CN104797415A - Lightweight felt material - Google Patents

Lightweight felt material Download PDF

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Publication number
CN104797415A
CN104797415A CN201480003115.4A CN201480003115A CN104797415A CN 104797415 A CN104797415 A CN 104797415A CN 201480003115 A CN201480003115 A CN 201480003115A CN 104797415 A CN104797415 A CN 104797415A
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CN
China
Prior art keywords
felt materials
nonwoven sheet
fiber
lightweight felt
hard cotton
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Granted
Application number
CN201480003115.4A
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Chinese (zh)
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CN104797415B (en
Inventor
仮屋英树
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Fuji Industrial Co Ltd
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Fuji Industrial Co Ltd
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    • 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
    • B32B5/22—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
    • 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
    • B32B5/26—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 another layer next to it also being fibrous or filamentary
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • 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
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple 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
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • 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
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • 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
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • 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
    • B32B2307/718—Weight, e.g. weight per square meter
    • 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
    • B32B2437/00—Clothing
    • 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
    • B32B2437/00—Clothing
    • B32B2437/02—Gloves, shoes
    • 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

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)

Abstract

This invention addresses the problem of providing a lightweight felt material that is soft, highly sound-absorbent and flame-retardant, and suitable as an interior material for an automobile or other vehicle, industrial material, clothing material, or another such material. This lightweight felt material has a nonwoven sheet interposed between two hard cotton layers so as to integrate the overall material, wherein: 20-80% of an ultrafine fiber having a fineness of 1.1 dtex or less, 10-60% of a hollow fiber for imparting bulkiness, and 10-60% of a low-melting-point fiber which melts when the overall material is thermally treated are fiber-blended in each of the two hard cotton layers; and the nonwoven sheet has a fiber diameter of 2-20 [mu]m and a basis weight of 20-100 g/m2.

Description

Lightweight felt materials
Technical field
The present invention relates to a kind of sound absorption properties and anti-flammability is high and soft, be applicable to automobile, the lightweight felt materials of the interior material, industrial materials, dress material etc. of vehicle.
Background technology
In the car, usually in boot, luggage case etc., post interior material, in most cases use the epidermal graft of the soft-touch of striped matte style (ベ ロ ア Tone: vilour) or hairbrush matte style (デ ィ ロ ア Tone: dilour) as this interior material.This epidermal graft is bonded on plastics or felt in the downside of skin material, sound absorption properties can be improved thus and reduce the noise entering into car indoor from boot, in addition can improve rigidity and formability and keep certain intensity, but being difficult to obtain desired three-dimensional shape in the past.
The applicant at a kind of interior material of sale, this interior material be integrated carrying out complexing by acupuncture to medium-sized skin material and felt in order to obtain desired three-dimensional shape after carry out hot-forming and formed.In addition, in No. 5027456th, patent, use the spun-bonded non-woven fabrics integrated with felt, during granular molten mass processes before heating, dispersion is formed on the whole surface of this spun-bonded non-woven fabrics, thus when heating individually, spun-bonded non-woven fabrics can melt surface fit with skin material thus form processing again.This interior material felt materials can be shaped by colding pressing, and can not be heated, pressurize in the surface of skin material thus, so the color of the epidermis that can be maintained and the interior material of piloerection sense.
Common polyester fiber generally mixes with the polyester fiber of low melting point and carries out integrated manufacture further by acupuncture by above-mentioned felt.The fineness ratio of the fiber that this felt uses is higher, so not too can improve sound absorption qualities, and is transferred to thickness direction due to needling fiber, and overall sound absorption qualities is inevitable easily to decline.On the other hand, No. 53-41577, Japanese Laid-Open Patent Publication, No. 6-212545, Japanese Unexamined Patent Publication and No. 6-212546, Japanese Unexamined Patent Publication provide the melt spraying non-woven fabrics (trade name: THINSULATE) adopting superfine fibre and polyester staple fiber, the sound absorption properties of this non-woven fabrics is high and soft and easily process, so be suitable as interior material.
Patent document 1: patent No. 5027456 publication
Patent document 2: Japanese Laid-Open Patent Publication 53-41577 publication
Patent document 3: Japanese Unexamined Patent Publication 6-212545 publication
Patent document 4: Japanese Unexamined Patent Publication 6-212546 publication
Summary of the invention
Melt spraying non-woven fabrics is such as that the superfine fibre of less than 10 μm and the polyester staple fiber with anti-flammability etc. carry out integration and manufacture to the fiber diameter by meltblown spinning, generally quite excellent in sound absorption properties and thermal insulation.Melt spraying non-woven fabrics has light weight and fluffy degree concurrently, is not only applicable to sound-absorbing material and is also applicable to heat-barrier material, but user requires to propose more high performance interior material now.
In addition, melt spraying non-woven fabrics is bonded with the skin materials such as spunlace non-woven cloth on its surface and the back side, uses in certain vehicle as car roof tarpaulin.In this roof tarpaulin, its surface and the back side are bonded with spunlace non-woven cloth etc., and this spunlace non-woven cloth easily produces fold thus, is difficult to make it be suitable for the shape of interior facing.This roof tarpaulin is also noted, and when carrying out shape stamping-out by Thomson (Thomson) cutter, cutting off end face and can be attached to cutter, being therefore more difficult to make it be suitable for the shape of interior facing.
The present invention proposes in order to the inner decoration material for automobile improved further in the past, its objective is and provides a kind of sound absorption properties and excellent in flame retardance and the lightweight felt materials of balance that can obtain thickness, weight, density.Other objects of the present invention be not only applicable to automobile, vehicle interior material and also be applicable to the lightweight felt materials of industrial materials, cold-proof dress material etc.
Nonwoven sheet to be clipped between two-layer hard cotton layer and to make overall integration by lightweight felt materials of the present invention.In this lightweight felt materials, be mixed with in two-layer hard cotton layer: the low-melting fiber of melting when the fineness of 20 ~ 80% is the superfine fibre of below 1.1 dtexs, the doughnut of imparting bulkiness of 10 ~ 60% and the entirety of 10 ~ 60% are heat-treated, the fibre diameter of nonwoven sheet is 2 ~ 20 μm, and the weight of unit are is 20 ~ 100g/m 2.
Nonwoven sheet to be clipped between two-layer hard cotton layer and to make overall integration by thermo-compressed by lightweight felt materials of the present invention.In this lightweight felt materials, preferably be mixed with in two-layer hard cotton layer: the low-melting fiber of melting when the fineness of 20 ~ 80% is the superfine fibre of below 1.1 dtexs, the doughnut of imparting bulkiness of 10 ~ 30% and the entirety of 10 ~ 60% are heat-treated, the fibre diameter of nonwoven sheet is 2 ~ 20 μm, and the weight of unit are is 20 ~ 100g/m 2.
In lightweight felt materials of the present invention, preferably the hard cotton layer of top is 1:1 ~ 1:4 with the ratio of the thickness of the hard cotton layer of below, and preferred nonwoven sheet is the non-woven fabrics by meltblown manufacture.In addition, in hard cotton layer, still can contain short fiber or the regenerated fiber of the synthetic fibers of the normal fineness of 10 ~ 30%.
In the manufacture method of lightweight felt materials of the present invention, the conveyer of movement loads successively superfine fibre, doughnut and low-melting fiber are carried out to the first net of complexing, nonwoven sheet, superfine fibre, doughnut and low-melting fiber carried out to the second net of complexing, thus form three layer laminates, then with the temperature exceeding the fusing point of low-melting fiber three layer laminates heat-treated and pressurize, completing overall felt and integration thus simultaneously.In this manufacture method, the brushing process preferably by embossing process during low temperature or surface makes the two sides of nonwoven sheet fluff, and this nonwoven sheet is engaged more reliably with the first net and the second net thus.
Invention effect
Lightweight felt materials of the present invention is the composite of hard cotton layer and nonwoven sheet, compared with known melt spraying non-woven fabrics, sound absorption properties and anti-flammability more excellent and less expensive.Lightweight felt materials of the present invention has flexibility and easily makes it be suitable for interior vehicle surface etc., be not only applicable to the interior material of automobile, vehicle, can be applicable to the cold-proof dress material such as filler of the industrial materials such as acousticing heat-insulating material, the insulation material of anorak or gloves, cap yet.
The weight of lightweight felt materials of the present invention and the unit are of known melt spraying non-woven fabrics, thickness and density are identical, and sound absorption qualities is high and have the anti-flammability meeting FMVSS302, determine the specification of balance obtaining thickness, weight, density.Lightweight felt materials of the present invention does not need adhesives etc. during fabrication, favourable in cost, by suitably adjusting sound absorption qualities, fire resistance, thus advantageously can use as the substitute of known melt spraying non-woven fabrics.
In the manufacture method of lightweight felt materials of the present invention, the first net, nonwoven sheet and the second net are carried out stacked while to heat-treat and integrated, so can unify to produce to lightweight felt materials by a production line.Utilize manufacture method of the present invention can manufacture lightweight felt materials efficiently, can manufacturing cost be reduced.In addition, if make the two sides of nonwoven sheet fluff in advance, then the peel strength of this felt materials entirety can be improved.
Accompanying drawing explanation
Fig. 1 is the amplification view representing lightweight felt materials of the present invention.
Fig. 2 is the amplification view of the variation representing lightweight felt materials.
Fig. 3 is the summary side elevation of the manufacturing process illustrating lightweight felt materials.
Fig. 4 is the partial perspective view of exploded representation three layer laminates.
Fig. 5 represents the felt materials of embodiment 2, embodiment 3 and compares the coordinate diagram of acoustic absorptivity of A ~ C.
Fig. 6 represents the felt materials of embodiment 5, embodiment 6 and compares the coordinate diagram of acoustic absorptivity of D.
Detailed description of the invention
As shown in Figure 1, that nonwoven sheet 5 is clipped between two-layer hard cotton layer 2,3 is integrated for lightweight felt materials 1 of the present invention.Hard cotton layer 2,3 is generally the weight of identical thickness, density and unit are, also can suitably adjust both thickness etc. as required and improve the sound absorption qualities of felt materials 1 further.When using as interior material, felt materials 1 is also bonded with the skin material with suitable outward appearance, sense of touch, piloerection sense etc. by normal temperature or heating.
Lightweight felt materials 1 is generally illustrate such three-layer structure, and hard cotton layer self also can be multilayer.In addition, two nonwoven sheet also can be configured between three layers of hard cotton layer, by three nonwoven sheet and be configured between four layers of hard cotton layer respectively by lightweight felt materials 1 respectively, in order to improve the adhesive strength of nonwoven sheet and hard cotton layer, can not hinder bonding powder or the coating adhering liquid of the amount of the degree of sound absorption qualities by dispenser between yet.
Hard cotton layer 2,3 to the superfine fibre of 20 ~ 80%, the doughnut of 10 ~ 60% and 10 ~ 60% low-melting fiber carry out complexing and formed, also suitably can add the synthetic fibers of normal fineness.Normally identical fibrous of hard cotton layer 2 and 3, but also can change according to the purposes of felt materials 1.The synthetic fibers of superfine fibre, doughnut and normal fineness are polyester, acrylic resin, polyamide, staple fibre, polypropylene, polyvinyl chloride, polyethylene etc., also can carry out multiple mixing to each fiber and use.From the angle of cost and heat resistance etc., the synthetic fibers of preferred superfine fibre, doughnut and normal fineness are all polyester.
In hard cotton layer 2,3, superfine fibre represents 1.1 dtexs (1 dawn) fiber below that common spinning is difficult to obtain, and superfine fibre also comprises superfine fibre, superfine fiber in the present invention.In order to manufacture the superfine fibre of short fiber, utilize meltblown, centrifugal spinning, flash-spinning method, beating method, blend spinning method, label (tag) spin processes etc.The addition of this superfine fibre is the mass fraction of 20 ~ 80%, preferably the mass fraction of many 40 ~ 80%.When the addition of superfine fibre is less than 20%, is difficult to the sound absorption qualities improving felt materials 1, on the other hand, when the addition of superfine fibre is more than 80%, is difficult to make felt materials 1 fluffy and uneconomical.
In hard cotton layer 2,3, doughnut is as the one of profiled fibre, special spinning-nozzle such as can be used in the melt spinnings such as polyester, acrylic resin, polyamide to carry out manufacturing or in staple fibre spinning time, make its fibrous inside produce bubble and manufacture the silk with hollow section.This doughnut seems that fineness is thicker and curling comparatively strong, general good heat preservation performance and light, strengthens the elasticity of felt materials.The addition of doughnut is the mass fraction of 10 ~ 60%, preferably can give the mass fraction of 10 ~ 30% of bulkiness.When only with the addition of the doughnut being less than 10%, being difficult to give bulkiness to felt materials 1, on the other hand, the flexibility of felt materials 1 can being damaged when doughnut is more than 60%.
In hard cotton layer 2,3, low-melting fiber is lower about 40 ~ 70 DEG C than the fusing point of the synthetic fibers of superfine fibre, doughnut and normal fineness, contributes to overall integration and bonding with nonwoven sheet 5 when heat treatment as binding agent.This low-melting fiber can example low-melting point polyester, low melting point polyamide, polyethylene, polypropylene etc., also can be the copolymer with ethene or butylene etc.This low-melting fiber is lower than the fusing point of common fiber, and fusing point also can be used to be known fiber, resin fibre or their composite fibre of 90 ~ 170 DEG C, is also preferably side by side or the composite fibre of sheath and core structures etc.The addition of low-melting fiber is the mass fraction of 10 ~ 60%, preferably makes overall integration be easy to the mass fraction of 20 ~ 50%.When this low-melting fiber is less than 10%, in heat treatment felt materials 1 integration or become difficulty with nonwoven sheet 5 bonding, on the other hand, when this low-melting fiber is more than 60%, felt materials 1 is overall really up to the mark.
When this low-melting fiber is sheath and core structures polyester fiber, the fiber of sheath to be fusing point the be low-melting point polyester of 110 DEG C, 130 DEG C, 150 DEG C, 160 DEG C etc., fusing point is used to be the fiber of 110 DEG C in an embodiment, the fiber of core to be fusing point the be conventional polyester of 250 DEG C.In addition, when for sheath and core structures PP/PE fiber, the fiber of sheath to be fusing point the be polyester of 130 ~ 134 DEG C, the fiber of core to be fusing point the be polypropylene of 165 DEG C.Although sheath and core structures PP/PE fiber is less expensive and can use, bonding effect is little compared with sheath and core structures polyester fiber, and elasticity is also slightly poor.
In hard cotton layer 2,3, except above-mentioned each fiber, also short fiber or the various regenerated fiber (reclaiming is cotton) of the synthetic fibers of the common fineness of 10 ~ 30% can also be contained, this interpolation is carried out mainly for cost degradation, and addition terminates in the scope that sound absorption qualities do not decline.In cost, it is favourable for adding regenerated fiber, thus can manufacture lightweight felt materials 1 with being dirt cheap.
In lightweight felt materials 1, the hard cotton layer 2 of top and the hard cotton layer 3 of below usually thickness and density identical.In addition, lightweight felt materials 6 is as shown in Figure 2 such, in order to improve sound absorption qualities further, the ratio of the thickness of hard cotton layer 2,3 can be changed to 1:4, preferably to 1:2.2, even if the ratio sound absorption qualities improving thickness more also rises hardly.If hard cotton layer 2 is different from the thickness of hard cotton layer 3, then need to be configured to sound and inject from thinner hard cotton layer 2 side, if sound is injected from thicker hard cotton layer 3 side, then the sound absorption qualities of felt materials 1 can decline.
Up in hard cotton layer 2, usual preferred thickness is the weight of 10 ~ 19mm and unit are is 100 ~ 300g/m 2, the thickness of suitable specification is about 12mm, and the weight of unit are is about 177g/m 2.On the other hand, in the hard cotton layer 3 in below, usual preferred thickness is the weight of 19 ~ 30mm and unit are is 100 ~ 300g/m 2, the thickness of suitable specification is about 25mm, and the weight of unit are is about 123g/m 2.
The superfine fibre that nonwoven sheet 5 is preferably 2 ~ 20 μm by fibre diameter is formed, and this nonwoven sheet can be manufactured, preferably by meltblown manufacture by above-mentioned each side's method.The density of melt-blown nonwoven sheet 5 is low and fluffy, and is rich in drapability and soft.For melt-blown nonwoven sheet 5, online, many adjacent ultimate fibres are bundled together each other, and form the connecting portion mutually bonding at least partially in fibre length direction.Such as, in melt-blown nonwoven sheet, blow out hot blast and mixing resin is pushed out to conveyer from nozzle, and by heat, superfine fibre combined closely and do slabbing.In melt-blown nonwoven sheet, the connection fiber containing connecting portion is preferably carrying out bonding with the intersection point of the fiber forming meltblown web.
Nonwoven sheet 5 preferred thickness is the thinner of 0.1 ~ 1.0mm and is rich in the non-woven fabrics of drapability, and the weight of unit are is 20 ~ 100g/m 2, the thickness of suitable specification is about 0.3mm, and the weight of unit are is about 40g/m 2.When the weight of the unit are of nonwoven sheet 5 is less than 30g/m 2time, fully cannot improve the sound absorption qualities of felt materials 1, on the other hand, if the weight of the unit are of nonwoven sheet 5 is more than 100g/m 2, then also less the and flexibility of the raising of sound absorption qualities easily declines.
Form the superfine fibre of nonwoven sheet 5 to be made up of polyester, acrylic resin, polyamide, polypropylene, polyethylene, polyvinyl chloride etc., generally from the viewpoint preferred polyester of cost and heat resistance.This superfine fibre also can spray fire retardant or be dipped in retardant solution after sheet is formed, and this is flame-retarded for hard cotton layer 2,3 too.
In order to manufacture lightweight felt materials 1 continuously, use the felt manufacturing installation 7 of roughly illustrative combination configuration in Fig. 3.Conveyer 8 has usually can the reticulated structure passed through of hot wind supply and cold wind, and move across the total length of felt manufacturing installation 7.In the adjacent first and second comb and parallel cotton fibers prior to spinning cross lapping machine 10,12, by known carding machine, superfine fibre, doughnut and low-melting fiber etc. mixed and form integrated layer, and by cross lapping machine, overlap carried out to this integrated layer and obtain the net 14,16 (with reference to Fig. 4) of predetermined thickness.
Flatly be arranged at by sheet take up roll 18 between comb and parallel cotton fibers prior to spinning cross lapping machine 10,12, rectangular nonwoven sheet 5 is delivered to conveyer 8 from this take up roll.On the other hand, rectangular nonwoven sheet 5 also can be sent into from device via multiple roller 20.If make the two sides of nonwoven sheet 5 fluff in advance by the brushing process on embossing process during low temperature or surface, then can carry out bonding to this nonwoven sheet with the first net and the second net more reliably.
Heat-treating machine 22 is arranged at the rear of the second comb and parallel cotton fibers prior to spinning cross lapping machine 12, by the hot blast at machine Inner eycle, heats equably on conveyor 8 to three layer laminates 24 (with reference to Fig. 4) of the second net 16, nonwoven sheet 5 and the first net 14.This heating-up temperature needs the fusing point of the low-melting fiber exceeded in net 14,16, makes low-melting fiber melting thus.At the rear of heat-treating machine 22, be also provided with a pair backer roll 26 and cooler 28 successively.Lightweight felt materials 1 is obtained by three layer laminates 24 by heat-treating machine 22 and a pair backer roll 26.
In felt manufacturing installation 7, first carry out complexing by the first comb and parallel cotton fibers prior to spinning cross lapping machine 10 pairs of superfine fibres, doughnut and low-melting fibers etc., and the first net 14 corresponding to the hard cotton layer 3 of below is sent on conveyer 8.Then, on conveyor 8 rectangular nonwoven sheet 5 is placed on the first net 14 continuously.In the second comb and parallel cotton fibers prior to spinning cross lapping machine 12, complexing is carried out to the superfine fibre of scheduled volume, doughnut and low-melting fiber etc., the second net 16 corresponding to the hard cotton layer 2 of top is sent on conveyer 8, and is placed in continuously in nonwoven sheet 5, thus make three layer laminates 24.
Three layer laminates 24 (with reference to Fig. 4) that have passed the second comb and parallel cotton fibers prior to spinning cross lapping machine 12 are uniformly heated on conveyor 8 in heat-treating machine 22, pressurizeed by a pair backer roll 26 further and reach overall felt and integration simultaneously, thus manufacturing lightweight felt materials 1 continuously.The lightweight felt materials 1 obtained by cooler 28, thus by the cold front heavy rain fallen in this cooler.
The usual preferred thickness of the lightweight felt materials 1 obtained is the weight of 8 ~ 50mm and unit are is 300 ~ 500g/m 2, the thickness of suitable specification is about 38mm, and the weight of unit are is about 340g/m 2.In special purposes, thickness can reach about 100mm, and the upper limit of the weight of unit are is 3000g/m 2left and right, the lower limit of density is 0.005g/cm 3, and the upper limit also can be 0.043g/cm 3above.
As the general requirements example of lightweight felt materials 1, if thickness be 8mm, the weight of unit are is 340g/m 2, then density is decided to be 0.0425g/cm 3.If thickness is 10 ~ 40mm, the weight of unit are is 340g/m 2, then when thickness is 10mm, density is 0.0340g/cm 3, when thickness is 15mm, density is 0.0227g/cm 3, when thickness is 20mm, density is 0.0170g/cm 3, when thickness is 25mm, density is 0.0136g/cm 3, when thickness is 30mm, density is 0.0113g/cm 3, when thickness is 35mm, density is 0.0097g/cm 3, when thickness is 40mm, density is 0.0085g/cm 3.In addition, if thickness is 50mm and the weight of unit are is 425g/m 2, thickness is 60mm and the weight of unit are is 510g/m 2, thickness is 70mm and the weight of unit are is 595g/m 2, thickness is 80mm and the weight of unit are is 680g/m 2, thickness is 100mm and the weight of unit are is 850g/m 2, then density is all 0.0085g/cm 3.
Embodiment 1
Then, based on embodiment, the present invention will be described, but the present invention is not limited to embodiment.In order to the lightweight felt materials 1 shown in shop drawings 1, use the felt manufacturing installation 7 shown in Fig. 3, fineness to 40% is the superfine polyester fiber at 0.75 dawn, the fineness of 15% is the hollow polyester fibre at 15 dawn, the fineness of 25% is the low melting point polyester fiber at 4 dawn and the fineness of 20% is that the polyester staple fiber at 3 dawn mixes, and the weight forming unit are is 150g/m 2two throw the net 14,16.As nonwoven sheet 5, the weight of applying unit area is 40g/m 2polyester meltblown sheet (trade name: Kuraflex BTS0040EM, Kuraray manufacture).
Clamp nonwoven sheet 5 by above-mentioned net 14,16, and make overall caking.The lightweight felt materials 1 obtained makes nonwoven sheet 5 be positioned at felt materials center, the thickness of the hard cotton layer 2,3 of top and below and the weight equalization of unit are.The thickness of this lightweight felt materials 1 is 38mm and the weight of unit are is 340g/m 2.
Embodiment 2
Adopt testing machine, the fineness in replacement embodiment 1 is that the polyester staple fiber at 3 dawn uses polyester regenerated fiber, thus manufactures the fibrous lightweight felt materials 1 identical with embodiment 1.In this lightweight felt materials 1, the thickness of the hard cotton layer 2 in top is 19mm and the weight of unit are is 155g/m 2, on the other hand, the thickness of the hard cotton layer 3 of lower floor is 19mm and the weight of unit are is 155g/m 2.
The thickness of the lightweight felt materials 1 obtained is 38mm and the weight of unit are is 350g/m 2.When being considered to this aspect, if about 20%, then can replace polyester staple fiber and add polyester regenerated fiber.
Embodiment 3
Use the felt manufacturing installation 7 shown in Fig. 3, net 14,16 is identical with embodiment 1 fibrous, clamps the nonwoven sheet 5 identical with embodiment 1, and make overall caking and manufacture lightweight felt materials 1 by two nets 14,16.The thickness of the lightweight felt materials 1 obtained is 38mm and the weight of unit are is 407g/m 2.
Lightweight felt materials 1 as embodiment 2 and embodiment 3 is compared with following product.
Relatively A: thickness is that (weight of unit are is 356g/m for the melt spraying non-woven fabrics (trade name: THINSULATETC3303 300) of 38mm 2)
Relatively B: thickness is the melt spraying non-woven fabrics (trade name: THINSULATEREGULAR 300) of 38mm
Relatively C: with identical with embodiment 3 fibrous and do not accompany nonwoven sheet 5 felt materials (thickness be 38mm and the weight of unit are for 386g/m 2)
The lightweight felt materials 1 of embodiment 2 and embodiment 3 and the thickness of Comparative examples A ~ C are all 38mm.Measure the sound-absorbing data of these products by vertically injecting method, and the results are shown in following table 1.
(table 1)
Frequency Embodiment 2 Embodiment 3 Relatively A Relatively B Relatively C
200 5.6 12.4 5.7 13.8 6.8
250 9.2 17.2 8.7 15.2 10.0
315 12.8 23.2 11.9 14.8 13.2
400 16.4 29.3 16.3 16.2 17.1
500 23.2 38.9 22.9 18.6 21.2
630 30.8 52.5 31.5 22.8 26.9
800 44.0 68.6 43.1 30.7 34.6
1K 57.7 83.9 58.7 42.4 43.5
1.25K 70.6 94.5 74.4 56.6 53.2
1.6K 85.7 99.5 88.7 70.3 66.1
2K 94.6 97.0 96.7 80.3 80.9
2.5K 99.2 90.1 97.4 83.8 91.0
3.15K 98.0 81.0 93.6 81.7 96.9
The result of table 1 represents in coordinate diagram by Fig. 5.According to this coordinate diagram, the lightweight felt materials 1 of embodiment 2,3 has and compares the equal above acoustic absorptivity of A and B as known melt spraying non-woven fabrics (trade name: THINSULATE).In addition, according to the acoustic absorptivity comparing C, in lightweight felt materials of the present invention, nonwoven sheet 5 is required.
Embodiment 4
Adopt the felt manufacturing installation 7 shown in Fig. 3, net 14,16 is identical with embodiment 1 fibrous, clamps the nonwoven sheet 5 identical with embodiment 1 by two nets 14,16, and makes overall caking and manufacture lightweight felt materials 6 (reference Fig. 2).In lightweight felt materials 6, the thickness of the hard cotton layer 2 in top is 12mm and the weight of unit are is 202g/m 2, on the other hand, the thickness of the hard cotton layer 3 of lower floor is 26mm and the weight of unit are is 165g/m 2.
Varying in weight and the heavy 50g/m of gross weight quantitative change of the unit are of the lightweight felt materials 6 that the thickness of hard cotton layer 2,3 is different 2left and right, and compared with the lightweight felt materials 1 identical with the thickness of hard cotton layer 2,3, sound absorption qualities improves a lot.
Embodiment 5
Lightweight felt materials 1 is manufactured with the fiber combinations identical with embodiment 1.But the thickness of the lightweight felt materials 1 obtained is 20mm and the weight of unit are is 327g/m 2.
Embodiment 6
Lightweight felt materials 1 is manufactured with the fiber combinations identical with embodiment 2.But the thickness of the lightweight felt materials 1 obtained is 20mm and the weight of unit are is 333g/m 2.
Lightweight felt materials 1 as embodiment 5 and embodiment 6 is compared with following product.
Relatively D: thickness is that (weight of unit are is 326g/m for the melt spraying non-woven fabrics (trade name: THINSULATETC3303 300) of 20mm 2)
The lightweight felt materials 1 of embodiment 5 and embodiment 6 and the thickness comparing D are all 20mm.Measure the sound-absorbing data of these products by vertically injecting method, and the results are shown in following table 2.
(table 2)
Frequency Embodiment 5 Embodiment 6 Relatively D
200 4.4 3.9 2.6
250 7.4 7.0 5.3
315 9.9 9.2 7.4
400 13.2 12.8 9.9
500 17.1 16.6 13.2
630 22.3 21.7 18.2
800 29.1 28.8 24.8
1K 38.7 38.0 34.5
1.25K 49.3 48.0 45.0
1.6K 62.5 64.7 58.8
2K 75.1 77.6 71.3
2.5K 89.9 90.7 82.1
3.15K 96.5 96.9 92.3
4K 99.5 98.3 96.1
5K 97.9 95.2 94.0
6.3K 95.4 91.5 90.5
The result of table 2 represents in coordinate diagram by Fig. 6.According to this coordinate diagram, the lightweight felt materials 1 of embodiment 5,6 also have when thickness is 20mm with as known melt spraying non-woven fabrics (trade name: THINSULATE) compare D equal more than acoustic absorptivity.
Description of reference numerals
1 lightweight felt materials
Hard cotton layer above in the of 2
Hard cotton layer below 3
5 nonwoven sheet

Claims (7)

1. a lightweight felt materials, nonwoven sheet to be clipped between two-layer hard cotton layer and to make the lightweight felt materials of overall integration, be mixed with in two-layer hard cotton layer: the low-melting fiber of melting when the fineness of 20 ~ 80% is the superfine fibre of below 1.1 dtexs, the doughnut of imparting bulkiness of 10 ~ 60% and the entirety of 10 ~ 60% are heat-treated, the fibre diameter of nonwoven sheet is 2 ~ 20 μm, and the weight of unit are is 20 ~ 100g/m 2, described lightweight felt materials is used for interior material etc.
2. a lightweight felt materials, nonwoven sheet is clipped in the fluffy lightweight felt materials making entirety integrated between two-layer hard cotton layer and by thermo-compressed, be mixed with in two-layer hard cotton layer: the low-melting fiber of melting when the fineness of 20 ~ 80% is the superfine fibre of below 1.1 dtexs, the doughnut of imparting bulkiness of 10 ~ 30% and the entirety of 10 ~ 60% are heat-treated, the fibre diameter of nonwoven sheet is 2 ~ 20 μm, and the weight of unit are is 20 ~ 100g/m 2, described lightweight felt materials is used for interior material etc.
3. lightweight felt materials according to claim 1 and 2, wherein,
The hard cotton layer of top is 1:1 ~ 1:4 with the ratio of the thickness of the hard cotton layer of below.
4. lightweight felt materials according to claim 1 and 2, wherein,
Nonwoven sheet is the non-woven fabrics by meltblown manufacture.
5. lightweight felt materials according to claim 1 and 2, wherein,
Short fiber or the regenerated fiber of the synthetic fibers of the normal fineness of 10 ~ 30% is also contained in hard cotton layer.
6. the manufacture method of a lightweight felt materials, the conveyer of movement loads successively superfine fibre, doughnut and low-melting fiber are carried out to the first net of complexing, nonwoven sheet, superfine fibre, doughnut and low-melting fiber carried out to the second net of complexing, thus form three layer laminates, then with the temperature exceeding the fusing point of low-melting fiber three layer laminates heat-treated and pressurize, completing overall felt and integration thus simultaneously.
7. the manufacture method of lightweight felt materials according to claim 6, wherein,
By the brushing process on embossing process during low temperature or surface, fluffed in the two sides of nonwoven sheet, thus described nonwoven sheet is engaged more reliably with the first net and the second net.
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KR20160045619A (en) 2016-04-27
KR102059557B1 (en) 2019-12-26

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