叠体。通过上述记载的方法测定所得的发泡成型用非织造布层叠体的物性。结果示于表2。
[比较例1]
致密层中仅使用目付为7g/m2的熔喷非织造布层，与实施例1同样地得到发泡成型用非织造布层叠体。针刺加工时，粉尘大量产生，在非织造布层叠体表面上可显著观察到。另外，由显微镜观察几乎观察不到致密层的熔喷纤维和基材层的纺粘纤维之间的交织。结果示于表2。
[比较例2]
除了使在两侧层叠的纺粘非织造布层的目付为50g/m2、纤维直径为35μm以外，与比较例1同样地得到发泡成型用非织造布层叠体。与比较例1同样地，针刺加工时，粉尘大量产生，在非织造布层叠体表面上可显著观察到。另外，由显微镜观察几乎观察不到致密层的熔喷纤维和基材层的纺粘纤维之间的交织。结果示于表2。
表2
Figure BDA0000132942820000131
工业实用性
本发明的发泡成型品用增强材能够适用于任一发泡成型品，例如适用于由聚氨酯等形成的发泡成型品，可以赋予良好的刚性和防止异常声响。例如可以适用于汽车座椅等车辆座席用座椅、家具、椅子、床等各种用途的发泡成型品的成型。

Claims (15)

1.一种发泡成型用非织造布层叠体，其为在致密层的至少一侧层叠增强层而形成的发泡成型用非织造布层叠体，其特征在于，
致密层是在熔喷非织造布层(A)的两侧层叠纺粘非织造布层(B)、并且将该熔喷非织造布层(A)和纺粘非织造布层(B)进行部分热压接而形成的。
2.如权利要求1所述的发泡成型用非织造布层叠体，其中，构成致密层的熔喷非织造布层(A)的纤维直径在0.1～5μm的范围内。
3.如权利要求1所述的发泡成型用非织造布层叠体，其中，构成致密层的熔喷非织造布层(A)的目付在0.1～5g/m2的范围内。
4.如权利要求1所述的发泡成型用非织造布层叠体，其中，构成致密层的纺粘非织造布层(B)的纤维直径在10～20μm的范围内。
5.如权利要求1所述的发泡成型用非织造布层叠体，其中，构成致密层的纺粘非织造布层(B)的目付在10～20g/m2的范围内。
6.如权利要求1所述的发泡成型用非织造布层叠体，其中，致密层的体积密度在0.05～0.5g/cm3的范围内。
7.如权利要求1所述的发泡成型用非织造布层叠体，其中，致密层的目付在10～60g/m2的范围内。
8.如权利要求1所述的发泡成型用非织造布层叠体，其特征在于，增强层是纤维直径在12～50μm范围内以及目付在10～50g/m2范围内的纺粘非织造布层(C)。
9.如权利要求1所述的发泡成型用非织造布层叠体，其特征在于，发泡成型用非织造布层叠体的透气度为25～160(cm3/cm2/秒)。
10.如权利要求1所述的发泡成型用非织造布层叠体，其特征在于，发泡成型用非织造布层叠体的目付为20～160g/m2。
11.如权利要求1所述的发泡成型用非织造布层叠体，其特征在于，熔喷非织造布层(A)和纺粘非织造布层(B)均由丙烯系聚合物形成。
12.如权利要求1所述的发泡成型用非织造布层叠体，其为在所述非织造布层叠体的增强层侧进一步层叠发泡聚氨酯而形成的。
13.一种车辆用座椅，其含有权利要求12所述的发泡成型用非织造布层叠体而形成。
14.一种椅子，其含有权利要求12所述的发泡成型用非织造布层叠体而形成。
15.一种发泡成型用非织造布层叠体的制造方法，其特征在于，在熔喷非织造布层(A)的两侧层叠纺粘非织造布层(B)后进行部分热压接而形成致密层，在所述致密层的至少一面层叠增强层后，进行交织处理。
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