CN110062827A - 汽车装备用半成品的制造方法 - Google Patents

汽车装备用半成品的制造方法 Download PDF

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CN110062827A
CN110062827A CN201780076527.4A CN201780076527A CN110062827A CN 110062827 A CN110062827 A CN 110062827A CN 201780076527 A CN201780076527 A CN 201780076527A CN 110062827 A CN110062827 A CN 110062827A
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sheath
core
motor vehicle
conjugate fiber
vehicle equipment
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花谷和俊
高桥达
神之门英明
赤尾昌哉
永塚裕介
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Unitika Ltd
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Abstract

本发明提供能够在较宽范围的加热温度成型并且能够得到具有高刚性的最终产品的汽车装备用半成品的制造方法。该汽车装备用半成品的制造方法是对由芯鞘型复合纤维集聚而成的纤维网实施针刺，使芯鞘型复合纤维相互间三维交织的方法。芯鞘型复合纤维的芯成分由乙二醇和对苯二甲酸的共聚物形成。芯鞘型复合纤维的鞘成分由含有乙二醇、己二酸和对苯二甲酸的共聚物形成。芯鞘型复合纤维中的芯成分与鞘成分的重量比为芯成分：鞘成分＝1～3：1。将芯成分和鞘成分同心配置。纤维网是通过鞘成分的软化或熔融将芯鞘型复合纤维相互间粘接而得的。

Description

汽车装备用半成品的制造方法
技术领域
本发明特别是涉及适合得到汽车外饰材等汽车装备的半成品的制造方法，特别是涉及成型性和成型后的硬度优异的半成品的制造方法。
背景技术
以往，对汽车附加了各种外饰材。例如，附加了覆盖汽车的底面侧的底罩、覆盖轮罩的内侧的盖(轮罩盖)。底罩的目的是使通过汽车的底面的空气流的流动良好，由此降低空气阻力而实现低油耗。另外，也是为了防止在走行中飞石损伤汽车的底面，同时实现飞石撞击底面的声音的减少。另外，轮罩盖的使用目的是防止在走行中卷入轮胎的砂石损伤轮罩内面，并且实现砂石撞击内面的声音的减少。
底罩、轮罩盖是将合成树脂制片材或合成树脂制布帛等半成品以与汽车的形状相吻合的方式成型而得的部件。例如，在专利文献1中，公开了将以由热塑性合成短纤维形成的针刺无纺布为一种素材的半成品进行加热和压缩成型而得的底罩(专利文献1、权利要求1)。作为热塑性合成短纤维，记载了使用聚丙烯纤维、聚酯纤维。然而，该纤维在加热和压缩成型时，加热温度的范围窄，需要严密的温度管理。另外，即便进行压缩成型，有时也得不到高刚性的成品。
现有技术文献
专利文献
专利文献1：WO2012/164977小册子(权利要求1)
发明内容
本发明提供能够在较宽范围的加热温度成型、并且能够得到具有高刚性的最终产品的汽车装备用半成品。
本发明通过使用特定的纤维作为构成属于半成品的无纺布的纤维，解决了上述课题。即，本发明涉及一种汽车装备用半成品的制造方法，其特征在于，通过对由芯鞘型复合纤维集聚而成的纤维网实施针刺，从而使该芯鞘型复合纤维相互间三维交织，该芯鞘型复合纤维中的芯成分由以乙二醇和对苯二甲酸构成的共聚物形成，该芯鞘型复合纤维中的鞘成分由含有乙二醇、己二酸和对苯二甲酸的共聚物形成。
本发明中，首先得到将特定的芯鞘型复合纤维作为构成纤维的纤维网。在此，特定的芯鞘型复合纤维是指芯成分由乙二醇和对苯二甲酸的共聚物形成、鞘成分由含有乙二醇、己二酸和对苯二甲酸的共聚物形成的纤维。构成芯成分的共聚物是将乙二醇作为二醇成分、将对苯二甲酸作为二羧酸成分进行脱水缩合而得的聚酯。应予说明，作为二羧酸成分，可以混合极少量的间苯二甲酸等其它的二羧酸成分。构成芯成分的共聚物的熔点约为260℃，玻璃化转变温度约为70～80℃。构成鞘成分的共聚物是将乙二醇作为二醇成分、将己二酸和对苯二甲酸作为二羧酸成分进行脱水缩合而得的共聚聚酯。作为二羧酸成分的己二酸与对苯二甲酸的混合比例是任意的，为己二酸：对苯二甲酸＝1：1～10(摩尔比)左右。作为二醇成分，优选混合少量的二乙二醇。二乙二醇的混合量在二醇成分中为0.5～5.0摩尔％左右。另外，作为二羧酸成分，优选混合少量的间苯二甲酸。间苯二甲酸的混合量在二羧酸成分中为2.0～5.0摩尔％左右。混合少量的二乙二醇、间苯二甲酸是为了适当地调整得到的纤维的刚性。构成鞘成分的共聚物的熔点约为200℃，玻璃化转变温度约为40～50℃。
芯成分与鞘成分的重量比例为芯成分：鞘成分＝0.3～3：1(重量比)左右。如果芯成分的重量比例过低，则有加热时的形态保持性降低的趋势，另外，产生最终得到的汽车装备的强度、刚性降低的趋势。另外，如果芯成分的重量比例过高，则通过加热和压缩成型难以一体化，在表面容易产生绒毛。芯成分和鞘成分可以同心配置，也可以偏心配置。然而，如果偏心配置，则在加热和压缩成型时，容易产生收缩，因此优选同心配置。
芯鞘型复合纤维可以通过将成为芯成分的聚酯和成为鞘成分的共聚合聚酯供给到具有复合纺丝孔的纺丝装置进行熔融纺丝这样公知的方法得到。芯鞘型复合纤维可以为芯鞘型复合长纤维，也可以为芯鞘型复合短纤维，但使用芯鞘型复合长纤维能够得到刚性高的汽车装备，因而优选。使用芯鞘型复合长纤维得到纤维网一般采用所谓的纺粘法。即，将通过熔融纺丝而得到的芯鞘型复合长纤维立刻集聚成片状，可以得到纤维网。另外，使用芯鞘型复合短纤维得到纤维网可以通过使芯鞘型复合短纤维通过梳毛机进行开纤，集聚成片状。纤维网的重量为200～2000g/m2左右。如果纤维网的重量过低，则不适合作为汽车装备的用途。另外，如果纤维网的重量过高，则汽车变成高重量，油耗变差。
纤维网可以在芯鞘型复合纤维相互间没有粘接的状态下实施针刺，也可以在芯鞘型复合纤维相互间粘接的状态下实施针刺。如果为前者的方法，则由于纤维相互间没有粘接，所以实施针刺时对纤维的损伤少，不易发生因断头等引起的强度下降，因而优选。另外，如果为后者的方法，则由于为纤维相互间粘接的状态的纤维网，所以容易操作，容易搬运。针刺用公知的方法进行，由此得到芯鞘型复合纤维相互间三维交织的致密的半成品。应予说明，即便在芯鞘型复合纤维相互间粘接的情况下，通过针刺，该粘接也被破坏，使芯鞘型复合纤维相互间三维交织。针刺密度优选为10针以上/cm2。
对如此得到的汽车装备用半成品实施加热和压缩成型，得到汽车装备。在本发明中，加热温度的范围为120～220℃左右。压缩时的加压优选根据压缩的程度任意地选择。另外，加热和压缩成型的时间为5～60秒左右便足够。在实施以上的加热和压缩成型后，放置在室温中，由此构成半成品的芯鞘型复合纤维的鞘成分熔融固化，使得芯鞘型复合纤维相互间紧密地粘接，得到具有刚性的汽车装备。该汽车装备可适当地用作汽车的底罩、轮罩盖、顶棚材料、挡板消声器、机罩消声器、挡泥板衬垫、汽车用地毯基布等地板材料或者各种托架材料等。应予说明，也可以不用于汽车装备，也可用作过滤基材、加湿器用蒸散板、吸音材料(防止异响材料)、内饰部件、地毯基布用基布或者各种板材。
用本发明涉及的方法得到的汽车装备用半成品由于以鞘成分由含有乙二醇、己二酸和对苯二甲酸的共聚物形成的芯鞘型复合纤维构成，使用己二酸作为该共聚物的结构单元，使鞘成分的熔点降低至200℃左右，所以能够发挥在宽泛的加热温度范围进行加热和压缩成型的效果。而且，由于鞘成分的熔点低，所以可得到刚性高的汽车装备，特别是芯鞘型复合纤维为长纤维的情况下，与鞘成分的熔点低的因素协同作用，能够发挥得到刚性更高的汽车装备的效果。
具体实施方式
实施例
实施例1
作为芯成分，准备乙二醇和对苯二甲酸的共聚物(熔点250℃)。作为鞘成分，准备乙二醇、二乙二醇、己二酸、对苯二甲酸和间苯二甲酸的共聚物(熔点200℃)。应予说明，作为二醇成分的乙二醇为98.8摩尔％，二乙二醇为1.2摩尔％，作为二羧酸成分的己二酸为18.8摩尔％，对苯二甲酸为78.0摩尔％，间苯二甲酸为3.2摩尔％。将上述的芯成分和鞘成分这两者供给到具有复合纺丝孔的纺丝装置，进行熔融纺丝，得到芯鞘型复合长纤维。芯成分与鞘成分的重量比例为芯成分：鞘成分＝7：3。在得到芯鞘型复合长纤维后，将其导入设置在纺丝装置的下方的吸气管，以高速进行牵引细化后，用公知的开纤装置使其开纤，将其捕集和集聚在移动的螺旋输送机上而得到纤维网。将该纤维网导入一对加热辊间，使鞘成分软化而使芯鞘型复合长纤维相互间粘接后，搬运到针刺装置，以针刺密度90针/cm2实施针刺，得到重量525g/m2的汽车装备用半成品。
比较例1
作为芯成分，准备实施例1中使用的共聚物。作为鞘成分，准备乙二醇与对苯二甲酸和间苯二甲酸的三元共聚物(熔点230℃)。将这两者供给到具有复合纺丝孔的纺丝装置，进行熔融纺丝，得到芯鞘型复合长纤维。芯成分与鞘成分的重量比例为芯成分：鞘成分＝6：4。在得到芯鞘型复合长纤维后，将其导入设置在纺丝装置的下方的吸气管，以高速进行牵引细化后，用公知的开纤装置使其开纤，将其捕集和集聚在移动的螺旋输送机上而得到纤维网。将该纤维网导入一对加热辊间，使芯成分软化从而使芯鞘型复合长纤维相互间粘接后，搬运到针刺装置，以针刺密度90针/cm2实施针刺，得到重量500g/m2的汽车装备用半成品。
比较例2
准备芯鞘型复合短纤维(尤尼吉可株式会社制，型号“2080”，纤度为4.4分特、纤维长度：51mm、芯成分：鞘成分＝1：1、鞘成分的熔点为200℃的芯鞘型复合短纤维)。应予说明，该芯鞘型复合短纤维的芯成分与实施例1中使用的共聚物相同，鞘成分为乙二醇与对苯二甲酸和间苯二甲酸的三元共聚物，但间苯二甲酸的混合比例更多，熔点低。将该芯鞘型复合短纤维用梳毛机进行开纤和集聚，得到纤维网后，立即搬运到针刺装置，以针刺密度90针/cm2实施针刺，得到重量500g/m2的汽车装备用半成品。
将实施例1、比较例1和2中得到的汽车装备用半成品夹在加热的金属制平板之间，在压力30kPa、时间1分钟的条件下，进行加热和压缩成型。加热的金属制平板在120℃、130℃、140℃、150℃、160℃、180℃、200℃、210℃、220℃这9个条件进行，结果如下。即，实施例1中得到的半成品能够在150℃～210℃的温度良好地成型，可得到高刚性的装备。虽然能够在120℃～140℃和220℃的温度成型，但是刚性有些不足。另一方面，比较例1中得到的半成品无法在120℃～180℃成型，虽然能够在200℃～220℃成型，但是刚性不足。比较例2中得到的半成品能够在160℃～180℃的温度良好地成型，可得到高刚性的装备。虽然能够在120℃～150℃和200℃～220℃的温度成型，但是刚性不足。

Claims (9)

1.一种汽车装备用半成品的制造方法，其特征在于，通过对由芯鞘型复合纤维集聚而成的纤维网实施针刺，从而使该芯鞘型复合纤维相互间三维交织，所述芯鞘型复合纤维中的芯成分由以乙二醇和对苯二甲酸构成的共聚物形成，所述芯鞘型复合纤维中的鞘成分由含有乙二醇、己二酸和对苯二甲酸的共聚物形成。
2.根据权利要求1所述的汽车装备用半成品的制造方法，其中，鞘成分为由乙二醇、己二酸、对苯二甲酸、间苯二甲酸和二乙二醇构成的共聚物。
3.根据权利要求1所述的汽车装备用半成品的制造方法，其中，芯成分与鞘成分的重量比为芯成分：鞘成分＝1～3：1。
4.根据权利要求1所述的汽车装备用半成品的制造方法，其中，在芯鞘型复合纤维中，将芯成分和鞘成分同心配置。
5.根据权利要求1所述的汽车装备用半成品的制造方法，其中，芯鞘型复合纤维为芯鞘型复合长纤维或者芯鞘型复合短纤维。
6.根据权利要求1所述的汽车装备用半成品的制造方法，其中，通过鞘成分的软化或熔融将纤维网中的芯鞘型复合纤维相互间粘接。
7.根据权利要求1所述的汽车装备用半成品的制造方法，其中，汽车装备为覆盖汽车的底面的底罩。
8.一种汽车装备的制造方法，其特征在于，具备下述工序：
得到由芯鞘型复合纤维集聚而成的纤维网的工序，所述芯鞘型复合纤维中的芯成分由乙二醇和对苯二甲酸的共聚物形成，所述芯鞘型复合纤维中的鞘成分由含有乙二醇、己二酸和对苯二甲酸的共聚物形成，
通过对所述纤维网实施针刺，从而使所述芯鞘型复合纤维相互间三维交织而得到汽车装备用半成品的工序，以及，
对所述汽车装备用半成品实施加热和压缩的工序。
9.根据权利要求8所述的汽车装备的制造方法，其中，鞘成分为由乙二醇、己二酸、对苯二甲酸、间苯二甲酸和二乙二醇构成的共聚物。
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