EP0312090A2 - Faseriger Schichtstoff und Verfahren zur Herstellung desselben - Google Patents

Faseriger Schichtstoff und Verfahren zur Herstellung desselben Download PDF

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Publication number
EP0312090A2
EP0312090A2 EP88117120A EP88117120A EP0312090A2 EP 0312090 A2 EP0312090 A2 EP 0312090A2 EP 88117120 A EP88117120 A EP 88117120A EP 88117120 A EP88117120 A EP 88117120A EP 0312090 A2 EP0312090 A2 EP 0312090A2
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EP
European Patent Office
Prior art keywords
fiber
woven fabric
fibers
laminate
mat
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.)
Granted
Application number
EP88117120A
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English (en)
French (fr)
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EP0312090A3 (en
EP0312090B1 (de
Inventor
Naoyuki C/O Mitsubishi Yuka Kato
Etsuo C/O Mitsubishi Yuka Wakabayashi
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.)
Mitsubishi Chemical BASF Co Ltd
Original Assignee
Mitsubishi Yuka Badische 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 JP62260557A external-priority patent/JPH01104868A/ja
Priority claimed from JP63035805A external-priority patent/JPH01209131A/ja
Priority claimed from JP63048330A external-priority patent/JPH01221234A/ja
Application filed by Mitsubishi Yuka Badische Co Ltd filed Critical Mitsubishi Yuka Badische Co Ltd
Publication of EP0312090A2 publication Critical patent/EP0312090A2/de
Publication of EP0312090A3 publication Critical patent/EP0312090A3/en
Application granted granted Critical
Publication of EP0312090B1 publication Critical patent/EP0312090B1/de
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    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/485—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs

Definitions

  • This invention relates to a fibrous laminate excellent in heat moldability, form-retentability, and cushoning property and a process of the production thereof. More particularly, the invention relates to a fibrous laminate excellent in heat moldability, form retentability, and cushoning property as internal decorating materials for vehicles such as motor cars, etc., and a process of the production thereof.
  • moldable fiber fabric mats obtained by coating or impregnating a needle punched non-woven fabric with an aqueous emulsion of a thermoplastic resin having a softening point of from 100°C to 130°C followed by drying and a carpet obtained by heating a non-woven fabric mat composed of mixed fibers of high-melting fibers such as polyethylene terephthalate fibers, etc., and a thermoplastic resin fiber binder having melting point of from 100°C to 130°C and press molding the non-woven fabric mat in conformity with the floor form of motor car.
  • JP-A As a process of lining a carpet without reducing the gas permeability of the carpet, the inventor previously proposed a process of lining a tufted carpet by applying a web onto the carpet through a fiber binder non-­woven fabric under heating and pressing and forming them, said web being produced by needling a felt layer composed of a mixture of a thermoplastic resin fiber binder having melting point of from 60°C to 200°C and fibers having melting point of at least 40°C higher than the melting point of the aforesaid fiber binder in JP-A-61-135614 (The term "JP-A" as used herein means an "unexamined published Japanese patent application").
  • the method of lining a carpet proposed by JP-A-61-­135614 described above is excellent in the point of not reducing the gas permeability and flexibility of the carpet since the fiber non-woven binder is a discontinuous layer having vacant spaces, different from conventional processes wherein a hot melt adhesive film is a continuous layer.
  • hot melt adhesives i.e., non-woven binder, thermoplastic resin film, thermoplastic resin powder, etc.
  • thermoplastic resin film i.e., thermoplastic resin film, thermoplastic resin powder, etc.
  • An object of this invention is to provide a process of producing a fibrous laminate capable of producing easily and at low cost a lined carpet having excellent moldability and form-retentabivity by further improving the aforesaid carpet lining process.
  • the 1st embodiment of this invention provides a process of producing a fibrous laminate which comprises laminating a non-woven fabric (A) composed of a thermoplastic resin fiber binder having a melting point of from 60°C to 200°C on the surface of a fiber mat (B) composed of synthetic fibers or natural fibers, said synthetic fibers or natural fibers having a melting point of at least 40°C higher than the melting point of the aforesaid fiber binder under non-woven fabric, applying needling to the laminate from the side of the thermoplastic resin binder non-woven fabric (A) to provide a laminate mat (C) wherein the binder fibers of the non-­woven fabric (A) and the fibers of the fiber mat (B) are entangled with each other, placing a surface decorating material (D) on the surface side of the non-woven fabric (A), and heating them to a temperature of not melting the surface decorating material (D) and the fibers of the fiber mat (B) but melting the binder fibers of the non-­ woven fabric
  • the 2nd embodiment of this invention provides a fibrous laminates obtained by laminating non-woven fabrics (A) and (A′) composed of a thermoplastic resin fiber binder having a melting point of from 60°C to 200°C, respectively, on both surfaces of a fiber mat (B) mainly composed of synthetic fibers or natural fibers, said synthetic fibers or natural fibers having a melting point of at least 40°C higher than the melting point of the aforesaid fiber binder, applying needling to the laminate to provide a laminate mat (C) wherein the fibers of the fiber binder non-woven fabric (A), (A′) and the fibers of the fiber mat (B) are entangled with each other, superposing a surface decorating material (D) on the laminate mat (C), and heating them under compressing to a temperature of higher than the melting point of the fiber binder of the aforesaid fiber binder non-woven fabric (A) but not melting the aforesaid surface decorating material (D) and the fibers as the main component of
  • the entangling of the high-melting fibers of the fiber mat (B) and the low-melting fibers of the fiber binder non-woven fabrics (A) and (A′) is enhanced to more strongly fix the fibers of the fiber mat (B) by the molten binder fibers.
  • the fiber non-woven fabric (A′) exists at the opposite side of the fiber mat (B) to the side of carrying the surface decorating material (D), if an under felt or a foam resin sheet is brought into contact with the surface of the non-woven fabric (A′) at press molding, the felt or sheet adheres to the surface of (A′).
  • the 3rd embodiment of this invention provides a fibrous laminate comprising a surface decorating material (D), a non-woven fabric (A) composed of a thermoplastic resin fiber binder having a melting point of from 60°C to 200°C, and a base material (B′) composed of a fiber mat (B) composed of synthetic fibers or natural fibers, said synthetic fibers or natural fibers having a melting point of at least 40°C higher than the melting point of the aforesaid fiber binder non-woven fabric (A) having dispersed therein resin particles of an aqueous resin emulsion, which are adhered to each other in this order (D/A/B′) in a body.
  • D surface decorating material
  • A non-woven fabric
  • A composed of a thermoplastic resin fiber binder having a melting point of from 60°C to 200°C
  • B′ composed of a fiber mat
  • B composed of synthetic fibers or natural fibers
  • said synthetic fibers or natural fibers having a melting point of at least 40°C
  • the fibers of the fiber mat (B) are fixed by applying needling to entangle the fibers of the fiber mat (B) and the fibers of the fiber binder non-woven fabric (A) with each other and melting the fiber binder
  • the fibers of the base material layer (B′) are fixed by impregnating the fiber mat (B) with a resin emulsion.
  • the fibers of the fiber binder non-woven fabric (A) and the fibers of the fiber mat (B) may be entangled with each other by the application of needling and in the case of employing needling for entangling fibers in the 3rd embodiment of this invention, the fibers of the base material layer (B′) can be more strongly fixed by the synergistic action of the needling and the impregnation of the emulsion.
  • the fiber mat (B) layer When needling is shallowly applied in the 3rd embodiment of this invention, the fiber mat (B) layer is wholly impregnated with the resin emulsion but when needling is wholly applied, the fiber mat (B) layer may be impregnated with the resin emulsion wholly or to an extent of the depth of from 30 to 80% in the thickness direction of the fiber mat (B) layer. The latter case of imperfectly impregnating, the fiber mat layer less loses the cushioning property of the fibrous laminate.
  • the 4th embodiment of this invention provides a fibrous laminate comprising a laminate mat (C) and a surface decorating material (D) laminated thereon, said laminate mat (C) comprising a pair of outer non-woven fabric layers (A) and (A′) composed of a thermoplastic resin fiber binder having a melting point of from 60°C to 200°C and a fiber mat layer (B) mainly composed of synthetic fibers or natural fibers, said synthetic fibers or natural fibers having a melting point of at least 40°C higher than the melting point of the aforesaid thermoplastic fiber binder non-woven fabric, sandwiched in said outer non-woven fabric layers (A) and (A′), the fibers of the fiber non-woven fabric of said outer non-­woven fabric layers (A) and (A′) being entangled and joined with the synthetic fibers or natural fibers of the fiber mat layer (B) by the application of needling, and the aforesaid fiber mat layer (B) mainly composed of the synthetic fibers or natural fibers containing
  • the 5th embodiment of this invention provides a fibrous laminate obtained by applying the steps of needling and the impregnating with the aquous resin emulsion in the aforesaid 4th embodiment of this invention to the case of sandwiching the fiber mat (B) in the fiber binder non-woven fabrics (A) and (A′).
  • the embodiment provides a fibrous laminate obtained by laminating a surface decorating material (D) on a laminate mat (C) comprising a pair of outer non-woven fabric layers (A) and (A′) composed of a thermoplastic fiber binder having a melting point of from 60°C to 200°C and a fiber mat layer (B) mainly composed of synthetic fibers or natural fibers, said synthetic fibers or natural fibers having a melting point of at least 40°C higher than the aforesaid thermoplastic fiber binder non-­woven fabric, sandwiched in said outer non-woven fabric layers (A) and (A′), said fiber mat layer (B) at least partially containing solid components of an emulsion of a resin having a glass transition point of at least 50°C.
  • a surface decorating material D
  • a laminate mat comprising a pair of outer non-woven fabric layers (A) and (A′) composed of a thermoplastic fiber binder having a melting point of from 60°C to 200°C and a fiber mat layer (B)
  • the fiber mat layer (B) may be impregnated with the resin emulsion wholly or partially in the thickness direction of the layer.
  • the fiber binder non-woven fabric (A) or (A′) for using in this invention is a non-woven fabric composed of thermoplastic resin fibers. That is, the non-woven fabric is obtained by entangling fibers of a thermoplastic resin such as polyethylene, polypropylene, linear polyester, polyamide, etc., or composite fibers thereof having a melting point of from 60°C to 200°C, and preferably from 90°C to 170°C, the size of the fibers may be thick or thin but is usually at least 3 deniers and the fiber length being preferably at least 8mm from the point of entagling, by a spun bond method, a needle punch method, etc. Also, the non-woven fabric may be a fiber web obtained by carding engine, etc.
  • a thermoplastic resin such as polyethylene, polypropylene, linear polyester, polyamide, etc.
  • composite fibers thereof having a melting point of from 60°C to 200°C, and preferably from 90°C to 170°C
  • the size of the fibers may be
  • the non-woven fabric has gas permeability.
  • the non-woven fabric is preferably composed of the fibers having a unit weight per square of from 6 g/m2 to 600 g/m2.
  • the fiber binder non-woven fabric (A) or (A′) may be produced by melting pellets of a resin such as polypropylene, low-melting polyester, low-melting polyamide, etc., using an extruder, extruding the molten resin through a die having many fine holes into filaments while carrying them by wind so that the filaments are not collected, accumulating them on a screen under the die, and gathering them by a winder.
  • a resin such as polypropylene, low-melting polyester, low-melting polyamide, etc.
  • Such fiber binder non-woven fabrics are commercially available as follows. That is, for example, non-woven fabrics having many pores capable of passing water therethrough are commercially available as a trade name of Meltron W from Diabond Kogyo K.K., with polyamide series non-woven fabrics having grade names of PAY-200 and PAS-200, polyester series non-woven fabrics having grade names of ES-500, etc., acetic acid copolymer series non-­woven fabrics having grade name of Y-7.
  • polypropylene series non-woven fabrics as trade names of Sintex PK-103, PK-106, PK-404, and PK-408 from Mitsui Petrochemical Industris, Ltd.
  • polyethylene series non-­woven fabrics as trade name of Admel from Mitsui Petrolchemical Industries, Ltd.
  • similar non-woven fabrics trade name of DYNAC with grade names of LNS-0000, LNS-2000, ES-00, B-1000, B-2000, B-3000, etc., from Kureha Suni K.K. are commercially available.
  • the melting point of the fiber binder non-woven fabric (A) or (A′) for use in this invention is at least 40°C lower than the melting point of the fibers mainly constituting the fibers of the fiber mat (B). This is because the temperature of melting the non-­woven fabric (A) is usually from 20°C to 30°C higher than the melting point of the binder fibers of the non-woven fabric (A).
  • the basis weight of the non-woven fabric (A) or (A′) is generally from 10 g/m2 to 500 g/m2.
  • the fiber binder non-woven fabric may be composed of a single kind of fibers or mixed fibers of, for example, polypropylene fibers and polyamide fibers. That is, the non-woven fabrics may be composed of mixed fibers or a laminate of these mixed fibers if the melting points of these fibers are at least 40°C lower than the melting point of the fiber mat (B). Furthermore, the mixed fibers may contain high-melting fibers to some extent (less than 30%). Recovered fibers may be used but in this case, the fibers are required to be mixed well.
  • fibers constituting the fiber mat (B) which is used for the fiber laminates of this invention synthetic fibers or natural fibers are used.
  • the synthetic fibers or natural fibers have a melting point of at least 40°C, and preferably at least 70°C higher than the melting point of the aforesaid fiber binder non-woven fabric (A), (A′) (practically having a melting point of from 200°C to 280°C).
  • the synthetic fibers are used such as polyethylene terephthalate fibers, polyamide fibers, polyacrylonitrile fibers, etc. and as natural fibers, cotton, hemp, wool, rough felt, waste poly fibers, etc. are used.
  • the fiber mat (B) may contain a fiber binder having a melting point of from 60°C to 200°C in a ratio of from 15 to 50% by weight.
  • the fiber mat (B) for use in this invention is subjected to needling together with the aforesaid fiber binder non-woven fabric (A) or (A′) laminated on the surface thereof for entangling the fibers of the mat and the fibers of the non-woven fabric in a body, it is unnecessary to previously impart a sufficient form retentability to the fiber mat itself by needling and also the purpose is sufficiently attained by using a web of waste fibers by not always using fibers of good quality.
  • an original good for tufted carpet obtained by raising piles of polyamide or polyethylene terephthalate on a primary base cloth formed by knitting with flat polypropylene yarns an original good for tufted carpet obtained by raising piles on a primary base cloth of the aforesaid needle punched carpet, a needle punched carpet, woven-­fabrics, papers, etc., are used.
  • the aqueous resin emulsion is an emulsion of resin particles having a glass transition point of at least 50°C, and preferably from 80°C to 180°C, and the particle size is from 0.05 to 1.5 ⁇ m.
  • thermoplastic resins such as a lower ester copolymer of styrene ⁇ lower alkyl ester of acrylic acid (carbon atoms of the ester being from 2 to 6)), a copolymer of lower alkyl ester of acrylic acid ⁇ styrene ⁇ acrylic acid, a copolymer of a lower alkyl ester of methacrylic acid (carbon atoms of the ester being from 2 to 6), a vinylidene chloride copolymer (containing more than 85% by weight of vinilydene chloride), a styrene ⁇ diene copolymer, etc.
  • thermoplastic resins such as a lower ester copolymer of styrene ⁇ lower alkyl ester of acrylic acid (carbon atoms of the ester being from 2 to 6)
  • a copolymer of lower alkyl ester of acrylic acid ⁇ styrene ⁇ acrylic acid a copolymer of a lower alkyl ester of meth
  • the most suitable resin examples include (a) an aqueous emulsion of a homopolymer such as n-propyl polymethacrylate (Tg 81°C), polystyrene (Tg 100°C), polyacrylonitrile (Tg 100°C) methyl polymethacrylate (Tg 105°C), polymethacrylic acid (Tg 130°C), polyitaconic acid (Tg 130°C), polyacrylamide (Tg 153°C), etc., (b) an aqueous emulsion of a copolymer of from 50 to 100% by weight, and preferably from 65 to 95% by weight of the vinyl monomer which is the raw material of the aforesaid homopolymer and other vinyl monomer such as 2-­ethylhexyl acrylate (Tg 85°C), n-butyl acrylate (Tg-­54°C), ethyl acrylate (Tg -22°C), isopropyl acrylate
  • the aforesaid aqueous emulsion may contain a filler such as calcium carbonate, iron oxide, ferrite, barium sulfate, etc., for imparting a massive feeling to the fibrous laminate obtained and may contain a powder of a low-melting resin such as a low-density polyethylene or polystyrene, an ethylene.vinyl acetate copolymer, etc., for imparting a moldability to the fibrous laminate.
  • a filler such as calcium carbonate, iron oxide, ferrite, barium sulfate, etc.
  • a powder of a low-melting resin such as a low-density polyethylene or polystyrene, an ethylene.vinyl acetate copolymer, etc.
  • Such an aqueous emulsion is generally coated on the fiber mat (B) or a laminate mat obtained by laminating the fiber binder non-woven fabric (A) on the fiber mat (B) followed by, if necessary, needling at the back side surface of the fiber mat layer (B) for impregnation and dried or the laminate mat described above is immersed in the aqueous emulsion followed by drying, whereby the resin particles of the emulsion are dispersed in the fiber mat (B).
  • the resin particles of the aqueous emulsion having a glass transition point of at least 40°C lower than the heat deformation temperature of the materials for the surface decorating material (D) and the fiber mat (B) of the base material layer (B′).
  • the fibrous laminate obtained according to the process in the 1st embodiment of this invention has the structure formed by laminating a carpet (D) as the upper layer of a surface decorating material, such as a needle punched carpet, tufted carpet, etc., on the surface of a laminate mat (C) having a double layer structure formed by laminating a fiber binder non-woven fabric (A) on the surface of a fiber mat (B) followed by needling and heating under compression the laminate to melt the aforesaid fiber binder non-woven fabric (A) and weld the surface decorating material (D) and the laminate mat (C).
  • a carpet D
  • a surface decorating material such as a needle punched carpet, tufted carpet, etc.
  • the fiber binder non-woven fabric (A) is used in an amount of from 10 to 200% by weight of the fiber mat (B).
  • Needling is performed in the manner that the fiber binders of the non-woven fabric (A) are perpendicularly inserted into the fiber mat (B) and needles penetrate through the fiber mat (B).
  • the fiber binders of the non-woven fabric (A) exist throughout the whole fiber mat (B) layer in an amount of from 5 to 80% by weight. In this case, however, when the fiber mat (B) containing from 5 to 50% by weight of a fiber binder therein before needling is used, it is unnecessary to insert needles until the needles completely penetrate the fiber mat (B) layer.
  • the fiber binder of the non-woven fabric (A) is inserted in the fiber mat (B) in an amount of from 5 to 80% by weight and also always remain at the surface thereof in an amount of from 95 to 20% by weight to form a clear double layer structure of the fiber binder layer (A) and the fiber mat layer (B). Also, the binder fibers of the non-woven fabric (A) exists in the fiber mat (B).
  • the surface decorating material (D) is placed on the fiber binder non-woven fabric (A) and is finally brought into a form of being heat-adhered thereto.
  • a system of entangling the fibers of the surface decorating material (D) by applying light needling and then heat-adhere the surface decorating material (D) to the fiber binder non-woven fabric (A) at heat-molding may be employed but this system roughens the surface of the surface decorating material (D) and also has an disadvantage of requiring the addition step.
  • the laminated materials it is particularly important to heat the laminated materials to at least a temperature of melting the fiber binder non-woven fabric (A) and a temperature of not melting the upper layer carpet (D) and the fiber mat (B).
  • a roll pressure of about 1 kg/cm2 is enough for heat-adhering only but when molding and the control of density are performed simultaneously with heat adhering, a roll pressure of from 5 kg/cm2 to 50 kg/cm2 is required.
  • the heating and compression can be continuously performed using ordinary rolls. It is preferred to apply needling so that from 5% to 100% of the binder fibers of the non-woven fabric (A) are entangled with the fibers of the fiber mat (B).
  • the fibrous laminate of this invention can be heat molded in conformity with a floor, etc., being laid.
  • the fibrous laminate can be molded into a desired form according to the purposes simultnaeously with or after adhereing the aforesaid upper layer carpet thereto.
  • the fibers of the fiber binder non-woven fabric (A) enter the fiber mat (B) by needling and are entangled with the fibers of the fiber mat (B), the fiber mat (B) itself is het set to impart the strength, hardness and form retentabivity as the backing material layer (C).
  • the surface of base layer is mainly composed of the binder fibers of the fiber binder non-woven fabric (A) after needling, there is an advantage that the surface decorating material (D) adhers to the base material layer (B′) without particularly requiring an adhesive means such as adhesive cloth, powder, hot melt, etc.
  • the fibrous laminate is excellent in moldability by heat molding by the existent of the fiber binder non-woven fabric, with particularly suitable for deep drawing molding, and good in form retentability after molding.
  • the fiber mat (B) and the fiber binder (A) are entangled by needling in a laminated state of both the components, a step of uniformly mixing the fibers of both components different from conventional techniques is unnecessary and the production process for the fibrous laminate is simplified.
  • the fibrous laminate has the structure obtained by superposing, for example, a needle punched carpet as a surface decorating material (D) on one surface of a laminate mat (C) formed by needing the laminate of three-layer structure comprising a fiber mat (B) and fiber binder non-woven fabrics (A) and (A′) laminated on both surfaces of the fiber mat (B) followed by heatin them under compression to melt the binder fibers of the aforesaid fiber binder non-woven fabric (A) and, thereby, adhere the surface decorating material (D) to the laminate mat (C).
  • a laminate mat formed by needing the laminate of three-layer structure comprising a fiber mat (B) and fiber binder non-woven fabrics (A) and (A′) laminated on both surfaces of the fiber mat (B) followed by heatin them under compression to melt the binder fibers of the aforesaid fiber binder non-woven fabric (A) and, thereby, adhere the surface decorating material (D) to the laminate mat (C).
  • the non-woven fabric (A) is used in a ratio of from 10 to 100% by weight of the fiber mat (B).
  • the non-­woven fabric (A′) of the lower layer is used in unit weight per square of from 10 to 500 g/m2.
  • the laminate mat (C) wherein the fibers of the fiber binder non-woven fabrics (A) and (A′) and the fibers of the fiber mat (B) are entangled with each other is obtained and for the purpose it is required to perform the needling so that the needles penetrate the fiber mat (B).
  • the binder fibers of the fiber binder non-woven fabric (A) or (A′) exists in the whole layer of the fiber mat (B) at from 5 to 80% by weight.
  • the fiber mat (B) containing from 5 to 50% by weight of fiber binder in the layer of the fiber mat (B) before needling is used, it is not always necessary to insert the needles in the fiber mat (B) until the needles completely penetrate therethrough.
  • Needling may be applied to the laminate from any side of the laminate but when needling is applied thereto from the side of the fiber binder non-woven fabric (A), the binder fibers of the fiber binder non-woven fabric (A) are inserted in the fiber mat (B) in an amount of from 5 to 80% by weight thereof by the needling but remaining 95 to 20% by weight of the fibers remain as a fiber binder layer at the surface of the laminate mat (C) to give the clear layer structure of the fiber binder layer (A) and the fiber mat (B) and also the binder fibers of the fiber binder fabric (A) exist in the fiber mat (B).
  • part of the fibers of the fiber mat (B) are inserted into the fiber binder non-woven fabric (A′) disposed at the opposite side to the fabric (A) and are entangled therewith.
  • the fibers of the fiber binder non-woven fabric (A) are perpendicularly inserted into the fiber mat (B) and also the fibers of the fiber mat (B) are inserted into the fiber binder non-woven fabric (A′) disposed at the opposite side to the fabric (A) by needling, whereby the fibers of the three layers are entangled with each other in a body.
  • needling may be applied to the laminate from the side of the fiber binder non-woven fabric (A′).
  • the needling being applied after laminating the aforesaid fiber mat (B) and the fiber binder non-woven fabric (A) is applied by piercing needles into the opposite side in the perpendicular direction at a ratio of from 80 to 300 needles per square inches.
  • the needling is performed so that from 5 to 80% by weight of the binder fibers of the fabric (A) are entangled with the fibers of the fiber mat (B).
  • the surface decorating material (D) is placed on the fiber binder non-woven fabric (A) of the laminate mat (C) and is finally in the form of being heat-adhered thereto and in this case, a system of entangling the surface decorating material (D) by light needling and letting the material heat-adhere to the fiber binder non­woven fabric (A) at heat molding may be employed.
  • the system roughens the surface of the surface decorating material (D) and has a disadvantage of requiring an addition step.
  • the laminate it is particularly important to heat the laminate to at least a temperature of melting the fiber binder non-woven fabrics (A) and (A′) and a temperature of not melting the surface decorating material (D) and the fiber mat (B).
  • a pressure of about 1 kg/cm2 by press rolls is enough in the case of heat-adhering only but a pressure of from 5 to 50 kg/cm2 is necessary in the case of molding and controlling the density of the mat simulataneously with heat-adhering.
  • the heating and the compression can be continuously performed using rolls, etc.
  • the fibrous laminate according to the 2nd embodiment of this invention can be heat-molded in conformity with the form of a floor to be layed and in this case, the fibrous laminate can be heat-adhered to other materials.
  • the aforesaid molding can be performed simultaneously with the adhesion of the aforesaid surface decorating material. Also, the assembly once heat-adhered can be formed into a necessary form according to the purpose.
  • the fibrous laminate of this embodiment has the following effects.
  • the fiber mat (B) is sandwiched in the fiber binder non-woven fabrics (A) and (A′), and the fibers of the fiber binder non-woven fabric (A) are inserted into the fiber mat (B) and are entangled with the fibers of the latter, the fiber mat (B) itself is heat set by heating to be imparted with the strength, hardness, and form retensitivity as a backing layer.
  • the surface of the laminate mat (C) of the backing layer is mainly composed of the binder fibers of the fiber binder non-woven fabric (A) after needling, there is an advantage that for adhering the laminate mat (C) to the surface decorating material (D), an adhesive means such as adhesive cloth, powder, hot melt, etc. is not required.
  • the fibrous laminate has a layer mainly composed of the fiber binder non-woven fabric (A′) as the lower layer, the fibrous laminate is excellent in moldability at heat molding and hence the laminate is particularly suitable for molding of deep drawing and is good in form retensitivity after molding. Furthermore, the fibrous laminate can be adhered to other material by the fiber binder non-woven fabric (A′) as the lower layer.
  • the fiber mat and the fiber binder non-woven fabric (A) and (A′) are entangled with each other by needling the laminate of them, it is unnecessary to uniformly mix the fibers of both the components different from conventional techniques, which can simplify the production process for the fibrous laminate.
  • the fibrous laminate has the structure composed of a surface decorating material (D), a fiber binder non-woven fabric (A) of a thermoplastic resin having a melting point of from 60°C to 200°C, and a base material layer (B′) composed of a fiber mat (B) of synthetic fibers or natural fibers, said synthetic fibers having a melting point of at least 40°C higher than the melting point of the aforesaid fiber binder non-woven fabric (A) having dispersed therein resin particles of an aqueous resin emulsion adhered with each other in this order (D/A/B′) in a body.
  • D surface decorating material
  • A fiber binder non-woven fabric
  • A thermoplastic resin having a melting point of from 60°C to 200°C
  • B′ base material layer
  • a fiber mat (B) of synthetic fibers or natural fibers said synthetic fibers having a melting point of at least 40°C higher than the melting point of the aforesaid fiber binder non-woven fabric (A)
  • the fibrous laminate is obtained by laminating the fiber binder non-woven fabric (A) of a thermoplastic resin having a melting point of from 60°C to 200°C on the surface of the fiber mat (B) composed of synthetic fibers or natural fibers having a melting point of at least 40°C higher than the melting point of the aforesaid fiber binder non-woven fabric (A), applying needling to the laminate from the side of the fiber binder non-woven fabric (A) thereof to provide a laminate mat wherein the binder fibers of the non-woven fabric (A) and the fibers of the fiber mat (B) are entangled with each other, placing the surface decorating material (D) on the side of the non-woven fabric (A), coating and impregnating the laminate mat with an resin emulsion at the side of the fiber mat (B) followed by drying, and heating the assembly to a temperature of not melting the surface decorating material (D) and the fiber mat (B′) but melting the binder fibers of the non-woven fabric (A) and the resin particles of
  • the non-woven fabric (A) is used in a ratio of from 10 to 200% by weight of the fiber mat (B). Also, the unit weight per square thereof is generally from 10 to 500 g/m2.
  • the resin particles (a) may be dispersed in the whole fiber mat (B) in the mat (B′) as shown in Fig. 3 or may be dispersed in the lower layer side (B2), i.e., in the layer of from 30 to 80% of the thickness of the whole mat (B) as shown in Fig. 4.
  • the fibrous laminate has a fiber mat layer (B1) containing no dispersion of the resin particles of the emulsion and hence the fibrous laminate is excellent in cushioning property but inferior in rigidity as compared with the former case. Also, in the latter case, it is preferred for not causing intralayer separation of the fibrous laminate at the mat layer (B1) that the fibers of the fiber binder non-woven fabric (A) and the fibers of the fiber mat (B) are previously entangled with each other by the application of needling or the fiber mat (B) is composed of mixed fibers of from 50 to 85% by weight synthetic fibers or natural fibers each having a melting point of at least 200°C and from 50 to 15% by weight a resin fiber binder having a melting point of at least 40°C lower than the melting point of the aforesaid fibers.
  • the resin emulsion imparts a heat moldability and form retentability to the fibrous laminate by the resin-impregnated fiber mat layer (B2) formed at the lower layer of the fiber mat (B) and also the resin mat layer (B1) containing no resin formed at the upper layer thereof imparts a cushioning property to the fibrous laminate.
  • the fiber laminate is produced by laminating the thermoplastic resin fiber binder non-woven fabric layer (A) on the surface of the fiber mat layer (B) mainly composed of synthetic fibers having a melting point of at least 40°C higher than the melting point of the fibers of the aforesaid fiber binder non-woven fabric layer (A) or natural fibers to provide a laminate mat, applying thereto, if necessary, needling, coating the back surface of the laminate mat with an emulsion of a resin having a glass transition point of at least 50°C to impregnate the aforesaid resin mat layer (B) partially or wholly with the emulsion followed by drying, superposing the surface decorating material (D) on the surface of the laminate mat, and heating under compression the assembly to melt the resin particles of the emulsion and the fiber binder of the non-woven fabric (A) and weld the surface decorating material (D) to the fiber mat layer (B′).
  • the fibrous laminate is produced by laminating the thermoplatic fiber binder non-woven fabric (A) on the back surface of the aforesaid fiber mat layer (B) followed by needling to provide a laminate mat, and after placing the surface decorating material (D) on the laminate mat followed by heating to weld them, coating an emulsion of a resin having a glass transition point of at least 50°C on the back surface of the laminate mat to form the resin-containing fiber mat layer (B′) in the aforesaid fiber mat layer (B).
  • the fibrous laminate may be produced by coating or impregnating the fiber mat (B) with the resin emulsion or immersing the fiber mat (B) in the resin emulsion followed by semi-drying or completely drying them, placing the fiber binder non-woven fabric (A) on the surface of the mat (B′) and further thereon the surface decorating material (D), and molding the assembly under heating and compressing.
  • the compression may be sufficiently performed at a pressure of about 1 kg/cm2 by press rolls but in the case of molding in conformity of the form of, for example, floor and controlling the density of the mat simultaneously with heat welding, a pressure of from 5 to 50 kg/cm2 is necessary.
  • the compression is performed after drying the impregnated emulsion to some extent.
  • the aforesaid needling which is applied in necessary in this embodiment is performed for preventing the occurence of deformation of the laminate mat or enabling the molding work.
  • the laminate mat (C) in which the fibers of the fiber binder (A) are entangled with each other, it is necessary to perform needling so that the needles penetrate through the fiber mat layer (B′), where­by the binder fibers of the fiber binder non-woven fabric (A) are inserted in the fiber mat layer (B′) at from 5 to 80% by weight of the fibers in the whole range of the fiber mat layer (B′).
  • the fiber mat layer (B) already contains from 15 to 50% by weight of the fiber binder before the application of needling is used, it is not always necessary to insert the needles until the needles completely penetrate the fiber mat layer (B).
  • the needling may be applied to the aforesaid laminate from any side thereof but when the needling is applied thereto from the fiber binder non-woven fabric layer (A), the binder fibers of the fiber binder non-woven fabric (A) are inserted in the resin mat layer (B) at from 5 to 80% by weight thereof by needling and from 95 to 20% by weight of remaining fibers remain at the surface of the laminate mat (C) as the fiber binder non-woven fabric layer (A) to form a clear layer structure of the fiber binder layer (A) and the fiber mat layer (B) as well as the binder fibers of the fiber binder layer (A) exist in the fiber mat layer (C).
  • the fibers of the fiber mat layer (B) are partially inserted in the fiber binder non-woven fabric (A) and entangled with the fibers of the non-woven fabric.
  • the binder fibers of the fiber binder non-woven fabric (A) are perpendicularly inserted in the fiber mat layer (B) and the fibers of the fiber mat layer (B) also are inserted into the fiber binder non-woven fabric layer (A) by needling, whereby the fibers of the two layers are entangled with each other in a body.
  • the needling may be applied from the side of the fiber mat (B).
  • the needling is applied by piercing needles into the opposite side in the perpendicular direction at a ratio of from 80 to 300 needles per square inches are performed so that from 5 to 80% by weight of the binder fibers of the fiber binder non-woven fabric layer (A) are entangled with the fibers of the fiber mat layer (B).
  • needling may be applied after laminating the surface decorating material (D) on the laminate mat.
  • the 4th embodiment of this invention provides a fibrous laminate formed by laminating a surface decorating material (D) on a laminate mat (C) composed of a pair of outer non-woven fabric layers (A) and (A′) of a thermoplastic resin fiber binder non-woven fabric having a melting point of from 60°C to 200°C and a fiber mat layer (B) mainly composed of synthetic fibers or natural fibers, said synthetic fibers or natural fibers having a melting point of at least 40°C higher than the melting point of the aforesaid thermoplastic fiber binder non-woven fabric, sandwiched in said outer non-woven fabric layers (A) and (A′), the fibers of the outer fiber binder non-woven fabric layers (A) and (A′) being entangled and joined with the synthetic fibers or natural fibers of aforesaid fiber mat layer (B), wherein the aforesaid fiber mat layer (B) mainly composed of the synthetic fibers or natural fibers may contain an emulsion of a resin having a
  • the fibrous laminate has the structure formed by laminating a surface decorating material (D) such as a needle punched carpet on one surface of a laminate mat (C) composed of a laminate having a three-layer structure formed by placing a fiber binder non-woven fabric layer (A) as an upper layer and a fiber binder non-woven fabric layer (A′) as a lower layer on both surfaces of a fiber mat layer (B′) containing solid resin components of a resin emulsion, the fibers of the fiber binder non-woven fabric layers (A) and (A′) being entangled and joined with the fibers of the fiber mat layer (B′) by applying needling, etc., to the laminate.
  • a surface decorating material such as a needle punched carpet
  • a laminate mat (C) composed of a laminate having a three-layer structure formed by placing a fiber binder non-woven fabric layer (A) as an upper layer and a fiber binder non-woven fabric layer (A′) as a lower layer on both surfaces of a fiber mat
  • the fibrous laminate is produced by laminating the thermoplastic resin fiber binder non-woven fabric layers (A) and (A′), respectively, on both surfaces of the fiber mat (B) mainly composed of synthetic fibers having a melting point of at least 40°C higher than the melting point of the afiresaid thermoplastic resin fiber binder non-woven fabric layers (A) and (A′) or natural fibers, applying needle punching thereto to provide the laminate mat (C) and after immersing the laminate mat (C) in an emulsion of a resin having a glass transition point of at least 50°C to impregnate the laminate mat with the emulsion, placing the surface decorating material (D) on the laminate mat (C) followed by heating and compressing, whereby the emulsion is dried and the fiber binder of the aforesaid fiber binder non-woven fabric layers (A) and (A′) are melted to heat-weld the surface decorating material (D) and the laminate mat layer (C).
  • the fiber binder non-woven fabric layers (A) and (A′) each may not be composed of a single kinds of fibers.
  • they may be composed of a mixed fibers of polypropylene and polyethylene.
  • the fibers may be mixed with high-melting fibers if the content thereof is within 30% by weight. In the case of using recovered fibers, fibers having high melting point are sometimes intermingled.
  • a polypropylene fiber binder non-woven fabric may be used as the non-woven fabric (A) and a polyethylene fiber binder non-woven fabric may be used as the non-woven fabric (A′).
  • the laminate mat (C) wherein the fibers of the fiber mat layer (B) are entangled with the fibers of the fiber binder non-­woven fabric layers (A) and (A′) is obtained and by impregnating the laminate mat (C) with the resin emulsion from the side of the non-woven fabric layer (A′) or by immersing the laminate mat (C) in the resin emulsion, the laminate mat (C) having wholly impregnated with the emulsion is obtained.
  • the laminate mat (C) wherein the fiber mat layer (B) is impregnated with the resin emulsion may be obtained by previously impregnating the fiber mat of the fiber mat layer (B) with the emulsion or immersing the fiber mat in the emulsion and after semi-drying or completely drying the emulsion, sandwiching the fiber mat layer (B) in the fiber binder non-woven fabric layers (A) and (A′).
  • the laminating amount of each of the fiber binder non-woven fabric layers (A) and (A′) is from 10 to 100% by weight of the fiber mat layer (B).
  • the emulsion can be uniformly dispersed in the laminate mat (C) as solid resin components of the emulsion by generally immersing the laminate mat (C) in the emulsion followed by squeezing by rolls to impregnate the mat with the emulsion and, if necessary, drying the mat.
  • the content of the solid resin components of the emulsion impregnated is from 10 to 100 parts by weight, and preferably from 20 to 80 parts by weight per 100 parts by weight of the synthetic fibers or natural fibers of the aforesaid fiber mat layer (B). If the content of the solid resin components of the emulsion is less than the aforesaid range, because the improvement of the regidity can not be obtained, the improvement of the form retentabivity after molding can not be expected. Also, if the content is too large, the fibrous laminate become hard and shows a resin felt feeling.
  • the 5th embodiment of this invention provides a fibrous laminate obtained by laminating a surface decorating material (D) on a laminate mat (C) composed of a pair of outer non-woven fabric layers (A) and (A′) of a termoplastic resin fiber binder non-woven fabric having a melting point of from 60 to 200°C and a fiber mat layer (B) mainly composed of synthetic fibers or natural fibers, said synthetic fibers having a melting point of at least 40°C higher than the melting point of the aforesaid thermoplastic resin fiber binder non-woven fabric, sandwiched in the aforesaid outer non-woven fabric layers (A) and (A′), wherein the aforesaid fiber mat (B) partially contains solid resin components of an emulsion of a resin having a glass transition point of at least 50°C.
  • the fiber mat layer (B) contituting the fibrous laminate of this embodiment is composed of a fiber mat layer (B2) containing solid resin components of the emulsion of a resin having a glass transition point of at least 50°C as the upper layer and a fiber mat layer (B1) containing no such resin as the lower layer.
  • the unit weight per square of the fiber mat layer (B) is generally from 100 to 1000 g/m2, and preferably from 300 to 740 g/m2.
  • the laminate After applying the emulsion to the lower surface of the fiber mat layer (B) before lamination or to the lower layer portion (A′) of the laminate mat (C) after forming the laminate mat (C) by spraying or coating using a foam coater or immersing the lower surface of the fibrous mat layer (B) or the lower layer portion (A′) of the laminate mat (C) in the emulsion followed by squeezing by rolls to impregnate the lower layer portion of the fiber mat layer (B) or the laminate mat (C) with the emuslion, the laminate is dried to form the resin-­impregnated fiber mat layer (B2) as the lower layer of the fiber mat layer (B).
  • the resin-impregnated fiber mat (B2) is generally formed in a thickness of from 5 to 80%, and preferably from 30 to 65% of the thickness of the fiber mat layer (B).
  • the fibrous laminate is imparted with a heat moldability and form retentabivity by the resin-­ impregnated fiber mat layer (B2) formed as the lower layer and also imparted with a cushioning property by the fiber mat layer (B1) containing no resin formed as the upper layer.
  • the laminate mat (C) wherein the fibers of the fiber mat layer (B) are entangled with the fibers of the fiber binder non-woven fabric layers (A) and (A′) can be obtained. Since the laminate mat (C) as described above is reluctant to deform, it is preferred to apply needling.
  • the laminating amounts of the fiber binder non-­woven fabric layers (A) and (A′) are from 10 to 100% by weight of the amount of the fiber mat layer (B) and each of the fiber binder non-woven fabric layers (A) and (A′) as the upper and lower layers is laminated in an amount of from 10 to 500 g/m2.
  • the laminate mat (C) wherein the fibers of the fiber binder are entangled it is necessary to apply needling so that the needles pierce through the fiber mat layer (B), whereby from 5 to 80% by weight of the binder fibers of the fiber binder non-woven fabrics (A) and (A′) are inserted into the fiber mat layer (B) in the whole range of the fiber mat layer (B).
  • needling so that the needles pierce through the fiber mat layer (B), whereby from 5 to 80% by weight of the binder fibers of the fiber binder non-woven fabrics (A) and (A′) are inserted into the fiber mat layer (B) in the whole range of the fiber mat layer (B).
  • the fiber mat layer (B) before the application of needling already contains from 5 to 50% by weight of the fiber binder, it is not always necessary to insert the needles until the needles completely penetrate the fiber mat layer (B).
  • the needling may be applied to the aforesaid laminate from any side thereof but when the needling is applied from the side of the fiber binder non-woven fabric layer (A), the binder fibers of the fiber binder non-woven fabric layer (A) are inserted in the fiber mat layer (B) in an amount of from 5 to 80% by weight by needling but remaining 95 to 20% by weight of the binder fibers remain on the surfaces of the laminate mat (C) as fiber binder non-woven fabric layers (A) and (A′) to give the clear layer structure of the fiber binder layer (A) and the fiber mat layer (B) as well as the binder fibers of the fiber binder layers (A) and (A′) exist in the fiber mat layer (B).
  • part of the fibers of the fiber mat layer (B) are inserted in the fiber binder non-woven fabric (A′) and entagled with the fibers of the non-woven fabric.
  • the binder fibers in the fiber binder non-woven fabric layer (A) are perpendicualrly inserted in the fiber mat layer (B) and also the fibers of the fiber mat layer (B) enter the fiber binder non-woven fabric layer (A′) at the opposite side to the layer (A) by needling, the fibers of the three layers are entangled in a body.
  • needling may be applied from the side of the fiber binder non-woven fabric layer (A′).
  • the needling is performed by piercing needles into the opposite side in the perpendicular direction at a ratio of from 80 to 300 needles per square inches and is performed until from 5 to 80% by weight of the binder fibers of the fiber binder non-woven fabric layers (A) and (A′) are entagled with the fibers of the fiber mat layer (B).
  • needling can be performed after laminating the surface decorating material (D) on the laminate mat (C).
  • the fibrous laminate of the 5th embodiment of this invention is produced by laminating the thermoplastic fiber binder non-woven fabric layers (A) and (A′) on the front and back surfaces, respectively, of the aforesaid fiber mat layer (B) mainly composed of synthetic fibers having a melting point of at least 40°C higher than the melting point of the thermoplastic fiber binder non-woven fabric layers (A) and (A′) or natural fibers followed by needling to form a laminate mat (C), coating an emulsion of a resin having a glass transition point of at least 50°C on the back surface of the laminate mat (C) to impregnate a part of the fiber mat layer (B) with the emulsion, and placing the surface decorating material (D) on the surface of the laminate mat (C) followed by heating and compressing, whereby the fiber binder was melted to heat-weld the surface decorating material (D) to the laminate mat layer (C).
  • the fibrous laminate is produced by laminating each of the thermoplastic fiber binder non-woven fabric layers (A) and (A′) on the front and back surfaces of the aforesaid fiber mat layer (B) followed by needling to form a laminate mat (C) and after placing the surface decorating material (D) on the laminate mat followed by heating to heat weld them, coating an emulsion of a resin having a glass transition point of at least 50°C on the back surface thereof followed by drying to form a resin-impregnated fiber mat layer (B2) at the lower layer portion of the aforesaid fiber mat layer (B).
  • the fiber mat layer (B) is semi-dried or completely dried and sandwiched in the fiber binder non-woven fabric layers (A) and (A′), and then the surface decorating material (D) is placed on the fiber binder layer (A) followed by heat molding.
  • a process of placing the surface decorating material (D) on the fiber binder non-woven fabric layer (A), applying light needling to the surface decorating material (D) to entangle the surface decorating material with the fiber binder non-woven fabric (A), and heat-welding the surface decorating material (D) and the laminate mat (C) by the fiber binder non-woven fabric (A) at heat molding may be employed.
  • the emulsion-impregnated layer at a part of the fiber mat layer (B), it is preferred to perform the compression after drying the impregnated emulsion to some extent.
  • fiber binder non-woven fabric (A) a web obtained by carding 250 g/m2 of propylene (melting point 164°C) fibers of 16 deniers and 50 mm in length was used.
  • the non-woven fabric (A) was superposed on the surface of a phenol felt (B), "Felt Top 10t” (trade name, made by Howa Seni K.K., 10 mm thick, soft type, and unit weight per square 550 g/m2) and needling was applied thereto using needles of 15-18-32-3RB at 150 needles/in2 to provide a laminate mat (C) of about 13 mm in thickness and 0.062 g/cm3 in apparent density.
  • B phenol felt
  • "Felt Top 10t” trade name, made by Howa Seni K.K., 10 mm thick, soft type, and unit weight per square 550 g/m2
  • a plain type needle punched carpet (D) composed of 300 g/m2 of a fiber mat formed by randomly laminating cards of colored polyethylene terephthalate (melting point 264°C) fibers of 6 deniers and 85 to 120 mm in fiber length was superposed on the upper surface of the fiber binder layer of the aforesaid laminate mat (C). Then, after melting the fiber binder made of polypropylene by heating the laminate at 190°C through a suction dryer, the laminate was immediately press-molded using a cold press mold at a pressure of 10 kg/cm2 to provide an integrated carpet for an internal decorating material having a thickness of 6 mm or 3 mm.
  • the carpets having 6 mm and 3 mm thick, respectively thus obtained each was cut into a piece of 150 mm x 50 mm and when the adhesive strength of the surface decorating material was measured using an Instron type testing machine, the peeling strength was 5.5 kg/5 cm width.
  • Example 2 By following the same procedure as Example 1 except that the fiber binder non-woven fabric (A) was not used (Comaprison Example 1) or a non-woven fabric made of polyethylene having melting point of 119°C ("Adomel ⁇ , trade name, made by Mitsui Petrochemical Industries, Ltd., unit weight per square 100 g/m2) was used as the non-woven fabric (Example 2), fibrous laminates were obtained.
  • the fiber binder non-woven fabric (A) was not used (Comaprison Example 1) or a non-woven fabric made of polyethylene having melting point of 119°C ("Adomel ⁇ , trade name, made by Mitsui Petrochemical Industries, Ltd., unit weight per square 100 g/m2) was used as the non-woven fabric (Example 2), fibrous laminates were obtained.
  • a web formed by carding 250 g/m2 of polypropylene (melting point 164°C) fibers of 16 deniers and 50 mm in length was used as the fiber binder non-woven fabric (A) and also a web formed similarly by carding 50 g/m2 of the aforesaid fibers was used as the fiber binder non-woven fabric (A′).
  • Fiber binder non-woven fabrics (A) and (A′) were respectively laminated on both surfaces of a phenol felt (B) (Feltop 10t, trade name, 10 mm thick, soft type, unit weight per square 550 g/m2, made by Howa Seni K.K.) and needling was applied thereto in the state at 150 needles/in2 to provide a laminate mat (C) having a thickness of about 13 mm and an apparent density of 0.065 g/cm3.
  • B phenol felt
  • C laminate mat having a thickness of about 13 mm and an apparent density of 0.065 g/cm3.
  • a plain type needle punched carpet composed of 300 g/m2 of a fiber mat formed by randomly laminating cards of colored polyethylene terephthalate (melting point 264°C) fibers of 16 deniers and from 85 to 120 mm in fiber length on the fiber binder non-woven fabric (A) of the aforesaid laminate mat (C) and heating the laminate to 190°C to melt the fiber binder made of polypropylene
  • the laminate was press-molded using a cooled press mold for 60 seconds at a pressure of 10 kg/cm2 to provide an integrated carpet for an internal decorating material having a thickness of 7 mm.
  • Feltop 6t (6 mm thick), a phenol felt made by Howa Seni K.K. was placed in the mold at molding the aforesaid laminate and the laminate was molded as above to provide a carpet.
  • a piece of 150 mm x 50 mm was cut from the carpet, and the peeling strength of the laminate mat (D) and the laminate mat (C) was measured using an Instron type testing machine.
  • the possibility of controlling the thickness of the laminate mat (C) in the case of peat-compressing the mat of 5 cm in thickness for 60 seconds at 180°C was determined.
  • the sample capable of controlling the thickness was shown by ⁇ .
  • the form retentability of the aforesaid product formed by molding using the mold at 180°C and 10 kg/cm2 was evaluated.
  • the product having the same form as the cavity of the mold was defined as .
  • a web formed by carding 250 g/m2 of polypropylene (melting point 164°C) fibers of 16 deniers and 50 mm in fiber length was used as the fiber binder non-woven fabric (A).
  • the non-woven fabric (A) was superposed on the surface of a phenol felt (B) ("Feltop 10t", trade name, 10 mm thick soft type, unit weight per square 550 g/m2, made by Howa Sensi K.K.) and needling was applied thereto in the state at 150 needles per square inches using needles of 15-18-32-3RB to provide a laminate mat having a thickness of about 13 mm and an apparent density of 0.062 g/cm3.
  • the laminate mat was coated and impregnated with 250 g/m2 (solid component) of an aqueous emulsion of an acrylic resin ("Acronal YJ-7082D", trade name, made by Mitsubishi Yuka Badische Co., Ltd., Tg 120°C, particles sizes 0.3 to 0.5 ⁇ m, solid component concentration 50%) at the side of the phenol felt (B) and compressed by means of a throttle rolls.
  • an acrylic resin "Acronal YJ-7082D", trade name, made by Mitsubishi Yuka Badische Co., Ltd., Tg 120°C, particles sizes 0.3 to 0.5 ⁇ m, solid component concentration 50%
  • a plain type needle punched carpet (D) composed of 300 g/m2 of a fiber mat formed by randomly laminating cards of colored polyethylene trephthalate (melting point 264°C) fibers of 6 deniers and from 85 to 120 mm in fiber lengths was placed on the surface of the fiber binder non-woven fabric (A) of the aforesaid laminate mat and after heating the laminate to 190°C through a suction dryer to melt the polypropylene binder fibers and the particles of the acrylic resin, the laminate was immediately press-molded using a cold press mold at a pressure of 10 kg/cm2 to provide a carpet for an internal decorating material having a thickness of 6 mm.
  • a test piece of 150 mm x 50 mm was cut from the carpet of 6 mm thick and when the adhesive strength of the surface decorating material was measured using an Instron type test machine, the peeling strength was 5.5 kg/5 cm width.
  • Example 10 By following the same procedure as Example 9 except that the fiber binder non-woven fabric (A) was not used (Comparison Example 5) or a polyethylene non-woven fabric having a melting point of 119°C ("Adomel", trade name, made by Mitsui Petrochemcial Industries, Ltd., unit weight per square 100 g/m2) was used as the non-woven fabric (Example 10), fibrous laminates were obtained.
  • Example 9 By following the same procedure as Example 9 except that an aqueous emulsion of an acrylic resin (Acronal YJ-7082) was spray-coated on the assembly to impregnate the lower layer of the fiber mat layer (C) at 30% of the thickness thereof, a fibrous laminate was obtained.
  • an acrylic resin Acronal YJ-7082
  • test piece 120 mm x 30 mm in area
  • the test piece was fixed at one end the bending resistance at the case of applying a deformation load to the test piece perpendicularly thereto at a portion of 100 mm apart from the fixed portion in the long length direction thereof at a rate of 50 cm/min was measured using an Instron type testing machine.
  • the fibrous laminate was layed and when the intial thickness thereof in the case of applying thereto a load of 50 g/cm2 is defined as to, the thickness thereof in the case of applying a load of 400 g/m2 for one minute was defined as t1, and the thickness thereof in the case of removing the load and elapsing one minute was defined as t2, the compressibility, the compression elasticity, and the deformability were calculated by the following equations;
  • a sample showing a low deformability and less changing ratio of thickness was evaluated to have good cushioning property.
  • PE Polyethylene (m.p. 123°C) **Kind of fiber mat PF: Phenol Felt FN: Fine Needle NF: Needle Felt ***Kind of surface decorating material PET: Polyethylene terephthalate
  • the fiber binder non-woven fabric layer (A) a web formed by carding 250 g/m2 of polypropylene (melting point 164°C) fibers of 16 deniers and 50 mm in fiber length and having a thickness of 3 mm was used. Also, as the fiber binder non-woven fabric layer (A′), a web formed by using 50 g/m2 of the same kind of fiber as above and having a thickness of 1 mm was used.
  • the fiber binder non-woven fabric layers (A) and (A′) were placed on the front surface and back surface of a phenol felt layer (B) ("Feltop 10t"- trade name, made by Howa Seni K.K, 10 mm thick, soft type, 550 g/m2), respectively and needling was applied thereto at a ratio of 150 needles per square inches in the state to provide a laminate mat (C) having a thickness of about 13 mm and an apparent density of 0.065 g/cm3.
  • the laminate mat (C) thus obtained was immersed in a bath containing an aqueous emulsion of a ternary copolymer of 85% by weight of styrene, 12% by weight of methyl acrylate, and 3% by weight of acrylic acid (mean particle size of the resin 0.1 ⁇ m, solid components 50% by weight, glass transition point of the resin about 120°C) and after withdrawing from the bath, the laminate mat (C) was squeezed so that the laminate mat (C) contained 30 parts by weight of the solid resin components of the emulsion (250 g/m2 of solid resin components ) per 100 parts by weight of the fibers in the laminate mat (C).
  • a plain type needle punched carpet composed of 300 g/m2 of fiber mat formed by randomly laminating cards of colored polyethylene terephthalate (melting point 264°C) fibers of 16 deniers and from 85 to 120 mm in fiber lengths as a surface decorating material (D) was placed on the fiber binder non-woven fabric layer (A) of the aforesaid laminate mat (C). Also, the laminate was heated to 190°C to dry the emulsion and melt the polypropylene fiber binder and thereafter press-molded using a cold press mold for 60 seconds at a pressure of 10 kg/cm2 to provide a carpet for an internal decorating material having a thickness of 6 mm.
  • the laminate mat was also molded by the same manner as above while placing "Feltop 6t" of 6 mm thick in the mold at molding.
  • the laminate mat was molded while placing "Feltop 6t" in the mold at molding and when the felt adhered to the thermoplastic fiber binder non-woven fabric layer (A′) at the lower layer was peeled off by breaking at the Feltop layer, the case that the fibers of the felt remained on the non-woven fabric layer (A′) was defined as and the case of remaining no felt fibers thereon was as X.
  • thermoplastic fiber binder non-woven fabric layers (A) and (A′) were not used, a fibrous laminate was obtained.
  • Example 14 By following the same procedure as Example 14 except that the laminate mat (C) was not immersed in the bath of an aqueous emulsion of a ternary copolymer of styrene, methyl methacrylate, and acrylic acid, a fibrous laminate was obtained.
  • thermoplastic fiber binder non-woven fabric layers (A) and (A′) By following the same procedure as Example 14 except that a polyethylene non-woven fabric having a melting point of 119°C ("Adomel", trade name, Mitsui Petrochemical Industries, Ltd., 100 g/m2) was used as the thermoplastic fiber binder non-woven fabric layers (A) and (A′), a fibrous laminate was obtained.
  • Example 14 By following the same procedure as Example 14 except that a polyester series rough felt ("Needle Felt”, trade name, made by Kansai Felt K.K., 8 mm thick, 650 g/m2) was used as the fiber mat (B), a fibrous laminate was obtained.
  • Needle Felt trade name, made by Kansai Felt K.K., 8 mm thick, 650 g/m2
  • Example 14 By following the same procedure as Example 14 except that a polyester fiber non-woven fabric was used in place of the polypropylene fiber binder non-woven fabric, a fibrous laminate was obtained.
  • the fiber binder non-woven fabric layer (A) a web formed by carding 250 g/m2 of polypropylene (melting point 164°C) fibers of 16 deniers and 50 mm in fiber length was used and also as the fiber binder non-woven fabric layer (A′), a web formed using 50 g/m2 of the same kind of fibers as above was used.
  • Fiber binder non-woven fabric layers (A) and (A′) were placed, respectively, on both surface of a phenol felt layer (B) ("Feltop 10t", trade name, made by Howa Seni K.K., 10 mm thick, soft type, unit weight per square 550 g/m2) and needling was applied thereto in the state at a ratio of 150 needles per square inches to provide a laminate mat (C) having a thickness of about 13 mm and an apparent density of 0.065 g/cm3.
  • a plain type needle punched carpet (D) composed of 300 g/m2 of fiber mat formed by randomly laminating cards of colored polyethylene terephthalate (melting point 264°C) fibers of 16 deniers and from 85 to 120 mm in fiber lengths as a surface decorating material and needling was applied to the laminate at a ratio of 150 needles per suqare inches to provide a laminate having a thickness of about 15 mm and an apparent density of 0.077 g/cm3.
  • an aqueous emulsion of a ternary copolymer of 85% by weight of styrene, 12% by weight of methyl acrylate, and 3% by weight of acrylic acid was sprayed onto the laminate at the side of the non-woven fabric layer (A′) in an amount of 250 g/m2 followed by compressing by rolls to impregnate the emulsion at a thickness of 6 mm.
  • the laminate was heated to 190°C to dry the emulsion thus impregnated and melt the polypropylene fiber binder and particles of resin of emulsion and then press-­molded using a cold press mold for 60 seconds at a pressure of 10 kg/m2 to provide a carpet for an internal decorating material having a thickness of 6 mm.
  • the web formed by carding 50 g/m2 of polypropylene (melting point 164°C) fibers of 16 deniers and 50 mm in fiber length as used in Example 19 was also used as the fiber binder non-woven fabric layers (A) and (A′). These fiber binder non-woven fabric layers (A) and (A′) were placed, respectively, on the front and back surfaces of the phenol felt (B) as used in Example 19 and needling was applied thereto in the state at a ratio of 150 needles per square inches to provide a laminate mat (C) having a thickness of about 13 mm and an apparent density of 0.065 g/cm3.
  • the surface decorating material (D) composed of 300 g/m2 a fiber mat formed by randomly laminating cards of colored polyethylene terephthalate (melting point 264°C) fibers of 16 deniers and from 85 to 120 mm in fiber lengths and the laminate was heated to 190°C and pressed for 80 seconds at a pressure of 10 kg/cm2 to melt the polypropylene fiber binder and weld the laminate mat (C) to the surface decorating material (D).
  • anaqueous emulsion of a ternary copolymer of 85% by weight of styrene, 12% by weight of methyl acrylate, and 3% by weight of acrylic acid was spray-coated on the back side of the laminate and then the laminate was heated to 120°C to dry the emulsion to provide a carpet for an internal decorating material having a thickness of 6 mm.
  • Example 19 By following the same procedure as Example 19 except that the whole laminate mat (C) was impregnated with the aqueous emulsion of the ternary copolymer of styrene, methyl acrylate, and acrylic acid, a fibrous laminate was obtained.
  • Example 19 By following the same procedure as Example 19 except that the aqueous emulsion of the ternary copolymer of styrene, methyl acryalte, and acrylic acid was not applied on the laminate mat (C), a fibrous laminate was obtained.
  • the fibrous laminate according to the 5th embodiment of this invention has the following advantages.
  • the fiber mat layer (B) is composed of the resin-impregnated fiber mat layer (B2) partially containing the solid resin components of the emulsion and the fiber mat layer (B1) containing no solid resin components, by heating the fiber binder non-woven fabric layers (A) and (A′) each disposed at both surfaces of the fiber mat layer (B), i.e., the surface of the fiber mat layer (B1) and the surface of the fiber mat layer (B2), the fiber mat layer (B) itself is easily heat-set, and also the fibrous laminate is imparted with the strength, hardness and form retentabivity as backing layer by the existent of the resin-impregnated fiber mat layer (B2) and imparted with a cushioning property by the existence of the fiber mat layer (B1) containing no resin component of the emulsion.
  • the fiber laminate has a layer mainly composed of the fiber binder non-woven fabric layer (A′) as the lower layer, it can adhere to other materials.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)
EP88117120A 1987-10-15 1988-10-14 Faseriger Schichtstoff und Verfahren zur Herstellung desselben Expired - Lifetime EP0312090B1 (de)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
JP62260557A JPH01104868A (ja) 1987-10-15 1987-10-15 繊維質積層体の製造方法
JP260557/87 1987-10-15
JP63035805A JPH01209131A (ja) 1988-02-18 1988-02-18 繊維質積層体及びその製造方法
JP35805/88 1988-02-18
JP63048330A JPH01221234A (ja) 1988-03-01 1988-03-01 繊維質積層体およびその製造方法
JP48330/88 1988-03-01

Publications (3)

Publication Number Publication Date
EP0312090A2 true EP0312090A2 (de) 1989-04-19
EP0312090A3 EP0312090A3 (en) 1990-06-13
EP0312090B1 EP0312090B1 (de) 1994-02-16

Family

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EP (1) EP0312090B1 (de)
DE (1) DE3887811T2 (de)

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0503048A4 (en) * 1990-10-03 1993-07-28 Milliken Research Corporation Rigid fiber composite
WO1994019524A1 (de) * 1993-02-20 1994-09-01 Corovin Gmbh Verbundvlies sowie verfahren zur herstellung eines verbundvlieses
WO1996002695A1 (en) * 1994-07-18 1996-02-01 Owens Corning Bicomponent and long fiber product definition for splittable pack
EP0684242B1 (de) * 1993-12-27 1999-05-06 Japan Tobacco Inc. Isoxazolidindionderivate und deren verwendung
FR2780420A1 (fr) * 1998-06-25 1999-12-31 Mci Technologies Procede de fabrication d'un revetement de fibres de verre
DE10252295A1 (de) * 2002-11-11 2004-06-09 MöllerTech GmbH Schutzvlies für Bauteile
CN104108337A (zh) * 2014-07-24 2014-10-22 江苏中联地毯有限公司 轻型汽车内饰地毯
US9410026B1 (en) 2009-05-22 2016-08-09 Columbia Insurance Company Rebond polyurethane foam comprising reclaimed carpet material and methods for the manufacture of same
US9724852B1 (en) 2009-05-22 2017-08-08 Columbia Insurance Company High density composites comprising reclaimed carpet material
WO2020169116A1 (zh) * 2019-02-21 2020-08-27 浙江华恒复合材料有限公司 一种干法制备真空隔热板芯材的方法
WO2025116235A1 (ko) * 2023-11-29 2025-06-05 한국재료연구원 섬유 복합 부직포 및 섬유 복합 부직포 제조 방법

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NZ544493A (en) 2005-12-22 2008-07-31 Nz Forest Research Inst Ltd Method for producing wood fibre composite products

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE6805255U (de) * 1968-11-04 1969-07-24 Schaeffler Teppichboden Gmbh Bodenbelag fuer kraftfahrzeuge
EP0016377A1 (de) * 1979-03-15 1980-10-01 Alkor GmbH Kunststoffe Verfahren zum Aufbringen einer Oberflächenveredelungsschicht auf eine Trägerplatte
EP0043390B1 (de) * 1980-06-27 1984-08-22 Teijin Limited Zusammengesetzte Schichtstruktur, Verfahren zu ihrer Herstellung und diese Struktur enthaltende Schichtstoffe
IT1138794B (it) * 1981-06-12 1986-09-17 Interplastica Engineering & Tr Lastra di copertura e di rivestimento,particolarmente per edilizia e relativo procedimento di fabbricazione
JPS59223350A (ja) * 1983-05-26 1984-12-15 株式会社クラレ 不織布およびその製法

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0503048A4 (en) * 1990-10-03 1993-07-28 Milliken Research Corporation Rigid fiber composite
US5993586A (en) * 1990-10-03 1999-11-30 Dunson; Samuel Eugene Rigid fiber composite
WO1994019524A1 (de) * 1993-02-20 1994-09-01 Corovin Gmbh Verbundvlies sowie verfahren zur herstellung eines verbundvlieses
EP0684242B1 (de) * 1993-12-27 1999-05-06 Japan Tobacco Inc. Isoxazolidindionderivate und deren verwendung
WO1996002695A1 (en) * 1994-07-18 1996-02-01 Owens Corning Bicomponent and long fiber product definition for splittable pack
FR2780420A1 (fr) * 1998-06-25 1999-12-31 Mci Technologies Procede de fabrication d'un revetement de fibres de verre
DE10252295A1 (de) * 2002-11-11 2004-06-09 MöllerTech GmbH Schutzvlies für Bauteile
US9410026B1 (en) 2009-05-22 2016-08-09 Columbia Insurance Company Rebond polyurethane foam comprising reclaimed carpet material and methods for the manufacture of same
US9724852B1 (en) 2009-05-22 2017-08-08 Columbia Insurance Company High density composites comprising reclaimed carpet material
CN104108337A (zh) * 2014-07-24 2014-10-22 江苏中联地毯有限公司 轻型汽车内饰地毯
WO2020169116A1 (zh) * 2019-02-21 2020-08-27 浙江华恒复合材料有限公司 一种干法制备真空隔热板芯材的方法
WO2025116235A1 (ko) * 2023-11-29 2025-06-05 한국재료연구원 섬유 복합 부직포 및 섬유 복합 부직포 제조 방법

Also Published As

Publication number Publication date
EP0312090A3 (en) 1990-06-13
DE3887811T2 (de) 1994-07-07
EP0312090B1 (de) 1994-02-16
DE3887811D1 (de) 1994-03-24

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