JP2000229369A - Nonwoven fabric laminate and interior finish material for automobile - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a lightweight, rigid nonwoven fabric laminate and an interior finish material for automobiles made by molding the laminate. SOLUTION: A nonwoven fabric laminate comprises a rigid layer of an entanglement type nonwoven fabric having at least 150 N/50 mm width in the average of longitudinal tensile strength and lateral tensile strength measured as a simple entanglement type nonwoven fabric whose shape is maintained only by the entanglement of fibers and a bulky layer of a nonwoven fabric of apparent density lower than that of the rigid layer. The laminate is molded in a desired shape to produce an interior finish material for an automobile.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a nonwoven fabric laminate and an automobile interior material. The nonwoven fabric laminate of the present invention,
Specifically, it can be molded into an automotive interior material such as a ceiling material, a rear package tray, a door trim, a floor insulator, a trunk trim, or a dash insulator, and the nonwoven fabric laminate is molded and used as an automotive interior material. Can be.

[0002]

2. Description of the Related Art Conventionally, as a material for automobile interior materials,
For example, a plastic board, a plastic foam, a resin felt made of a thermosetting resin, a cardboard, or a hard board or a paper board in which wood powder or waste paper is added to a thermosetting resin has been used. However, the plastic plate was heavy and hard, and had no sound absorption. Further, the plastic foam had no sound absorbing property, was easily broken, and could not be deep drawn. The resin felt is heavy, and the heating time required for molding the base material is long, and the skin material may be damaged in the single-stage molding. It was necessary to perform two-stage molding, and the molding workability was poor. The resin felt had low rigidity, and the obtained substrate had low mechanical strength. Further, corrugated cardboard, hardboard or paperboard cannot be deep-drawn, but must be formed by two-stage molding, and the hardboard is heavy.

[0003] Various techniques have been proposed for overcoming the above disadvantages. For example, Japanese Patent Application Laid-Open No. 7-3599 discloses a high-rigidity sound-absorbing material containing a high softening point fiber having a specific fineness and a low softening point fiber having a specific fineness at a specific compounding ratio. Japanese Patent Application Laid-Open No. H11-157, which discloses a high softening point fiber having a specific fineness and a low softening point fiber having a specific fineness at a specific compounding ratio, and discloses an automotive interior material using the specific low softening point fiber. Japanese Unexamined Patent Publication No. Hei 8-156161 discloses a fusible layer composed of a low-density nonwoven fabric, a rigid layer composed of a high-density nonwoven fabric disposed on both sides of the fusible layer, and a skin layer disposed as an uppermost layer. And a nonwoven fabric laminate having the following formula:

[0004] However, the techniques disclosed in the above publications have some effects in terms of, for example, sound absorption, rigidity, and light weight, but are still insufficient. In particular, in the case where an interior material for an automobile is composed of only polyester-based fibers as a recyclable material from the viewpoint of environmental protection in recent years, a light and rigid material has not yet existed. In other words, a certain amount of weight is required to increase the rigidity, and when the weight is reduced, the rigidity is lost.
None of the materials disclosed in the above publications can be actually used.

[0005]

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned problems of the prior art, and it is an object of the present invention to provide a lightweight and rigid nonwoven laminate and to prepare the nonwoven laminate by molding. It is an object to provide an interior material for an automobile.

[0006]

Therefore, according to the present invention, the average value of the tensile strength in the longitudinal direction and the tensile strength in the transverse direction measured in a state of a simple entangled nonwoven fabric whose shape is maintained only by entanglement of fibers is 150 N /. The present invention relates to a nonwoven fabric laminate including a rigid layer made of an entangled nonwoven fabric having a width of 50 mm or more and a bulky layer made of a nonwoven fabric having an apparent density lower than that of the rigid layer. The present invention also relates to an interior material for automobiles, which is obtained by molding the nonwoven fabric laminate.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION The nonwoven fabric laminate of the present invention has an average value of 150 N / m in the longitudinal tensile strength and the transverse tensile strength measured in the state of a simple entangled nonwoven fabric whose shape is maintained only by entanglement of fibers. It contains a rigid layer made of an entangled nonwoven fabric having a width of 50 mm or more. In the present specification, "simple entangled nonwoven fabric" is a nonwoven fabric obtained by entanglement treatment of a fiber web, and means a nonwoven fabric whose shape as a nonwoven fabric is maintained only by entanglement of constituent fibers. . In the present specification, the term “entangled nonwoven fabric” means a nonwoven fabric obtained by using the above simple entangled nonwoven fabric as a starting material and further performing a nonwoven fabric production process (for example, a fusion process or an adhesion process with a binder). The simple entangled nonwoven fabric itself is also included. In addition, the average value of the tensile strength in the longitudinal direction and the tensile strength in the lateral direction may be hereinafter simply referred to as “average tensile strength”. In addition, using the simple entangled nonwoven fabric as a starting material,
The average tensile strength of the entangled nonwoven fabric obtained through the fusion treatment and / or the bonding treatment with the binder is naturally higher than the average tensile strength of the simple entangled nonwoven fabric.

[0008] The fact that the average tensile strength of the simple entangled nonwoven fabric is 150 N / 50 mm width or more means that the degree of entanglement between the fibers is high, and that it has excellent rigidity. In addition, an entangled nonwoven fabric obtained by using such a simple entangled nonwoven fabric as a starting material and further performing an adhesion treatment with a binder or a binder has a higher average tensile strength. Therefore, by including the rigid layer made of the entangled nonwoven fabric having such high average tensile strength, the nonwoven fabric laminate of the present invention can have shape stability. In the nonwoven fabric laminate of the present invention, the rigidity of the entire nonwoven fabric laminate is ensured by including the rigid layer made of the entangled nonwoven fabric, and a bulky layer having a lower apparent density than the rigid layer is further provided. Since the entire nonwoven fabric laminate is reduced in weight by having the laminate, a lightweight and rigid nonwoven fabric laminate can be obtained. Moreover, since the interior material for automobiles of the present invention is molded from such a lightweight and rigid nonwoven fabric laminate, a lightweight and rigid molded article can be obtained.

The average tensile strength of the above simple entangled nonwoven fabric is preferably not less than 160 N / 50 mm width, more preferably not less than 170 N / 50 mm width, and still more preferably not less than 180 N / 50 mm width. It is more than 190N / 50mm width. Although the upper limit of the average tensile strength is not particularly limited, it is 500 N / 50 m
A width of about m is appropriate.

[0010] In the present specification, "tensile strength" means that both ends of an entangled nonwoven fabric (for example, a simple entangled nonwoven fabric) cut to a width of 50 mm are connected to a tensile strength tester (manufactured by Orientec, Inc.).
This is the force required to break when fixed to a chuck of Tensilon UCT-500 (distance between chucks = 100 mm) and pulled at a speed of 200 mm / min. The “longitudinal tensile strength” and the “horizontal tensile strength” are each an average value, which is a value obtained by measuring at least five points and averaging the measured values. The longitudinal direction of the simple entangled nonwoven fabric refers to the flow direction of the fiber web when producing the simple entangled nonwoven fabric, and the lateral direction refers to the direction orthogonal to the longitudinal direction.

The above average tensile strength of a simple entangled nonwoven fabric is a value of a nonwoven fabric whose shape is maintained only by entanglement, and thus serves as an index indicating the degree of pure entanglement.
That is, since the simple entangled nonwoven fabric is a nonwoven fabric that does not involve a bond other than entanglement, such as a fusion between fibers or a binder for bonding the fibers, it serves as an index indicating the degree of pure entanglement.

As described above, the average tensile strength is 150 N /
It is difficult to produce a simple entangled nonwoven fabric having a width of 50 mm or more by a needle punch method. For example, a fluid entanglement method that ejects a fluid flow having high energy (for example,
Water entanglement method). The high-energy fluid flow is represented by the following equation (1): E = R × P ² (1) [R is the nozzle diameter (unit = mm), and P is the internal pressure of the nozzle (unit = MPa) ) Is generally 6 or more (preferably 8).
Or more, more preferably 10 or more, and most preferably 12 or more). These high-energy fluid flows
By acting on the fiber web at least once,
A simple entangled nonwoven fabric as described above can be manufactured.
In addition, in view of the fact that the kinetic energy is proportional to the square of the mass and the velocity, the E value calculated by the above equation (1) is such that the larger the nozzle diameter, the larger the mass of the ejected and acting fluid becomes; In addition, the higher the internal pressure of the nozzle, the higher the velocity of the ejected fluid. Therefore, it is adopted as an index expressing the kinetic energy of the fluid flow.

The high-energy fluid flow has a diameter of, for example, 0.05 to 0.3 mm and a pitch of 0.2 to 3 mm.
Use a nozzle plate with nozzles arranged in one or more rows,
It can be generated by ejecting a fluid under conditions of an internal pressure of about 5 MPa to 30 MPa. In addition, when the high-energy fluid stream is jetted not only on one side of the fiber web but on both sides, the degree of entanglement can be increased, and therefore the average tensile strength can be increased. , Can increase the rigidity. By ejecting the fluid flow not once but twice or more, the degree of entanglement can be increased, the average tensile strength can be increased, and the rigidity can be increased. Fluid flow 2
In the case of ejecting the fluid more than once, it is preferable to use the fluid so that the total value of the E values of the individual fluid flows is preferably 12 or more (more preferably 16 or more, most preferably 20 or more). Further, as a support for supporting the fiber web when applying the fluid flow, it is preferable to use a support having an opening smaller than 0.295 mm so that the entire fiber web can be uniformly entangled. preferable.

When a single entangled nonwoven fabric (for example, a simple entangled nonwoven fabric) is used and the rigidity balance between the longitudinal direction and the lateral direction is poor, a plurality of fibers having different orientation directions are used. By applying the high-energy fluid flow as described above after laminating the fiber webs, it is possible to adjust the rigidity balance between the longitudinal direction and the lateral direction in the rigid layer. For example, on a first fiber web in which fibers are oriented in one direction, a second fiber web in which fibers are oriented in one direction has an angle of 10 ° or more with respect to the fiber orientation direction of the first fiber web. After stacking as described above, the balance of rigidity between the vertical direction and the horizontal direction can be adjusted by applying the high-energy fluid flow as described above.

The rigid layer used in the nonwoven fabric laminate of the present invention contains heat fusible fibers as constituent fibers of the entangled nonwoven fabric constituting the rigid layer, and the heat fusible fibers are fused. Is preferred. Hereinafter, heat fusible fibers are included as constituent fibers of the entangled nonwoven fabric, and the entangled nonwoven fabric to which the heat fusible fibers are fused is referred to as a “fused entangled nonwoven fabric”.
Called. The fusion of such heat-fusible fibers can further increase the rigidity of the rigid layer. In particular, the simple entangled nonwoven fabric used in the present invention is highly entangled and can provide many fusion points of the heat-fusible fibers, so that the rigidity of the fusion entangled nonwoven fabric is extremely high.

The heat-fusible fiber can be of the all-fused type or of the partially-fused type. However, the fiber shape can be maintained by the non-fused resin, and the rigidity is hardly reduced. It is preferable to use a partially fusible heat fusible fiber. This preferred partially fusible heat fusible fiber comprises a fusible component and a non-fusible component that does not fuse at the melting point of the fusible component, the fusible component being more than the non-fusible component. It is preferably made of a resin having a low melting point of 10 ° C. or more (preferably 20 ° C. or more). Further, the fusion component of the heat-fusible fiber is preferably made of a resin having a melting point lower by 10 ° C. or more (preferably 20 ° C. or more) than the melting point of other fibers constituting the fusion-entangled nonwoven fabric (rigid layer). preferable. The preferable cross-sectional shape of the partially fusible heat-fusible fiber may be, for example, a core-sheath shape, an eccentric shape, a sea-island shape, a bonded shape, an orange shape, or a multi-bimetal shape. Among these, it is preferable that the fused component occupy the entire fiber surface and has a core-sheath shape, an eccentric shape, or a sea-island shape having excellent fusion property.

As the resin constituting the heat-fusible fiber, for example, polyamide resin, polyester resin,
Polyolefin resin (for example, polyethylene resin,
Polypropylene-based resin or polymethylpentene-based resin) or the like can be used alone or in combination. Among these, heat-fusible fibers consisting essentially of only a polyester resin can be suitably used from the viewpoint of recyclability. Note that if the crystallinity of the fusion component in the heat-fusible fiber is low, the fusion force tends to decrease at high temperatures, so that the crystallinity is preferably high. That is, the heat of fusion is preferably 8 J / g or more, and more preferably 12 J / g or more.

The melting point in the present invention refers to a temperature at which a maximum value of a melting endothermic curve obtained by raising the temperature from room temperature using a differential scanning calorimeter at a rate of temperature rise of 10 ° C./minute is given. When there are two or more maximum values, the maximum value at the highest temperature is defined as the melting point. Further, the heat of fusion in the present invention refers to a value obtained from a melting endothermic curve obtained by raising the temperature from room temperature using a differential scanning calorimeter at a heating rate of 10 ° C./min.

The fineness of the heat-fusible fiber is not particularly limited, but is preferably thin so that the number of fusion points between the fibers is large, and specifically about 1 to 30 denier. Is preferred, and more preferably about 1 to 20 denier. This heat fusible fiber is in the fusion entangled nonwoven fabric,
It is preferable that about 10 to 90 mass% is contained,
More preferably, the content is about 20 to 70 mass%.

The fusion component of such a heat-fusible fiber is fused by a fusion process. This fusion process may be performed after forming the simple entangled nonwoven fabric and before forming the nonwoven fabric laminate. Alternatively, it can be carried out after laminating a simple entangled nonwoven fabric (rigid layer) and a bulky nonwoven fabric (bulky layer) described later to form a nonwoven fabric laminate.

The fusion treatment of the fusion components can be performed under no pressure, by applying pressure simultaneously with heating, or by applying pressure after heating. In the case where the fusion treatment is performed after the formation of the simple entangled nonwoven fabric and before the formation of the nonwoven fabric laminate, it is preferable to apply the pressure simultaneously with the heating or to apply the pressure after the heating so as to increase the rigidity. On the other hand, when performing the fusion treatment after forming the nonwoven fabric laminate using the simple entangled nonwoven fabric, the thickness is adjusted under no pressure or simultaneously with or after heating so as not to reduce the bulkiness of the bulky layer. It is preferable to apply a pressure as low as possible.

In the case where heating and pressurization are performed simultaneously in the fusion treatment of the fusion component, it is preferable to apply heat at a temperature within the range from the softening point to the melting point of the fusion component. When pressurizing or applying heat under no pressure, it is preferable to apply heat at a temperature from the softening point of the fusion component to a temperature about 20 ° C. higher than the melting point. Also,
When pressurizing, in any case, the linear pressure is 5 to 30 N /
cm.

The entangled nonwoven fabric (for example,
The simple entangled nonwoven fabric or the fusion entangled nonwoven fabric) may contain irregular cross-section fibers and / or hollow fibers. The rigidity can be further increased by using the former modified cross-section fiber, and the weight can be further reduced by using the latter hollow fiber. This irregular cross-section fiber refers to a fiber whose cross-sectional shape is not circular, for example, elliptical, elliptical,
There are fibers having a cross-sectional shape such as a T shape, a Y shape, a + shape, and a polygonal shape. The hollow fiber refers to a fiber having a void portion in which no resin component is present inside the fiber, and the void portion in which the resin component is not present is preferably continuous in the length direction of the fiber. When observing the cross section of the hollow fiber, it is not necessary that the void portion where no resin component exists is present in the center of the fiber. Further, the hollow fiber may have a form having a plurality of mutually independent voids. Furthermore, for example, when observing the cross section of a hollow fiber having voids continuous in the length direction, the shape of the voids where no resin component is present does not need to be circular, but may be elliptical or elliptical. It can be non-circular, such as a shape, a T shape, a Y shape, a + shape, or a polygonal shape.

Examples of the resin constituting the modified cross-section fiber or the hollow fiber include a polyamide resin, a polyester resin, and a polyolefin resin (eg, a polyethylene resin, a polypropylene resin, and a polymethylpentene resin). (A cross-sectional shape is, for example, core-sheath shape, eccentric shape, sea-island shape, bonded shape, orange shape, multiple bimetal shape Stuff) can. Among these, it is preferable that the modified cross-section fiber or the hollow fiber is substantially composed only of the polyester resin from the viewpoint of recyclability. The modified cross-section fiber or the hollow fiber may be capable of exhibiting crimping or generating a fine fiber by being divided. The fineness of the modified cross-section fiber or hollow fiber is not particularly limited, but is preferably about 1 to 90 denier, and more preferably about 1 to 60 denier.

An entangled nonwoven fabric (for example,
A simple entangled nonwoven fabric or a fusion entangled nonwoven fabric) is a structural fiber having a substantially circular cross-sectional shape and having no voids in which no resin component is present in the fiber cross section, for example, inorganic fibers such as glass fiber and carbon fiber. Natural fibers such as fibers, silk, wool, cotton, hemp, regenerated fibers such as rayon fibers, semi-synthetic fibers such as acetate fibers, polyamide fibers, polyvinyl alcohol fibers, acrylic fibers, polyester fibers, polyvinyl chloride fibers, Polyvinylidene chloride fiber, polyurethane fiber, polyethylene fiber, polypropylene fiber, polymethylpentene fiber, aromatic polyamide fiber, or a composite fiber having crimping or splitting properties composed of two or more resin components, etc. Synthetic fibers can be used. Among these structural fibers, polyester fibers are preferred because of their excellent recyclability. The fineness of these structural fibers is not particularly limited.
It is preferably about 0 denier, more preferably about 1 to 60 denier.

The areal density of the rigid layer made of the above-mentioned entangled nonwoven fabric (for example, simple entangled nonwoven fabric or fusion entangled nonwoven fabric) is as follows:
The weight is preferably about 40 to 400 g / m ² so that rigidity can be imparted and the weight is reduced.
More preferably, it is about 0 to 300 g / m ² . In addition, the thickness of the rigid layer can be about 0.3 to 3 mm, and preferably about 0.5 to 2 mm. It is more preferably about 0.6 to 2 mm, and still more preferably about 0.1 to 2 mm.
It is about 8 to 2 mm. In particular, by setting the thickness to 0.8 mm or more, a nonwoven fabric laminate having excellent rigidity can be prepared. In addition, if the fiber which comprises an entangled nonwoven fabric (for example, a simple entangled nonwoven fabric or a fusion entangled nonwoven fabric) (rigid layer) is made of short fibers of about 20 to 160 mm, the degree of freedom of the fibers is high and the moldability is excellent. Therefore, it is preferable.
The apparent density of the rigid layer is preferably about 0.08 g / cm ³ or more, and more preferably about 0.09 g / cm ³ or more. Further, when the surface density of the rigid layer is low and the apparent density of the rigid layer is 0.15 g / cm ³ or more, the thickness of the rigid layer tends to be too thin and the rigidity tends to decrease. The apparent density is 0.15 g / cm ³
And it is preferably less than, more preferably at 0.14 g / cm ³ or less, more preferably 0.13 g / cm ³ or less.

The nonwoven fabric laminate of the present invention comprises the above-described rigid layer and a bulky layer made of a nonwoven fabric having a lower apparent density than the rigid layer (hereinafter referred to as “bulky nonwoven fabric”). The bulky layer achieves weight reduction. The apparent density of the aforementioned rigid layer (entangled nonwoven fabric) is 0.08 g / c.
because it is m ³ approximately above apparent density of the bulky layer (loft nonwoven) is less than 0.08 g / cm ^3, more preferably about 0.02~0.06g / cm ^3. In addition,
"Apparent density" refers to a value obtained by dividing the surface density of a nonwoven fabric (for example, an entangled nonwoven fabric or a bulky nonwoven fabric) by the thickness of each nonwoven fabric, and a nonwoven fabric (for example, an entangled nonwoven fabric or a bulky nonwoven fabric) The thickness in ()) means a value at a load of 20 g per 1 cm ² . The apparent density difference between the rigid layer and the bulky layer is 0.
It is preferably 14 g / cm ³ or less, and 0.12 g / cm ³ or less.
more preferably cm ³ or less, 0.10 g / cm ³
It is more preferred that: When the difference in apparent density is small, the difference in shrinkage between the rigid layer and the bulky layer during molding is small, and peeling between these layers is unlikely to occur, so that a nonwoven fabric laminate having excellent rigidity and excellent moldability is prepared. can do.

Such a bulky nonwoven fabric can be prepared by, for example, a needle punch method, a fiber bond method for fusing heat-fusible fibers, a binder bond method for bonding with a binder such as emulsion or latex, or an air lay method or a card method. It can be produced by a method of simply opening fibers.

As the fibers constituting the bulky layer, the same heat-fusible fibers as those of the rigid layer are contained, and it is preferable that the heat-fusible fibers are fused because the form stability is improved. It is an aspect. As this heat-fusible fiber, a resin having a melting point of 10 ° C. or more (preferably 20 ° C. or more) lower than the melting point of other fibers constituting the bulky layer can be used. The heat-fusible fiber contains a resin component having a melting point higher than that of the fusion component by 10 ° C. or more (preferably 20 ° C. or more), and has a cross-sectional shape of a core-sheath, eccentric shape, sea-island shape,
A partially fused type such as a laminated shape, an orange shape, or a multi-bimetallic shape (preferably a core-sheath shape, an eccentric shape, or a sea-island shape) can be used.

As the resin constituting the heat-fusible fiber, for example, a polyamide resin, a polyester resin,
Polyolefin resin (for example, polyethylene resin,
Polypropylene-based resin, polymethylpentene-based resin) and the like, which can be composed of one type or a combination of two or more types.
Among these, heat-fusible fibers consisting essentially of only a polyester resin can be suitably used from the viewpoint of recyclability. Further, the heat of fusion of the fusion component in the heat-fusible fiber is preferably 8 J / g or more.
It is more preferably at least J / g. Further, the fineness of the heat-fusible fiber is preferably about 1 to 30 denier, and more preferably about 1 to 20 denier. The heat-fusible fiber is preferably contained in the bulky nonwoven fabric in an amount of 5 to 80 mass%, more preferably 10 to 60 mass%, so that the bulkiness can be maintained.

When the fusible component of the heat-fusible fiber constituting the bulky nonwoven fabric (bulky layer) of the present invention is fused, no bulkiness or bulkiness is maintained so that the bulkiness can be maintained. It is preferable to carry out at a pressure as low as possible. In this case, the melting point is 20 ° C. lower than the melting point based on the softening point.
It is preferable to fuse by applying heat at a temperature up to a temperature as high as possible. The fusion of the heat-fusible fibers can be performed when forming the bulky nonwoven fabric, after forming the bulky nonwoven fabric, and before forming the nonwoven fabric laminate, or after forming the nonwoven fabric laminate.

As the other fibers constituting the bulky nonwoven fabric, the same modified cross-section fibers and / or hollow fibers as those of the rigid layer can be used. Since these fibers are contained in the bulky nonwoven fabric, the rigidity can be improved, and together with the rigidity of the rigid layer, a nonwoven fabric laminate having higher rigidity can be obtained. It is preferable that the irregular cross-section fiber and / or the hollow fiber occupy 10 mass% or more of the bulky nonwoven fabric.

Examples of the resin constituting the modified cross-section fiber and / or the hollow fiber include a polyamide resin, a polyester resin, and a polyolefin resin (eg, a polyethylene resin, a polypropylene resin, and a polymethylpentene resin). And a combination of two or more of these resins (for example, the cross-sectional shape is, for example, a core-sheath shape, an eccentric shape, a sea-island shape, a bonded shape, an orange shape, or a multiple shape. Bimetal-like ones). The modified cross-section fiber and / or the hollow fiber may be capable of exhibiting crimping or being capable of being split to generate a thin fiber. Among these, modified cross-section fibers and / or hollow fibers substantially consisting only of a polyester resin can be suitably used from the viewpoint of recyclability. The fineness of the irregular cross-section fiber or the hollow fiber is preferably about 1 to 90 denier, and more preferably about 1 to 60 denier.

It is preferable that the fibers constituting the bulky nonwoven fabric (bulky layer) include fibers having a three-dimensional crimp, because the fibers can maintain the bulkiness. A fiber having such a three-dimensional crimp can be obtained by applying heat to a bonded or eccentric conjugate fiber composed of two or more resin components having different heat shrinkages. If the three-dimensionally crimped fiber is a modified cross-section fiber or a hollow fiber, rigidity can be imparted simultaneously with bulkiness. As the fiber having three-dimensional crimp, for example, polyamide resin,
Polyester resin, polyolefin resin (for example,
It is possible to use a combination of two or more resins having different heat shrinkages, such as a polyethylene resin, a polypropylene resin, and a polymethylpentene resin. Among them, fibers having a three-dimensional crimp consisting essentially of only a polyester resin can be suitably used from the viewpoint of recyclability. The fineness of the fiber having the three-dimensional crimp is preferably about 1 to 90 denier, and more preferably about 1 to 60 denier.

The bulky nonwoven fabric (bulky layer) of the present invention has a circular cross-sectional shape in addition to the above heat-fusible fibers, irregular cross-section fibers, hollow fibers, and fibers having three-dimensional crimps.
A structural fiber similar to that of the rigid layer, which has no portion where no resin component is present, can be used. Among the fibers having a circular cross section and no portion containing no resin component, polyester fibers are preferable because of their excellent recyclability. The fineness of this fiber is not particularly limited, but is preferably about 1 to 90 denier,
More preferably, it is about 0 denier.

The bulk density of the bulky layer made of the above-mentioned bulky nonwoven fabric is preferably about 50 to 1000 g / m ² , and is preferably 100 to 900 g / m ² so as to obtain excellent form stability and light weight. It is more preferably about m ² . Further, the thickness is preferably about 2 to 50 mm, more preferably about 5 to 30 mm. In addition,
The fibers constituting the bulky nonwoven fabric (bulky layer) are 20 to 160 m
A short fiber having a length of about m is preferable because the degree of freedom of the fiber is high and the moldability is excellent.

Since the nonwoven fabric laminate of the present invention includes the above-described rigid layer made of the entangled nonwoven fabric and the bulky layer made of the bulky nonwoven fabric, it is rigid and lightweight. The number and the state of lamination of the rigid layer and the bulky layer are not particularly limited. For example, a state in which one rigid layer and one bulky layer are laminated, a state in which rigid layers are laminated on both sides of the bulky layer, a rigidity There are a state where bulky layers are laminated on both sides of the layer, a state where two or more bulky layers and two or more rigid layers are alternately laminated, and the like. Among these, a state in which rigid layers are laminated on both sides of the bulky layer is preferable because it is lightweight and excellent in rigidity. When a skin layer as described below is laminated, a rigid layer is laminated on one side of the bulky layer,
It is preferable that a skin layer is laminated on the opposite side for the same reason.

By laminating such that the orientation direction of the fibers constituting the entangled nonwoven fabric (rigid layer) is different from the orientation direction of the fibers constituting the bulky nonwoven fabric (bulky layer),
The rigidity balance between the longitudinal direction and the lateral direction of the nonwoven fabric laminate can be adjusted. For example, if the fibers constituting the bulky nonwoven fabric (bulky layer) are oriented in the direction perpendicular to the orientation direction of the fibers constituting the entangled nonwoven fabric (rigid layer), the longitudinal direction and the lateral direction are reduced. A nonwoven fabric laminate having an excellent balance of rigidity between them can be obtained. The same applies to a case where a skin layer as described later is further laminated in addition to the rigid layer and the bulky layer, or a case where a skin layer is laminated instead of one of the rigid layers.

Further, when both the rigid layer (entangled nonwoven fabric) and the bulky layer (bulky nonwoven fabric) constituting the nonwoven fabric laminate of the present invention are made of only polyester fibers, the recyclability is excellent. Therefore, it is particularly suitable.

In the present invention, the rigid layer (1) as described above is used.
Layer or more) and a bulky layer (one or more layers), and may include a skin layer (one layer). This skin layer is arranged at a position constituting the surface of the nonwoven fabric laminate. This skin layer can be composed of, for example, natural leather, artificial leather, synthetic leather, woven fabric, knitted fabric, non-woven fabric (for example, spun-bonded non-woven fabric), and film. Among these, a nonwoven fabric suitable for deep drawing is preferred.

The non-woven fabric (hereinafter referred to as "skin non-woven fabric") constituting the skin layer is preferably a spun bond method, a needle punch method, a fluid flow entanglement method, or a heat-fusible fiber. It can be formed from a nonwoven fabric manufactured by a fiber bond method or a binder bond method of bonding with a binder such as emulsion or latex. Among these, it is preferable to manufacture the needle by the needle punch method which is excellent in design. The entanglement by the suitable needle punch method can be performed, for example, at a needle density of 300 to 500 needles / cm ² .
When the rigidity of the nonwoven fabric laminate is more required, it is preferable to use a skin nonwoven fabric manufactured by a fluid flow entanglement method.

The fibers constituting the skin non-woven fabric (skin layer) include the same heat-fusible fibers as the rigid layer.
It is preferable that the heat-fusible fibers are fused because the form stability of the nonwoven fabric laminate can be improved. That is, a heat-fusible fiber having a resin having a melting point lower by at least 10 ° C. (preferably at least 20 ° C.) than the melting point of other fibers constituting the skin layer can be used. This heat fusible fiber contains a resin component having a melting point higher than that of the fusible component by 10 ° C. or more (preferably 20 ° C. or more), and has a cross-sectional shape of core-sheath, eccentric, sea-island, bonded, or orange. It is preferably a partially fused type which is a multi-bimetal shape (preferably a core-sheath shape, an eccentric shape, and a sea-island shape).

As the resin constituting the heat-fusible fiber, for example, a polyamide resin, a polyester resin,
Polyolefin resin (for example, polyethylene resin,
Polypropylene resin, polymethylpentene resin) or the like can be used alone or in combination of two or more. Among these, heat-fusible fibers composed only of a polyester-based resin can be suitably used from the viewpoint of recyclability. The heat of fusion of the fusion component in the heat-fusible fiber is preferably 8 J / g or more.
More preferably, it is 2 J / g or more. Further, the fineness of the heat-fusible fiber is preferably about 1 to 30 denier, and more preferably about 1 to 20 denier.
The heat-fusible fiber is preferably 50% by mass or less, more preferably 30% by mass or less, in the skin nonwoven fabric so as not to impair the feel of the skin nonwoven fabric. In addition, in order to be excellent in form stability, 5 mass
% Is preferable. As described above, the heat-fusible fibers are contained in the skin nonwoven fabric (skin layer), and the rigidity can be improved by the fusion of the heat-fusible fibers. In some cases (however, one rigid layer is included).

When the heat fusible fiber is contained in the skin nonwoven fabric (skin layer) of the present invention, the fusion of the fusion component does not impair the feeling such as the touch feeling or the degree that the texture can be maintained without pressure. It is preferably performed at a low pressure. In this case, it is preferable to perform the fusion by applying heat at a temperature from the softening point of the fusion component to a temperature about 20 ° C. higher than the melting point.

As the fibers other than the heat-fusible fibers constituting the skin nonwoven fabric (skin layer), the same fibers as those constituting the rigid nonwoven fabric described above can be used. That is, use of structural fibers (including fibers having crimping or splitting properties) having irregular cross-section fibers, hollow fibers, and / or portions having a circular cross-section and no resin component present in the fiber cross-section. Can be. Similarly to the rigid layer and the bulky layer, it is preferable that the fibers constituting the skin layer (skin nonwoven fabric) also be made of polyester fibers because of excellent recyclability.
The fibers constituting the skin nonwoven fabric preferably have a fineness of about 1 to 20 denier, and more preferably about 2 to 10 denier, so as not to impair the feeling such as touch.

Since the skin non-woven fabric (skin layer) is located at a place where the human eye can see it, the fibers constituting the skin non-woven fabric (for example, heat-fusible fibers, irregular shaped fibers, etc.) can be enhanced in design. Cross-section fibers, hollow fibers, fibers having a circular cross-section and having no resin component in the cross-section of the fiber (including fibers having crimping or splitting properties), etc., are dyed or dyed. It is preferable that the fibers have a color other than white, such as white.

The surface density of such a skin nonwoven fabric (skin layer) is preferably about 30 to 300 g / m ² ,
More preferably, it is about 200 g / m ² . Also,
The thickness is preferably about 0.5 to 10 mm,
More preferably, it is about 5 mm. In addition, it is preferable that the fibers constituting the skin nonwoven fabric (skin layer) be short fibers of about 20 to 160 mm because the flexibility of the fibers is high and the moldability is excellent.

Lamination of the above-mentioned entangled nonwoven fabric (rigid layer) and bulky nonwoven fabric (bulky layer) (in some cases, skin layer)
For example, a needle punch method, a fluid flow entanglement method, a fiber bond method for fusing heat-fusible fibers constituting a rigid layer and / or a bulky layer (and a skin layer as the case may be), a binder such as emulsion or latex, The bonding can be performed by a binder bonding method or a method of bonding with a heat adhesive sheet interposed therebetween. In addition,
As a heat-adhesive sheet, a polyolefin resin is applied to both sides of a film (eg, a nylon film) 3
A layered sheet can be exemplified.

In the present invention, in order to further improve the rigidity of the nonwoven fabric laminate, an emulsion or latex binder can be attached to the rigid layer and / or the bulky layer. Examples of the binder include styrene / acrylate / acrylonitrile copolymer, styrene / acrylonitrile / butadiene,
Styrene-butadiene rubber (SBR type) or the like can be used. Further, the amount of the binder is preferably from 20 to 400 g / m ² about relative nonwoven laminate, more preferably about 50 to 200 g / m ^2.

Examples of the method of attaching such a binder include a method of spraying and drying the above binder, a method of drying after coating,
Alternatively, there is a method of drying after dipping in a binder bath. The adhesion of such a binder may be performed after forming the simple entangled nonwoven fabric or the fusion entangled nonwoven fabric and before forming the nonwoven fabric laminate, after forming the bulky nonwoven fabric and before forming the nonwoven fabric laminate, or after forming the nonwoven fabric laminate. it can.

The thickness of the laminated nonwoven fabric of the present invention is as follows.
For example, a bulky material having a size of about 3 to 40 mm, preferably about 5 to 30 mm can be used. Therefore, not only the function of the rigid layer (the bulky layer and / or the skin layer depending on the case) but also the rigidity is improved due to the thickness.
The average tensile strength of the laminated nonwoven fabric of the present invention is higher than the average tensile strength of the rigid layer, and is higher than 150 N / 50 mm width. The surface density of the layered nonwoven fabric of the present invention preferably is preferably in the range of about 400~1500g / m ^2, more preferably about 500~1200g / m ^2. The rigidity of the laminated nonwoven fabric of the present invention can be measured, for example, by the amount of sag (unit = mm) in a horizontal standing test. The specific operation of the horizontal standing test is described in the “rigidity evaluation test” in the examples described later. The laminated nonwoven fabric of the present invention has a sagging amount of 1 in a light weight (for example, 940 g / m ² or less) in the horizontal standing test.
Excellent rigidity of 7 mm or less. The rigidity of the laminated nonwoven fabric according to the present invention can be measured, for example, by a maximum point load. The specific operation of the maximum point load measurement is described in “Examination test of physical property values” in Examples described later. The laminated nonwoven fabric of the present invention exhibits excellent rigidity with a maximum point load of 5 N / 25 mm width or more.

The automotive interior material of the present invention is obtained by molding the above nonwoven fabric laminate into a desired shape (for example, a shape of a ceiling material, a rear package tray, a door trim, a floor insulator, a trunk trim, a dash insulator, etc.). It is lightweight and rigid. In addition,
As a molding method, a method similar to the conventional method can be adopted, for example, a method of heating and pressing with a pair of molds,
There is a method in which the nonwoven fabric laminate is heated (for example, a hot air circulation heat treatment machine, a far-infrared heating device, or the like), and then subjected to pressure molding using a pair of molds at room temperature or lower. Since the nonwoven fabric laminate of the present invention contains a bulky layer, it is excellent in moldability that is easily formed by deep drawing. Further, when the fibers constituting the rigid layer (entangled nonwoven fabric or fusion entangled nonwoven fabric) and the bulky layer (bulky nonwoven fabric) are made of short fibers, the degree of freedom of the fibers is high, and thus the moldability is more excellent. It is.

[0053]

EXAMPLES The present invention will be described below in more detail with reference to examples, but these examples do not limit the scope of the present invention.

Example 1 (1) Preparation of an entangled nonwoven fabric sheet A copolymer made of a copolyester (melting point = 245 ° C. or higher) and polyethylene terephthalate. A hollow polyester fiber (a fineness of 13), in which a void portion where no resin is present continuously in the center in the direction of the length (the shape of the void portion where no resin is present = circular) and a three-dimensional crimp can be expressed.
Denier, fiber length = 51mm, cross section = circular) 50m
ass%, and a copolyester fusion sheath component (melting point = 1)
Core-sheath type polyester-based heat-fusible fiber (fineness = 2 denier, fiber length = 51 mm) composed of a non-fused core component (melting point = 260 ° C.) and polyethylene terephthalate non-fused core component (60 ° C., heat of fusion = 15 J / g), 50 mass% And then opened by a carding machine to form a unidirectional fiber web.

Next, the unidirectional fiber web was placed on a plain woven net having an opening of 0.175 mm, and the diameter was 0.13 mm.
Nozzles are arranged in a row at a pitch of 0.8 mm, and a jet of water is ejected from a nozzle plate having an internal pressure of 10 MPa to the unidirectional fiber web (E value = 13). After the reversal, a water stream was jetted from the same nozzle plate at an internal pressure of 7 MPa (E value = 6.
4) Then, after reversing the unidirectional fiber web,
A water stream is jetted from the same nozzle plate at an internal pressure of 7 MPa (E value = 6.4) to entangle the fibers, and the surface density is 120 g /
A simple entangled nonwoven fabric sheet having an m ² , a thickness of 1 mm, and an apparent density of 0.12 g / cm ³ was produced. This simple entangled nonwoven fabric sheet had an average tensile strength of 180 N / 50 mm width.

(2) Preparation of bulky nonwoven fabric sheet On the other hand, 70 mass% of the hollow polyester fiber used in the preparation of the above simple entangled nonwoven fabric and the core-sheath type polyester hot melt used in the preparation of the above simple entangled nonwoven fabric Adhesive fiber 30
mass% and then opened with a card machine,
Surface density 700 g / m ² , thickness 20 mm, apparent density 0.0
A 35 g / cm ³ unidirectional bulky nonwoven sheet was produced.

(3) Preparation of Nonwoven Fabric Laminate Next, the above simple entangled nonwoven fabric sheet is laminated on both sides of the unidirectional bulky nonwoven fabric sheet so that their fiber orientations match each other. By performing needle punching at / cm ² , the unidirectional bulky nonwoven sheet and the simple entangled nonwoven sheet were laminated and integrated. Next, the sheath component of the core-sheath type polyester-based heat fusible fiber is fused with a hot air circulating heat treatment machine set to a temperature of 170 ° C., and at the same time, the hollow polyester-based fiber is crimped. Thus, a nonwoven fabric laminate (area density = 940 g / m ² , thickness = 20 mm) of the present invention was produced.

[0057]

Example 2 A unidirectional fiber web was formed in exactly the same manner as in the method for preparing an entangled nonwoven fabric sheet of Example 1 (1). Next, this unidirectional fiber web was placed on a plain woven net having an opening of 0.175 mm, and the diameter was 0.13 m.
m, the nozzles are arranged in a line at a pitch of 0.8 mm,
A water flow is jetted from a nozzle plate having an internal pressure of 15 MPa to the unidirectional fiber web (E value = 29.3), and after the unidirectional fiber web is inverted, a water flow is generated from the same nozzle plate at an internal pressure of 10 MPa. (E value = 1
3) After further reversing the unidirectional fiber web,
A water stream is jetted from the same nozzle plate at an internal pressure of 10 MPa (E value = 13) to entangle the fibers, and the surface density is 120 g / m2.
^2. A simple entangled nonwoven fabric having a thickness of 1 mm and an apparent density of 0.12 g / cm ³ was produced. The average tensile strength of this simple entangled nonwoven fabric sheet was 220 N / 50 mm width.

On the other hand, the same procedure as in the method for preparing the bulky nonwoven fabric sheet of Example 1 (2) was carried out, and the area density was 700 g /
A unidirectional bulky nonwoven fabric sheet having an m ² , a thickness of 20 mm, and an apparent density of 0.035 g / cm ³ was produced. Then, Example 1
By exactly the same operation as the method for preparing the nonwoven fabric laminate of (3), lamination of the unidirectional bulky nonwoven fabric sheet and the simple entangled nonwoven fabric sheet, needle punching, and core-sheath type polyester-based heat-fusible fiber are performed. The fusion of the sheath component and the development of crimping of the hollow polyester fiber were carried out to produce a nonwoven fabric laminate of the present invention (area density = 940 g / m ² , thickness = 20 mm).

[0059]

Example 3 A unidirectional fiber web was formed in exactly the same manner as in the method for preparing an entangled nonwoven fabric sheet of Example 1 (1). Next, this unidirectional fiber web was placed on a plain woven net having an opening of 0.175 mm, and the diameter was 0.13 m.
m, the nozzles are arranged in a line at a pitch of 0.8 mm,
A water flow is jetted from a nozzle plate having an internal pressure of 10 MPa to the unidirectional fiber web (E value = 13), and then the water flow is jetted from the same nozzle plate at an internal pressure of 15 MPa after inverting the unidirectional fiber web. (E value = 29.
3) After further reversing the unidirectional fiber web,
A water stream is jetted from the same nozzle plate at an internal pressure of 10 MPa (E value = 13), and further, after inverting the unidirectional fiber web, an internal pressure of 10 M is applied from the same nozzle plate.
A water stream is jetted out at Pa (E value = 13) to entangle the fibers, and the surface density is 120 g / m ² , the thickness is 1 mm, and the apparent density is 0.12 g
/ Cm ³ was produced. The average tensile strength of this simple entangled nonwoven fabric sheet was 260 N / 50 mm width.

On the other hand, the operation was carried out in exactly the same manner as in the method for preparing the bulky nonwoven fabric sheet of Example 1 (2), and the area density was 700 g /
A unidirectional bulky nonwoven fabric sheet having an m ² , a thickness of 20 mm, and an apparent density of 0.035 g / cm ³ was produced. Then, Example 1
By exactly the same operation as the method for preparing the nonwoven fabric laminate of (3), lamination of the unidirectional bulky nonwoven fabric sheet and the simple entangled nonwoven fabric sheet, needle punching, and core-sheath type polyester-based heat-fusible fiber are performed. The fusion of the sheath component and the development of crimping of the hollow polyester fiber were carried out to produce a nonwoven fabric laminate of the present invention (area density = 940 g / m ² , thickness = 20 mm).

[0061]

Comparative Example 1 A unidirectional fiber web was formed in exactly the same manner as in the method for preparing an entangled nonwoven fabric sheet of Example 1 (1). Next, the unidirectional fiber web is sewn with a needle density of 35.
The fibers were entangled by performing a needle punch at 0 fibers / cm ² to produce a simple entangled nonwoven fabric sheet having an areal density of 120 g / m ² , a thickness of 2.2 mm, and an apparent density of 0.055 g / cm ³ . The average tensile strength of this simple entangled nonwoven fabric sheet is 10
The width was 0 N / 50 mm.

On the other hand, the same procedure as in the method for preparing a bulky nonwoven fabric sheet of Example 1 (2) was carried out to obtain an areal density of 700 g /
A unidirectional bulky nonwoven fabric sheet having an m ² , a thickness of 20 mm, and an apparent density of 0.035 g / cm ³ was formed. Then, Example 1
Lamination of the unidirectional bulky nonwoven fabric sheet and the simple entangled nonwoven fabric sheet, needle punching, and core-sheath type polyester heat-fusible fiber by completely the same operation as the method for preparing the nonwoven fabric laminate of (3). The sheath component was fused and the hollow polyester fiber was crimped to produce a nonwoven fabric laminate (area density = 940 g / m ² , thickness = 20 mm).

[0063]

Comparative Example 2 A unidirectional fiber web was formed in exactly the same manner as in the method for preparing an entangled nonwoven fabric sheet of Example 1 (1). Next, this unidirectional fiber web was placed on a plain woven net having an opening of 0.175 mm, and the diameter was 0.13 m.
m, the nozzles are arranged in a line at a pitch of 0.8 mm,
A water flow is jetted from the nozzle plate having an internal pressure of 6 MPa to the unidirectional fiber web (E value = 4.7), and then the unidirectional fiber web is reversed. Is spouted (E value = 4.7) to entangle the fibers, the areal density is 120 g / m ² , and the thickness is 1.7 m
m, a simple entangled nonwoven fabric sheet having an apparent density of 0.071 g / cm ³ was produced. The average tensile strength of this simple entangled nonwoven fabric sheet was 120 N / 50 mm width.

On the other hand, the same procedure as in the method for preparing a bulky nonwoven fabric sheet of Example 1 (2) was carried out, and the area density was 700 g /
A unidirectional bulky nonwoven fabric sheet having an m ² , a thickness of 20 mm, and an apparent density of 0.035 g / cm ³ was produced. Then, Example 1
By exactly the same operation as the method for preparing the nonwoven fabric laminate of (3), lamination of the unidirectional bulky nonwoven fabric sheet and the simple entangled nonwoven fabric sheet, needle punching, and core-sheath type polyester-based heat-fusible fiber are performed. By fusing the sheath component and expressing the crimp of the hollow polyester fiber, a nonwoven fabric laminate (area density = 940 g / m ² , thickness = 20 mm) was produced.

[0065]

[Stiffness Evaluation Test] The nonwoven fabric laminates prepared in Examples 1 to 3 and Comparative Examples 1 and 2 were heated at 240 ° C. for 3 minutes and then adjusted to a thickness of 15 mm by a cold press. Next, the vertical direction is 300 mm and the horizontal direction is 50 mm
Cut into strips. Next, a portion of each of the strip-shaped nonwoven fabric laminates from one end to 70 mm was fixed on a rectangular parallelepiped stand, and the remaining 230 mm portion was protruded from the rectangular parallelepiped stand. Then, while maintaining this state, 9
It was left in a thermostat at 0 ° C. for 4 hours, and the amount of sag (unit = mm) at the tip of the portion protruding from the rectangular parallelepiped table was measured. The results were as shown in Table 1. From Table 1, it was found that the nonwoven fabric laminate of the present invention was rigid even at high temperatures. It was also found that the rigidity was excellent when the average tensile strength of the entangled nonwoven fabric was 150 N / 50 mm width or more. Furthermore, since the nonwoven fabric laminate of the present invention has rigidity even at a high temperature, it has been found that there is no problem even if it is used as an interior material for an automobile where the temperature becomes high (for example, midsummer).

[0066]

[0067]

[Test for Examination of Physical Property Values] (1) Preparation of Nonwoven Fabric Laminate Sample 1 A simple entangled nonwoven fabric sheet prepared by exactly the same operation as the method for preparing an entangled nonwoven fabric sheet described in Example 2 was tested at room temperature. Through the calendar of pressure 0.98MPa,
Area density 120 g / m ² , thickness 0.94 mm, apparent density 0.13 g / cm ³ , average tensile strength 234 N / 50 m
A nonwoven fabric laminate sample 1 was prepared in exactly the same manner as described in Example 1, except that a compressed entangled nonwoven fabric sheet (rigid layer) having a width of m was manufactured and this compressed entangled nonwoven fabric sheet was used as a rigid layer. (Area density: 940 g / m ² , thickness: 20
mm).

(2) Preparation of Nonwoven Fabric Laminate Sample 2 A simple entangled nonwoven fabric sheet prepared in exactly the same manner as the entangled nonwoven fabric sheet described in Example 2 was prepared at a temperature of 100 ° C. and a surface pressure of 0.1%. Through a calender of 98 MPa, areal density 120 g / m ² , thickness 0.61 mm, apparent density 0.20 g / cm ³ , average tensile strength 256 N / 5
Manufacture a compression-entangled nonwoven fabric sheet (rigid layer) with a width of 0 mm,
Except that this compression entangled nonwoven fabric sheet was used as a rigid layer, a nonwoven fabric laminate sample 2 (area density: 940 g / m ² , thickness:
20 mm).

(3) Preparation of Nonwoven Fabric Laminate Sample 3 A simple entangled nonwoven fabric sheet prepared by exactly the same operation as the method for preparing an entangled nonwoven fabric sheet described in Example 2 was prepared at a temperature of 150.degree. Through a 98 MPa calender, areal density 120 g / m ² , thickness 0.42 mm, apparent density 0.29 g / cm ³ , average tensile strength 264 N / 5
Manufacture a pressure entangled nonwoven fabric sheet (rigid layer) with a width of 0 mm,
Except that this press-entangled nonwoven fabric sheet was used as a rigid layer, a nonwoven fabric laminate sample 3 (area density: 940 g / m ² , thickness:
20 mm).

(4) Preparation of Nonwoven Fabric Laminate Sample 4 A simple entangled nonwoven fabric sheet prepared in exactly the same manner as the method for preparing an entangled nonwoven fabric sheet described in Example 2 was subjected to a temperature of 180 ° C. and a surface pressure of 0.1%. Through a 98 MPa calender, areal density 120 g / m ² , thickness 0.41 mm, apparent density 0.29 g / cm ³ , average tensile strength 407 N / 5
Producing a fusion entangled nonwoven fabric sheet (rigid layer) having a width of 0 mm,
Except that this fusion-entangled nonwoven fabric sheet was used as a rigid layer, the nonwoven fabric laminate sample 4 (area density: 940 g / m ² , thickness:
20 mm).

(5) Moldability Nonwoven fabric laminate sample 1 prepared in (1) to (4) above
To 4 are cut into strips having a length of 300 mm and a width of 50 mm, and heat-treated at 240 ° C. for 3 minutes by a hot air circulating heat treatment device (fusing the sheath component of the core-sheath type polyester-based heat-fusible fiber). After that, the thickness was adjusted to 15 mm by a cold press. At this time, in the nonwoven fabric laminate samples 2 to 4, wrinkles were generated between the rigid layer and the bulky layer, and the rigidity layer and the bulky layer were only partially fused, so that the moldability was poor. On the other hand, the nonwoven fabric laminate sample 1 was excellent in moldability without wrinkles between the rigid layer and the bulky layer. The nonwoven fabric laminates prepared in Examples 1 to 3 and Comparative Examples 1 and 2 were all excellent in moldability without wrinkles between the rigid layer and the bulky layer. Therefore, it was found that the apparent density difference between the rigid layer and the bulky layer was preferably 0.14 g / cm ³ or less.

(6) Amount of sag Table 2 below shows the amount of sag of Samples 1 to 4 measured in the same manner as in the method described in the rigidity evaluation test. As a result of the rigidity evaluation test, the thickness of the rigid layer is preferably 0.8 mm or more, and the apparent density of the rigid layer is 0.15 g / c.
It has been found that it is preferably less than m ³ .

(7) Evaluation of maximum point load Nonwoven fabric laminate sample 1 prepared in (1) to (4) above
~ 4 was heated at 240 ° C for 3 minutes, and then pressurized with a cold press to adjust the thickness to 15 mm. Next, the pressed nonwoven fabric laminate was vertically
The test piece was cut by cutting into a strip having a width of 25 mm. Next, the test piece is placed so as to straddle two supports placed at a distance of 100 mm from each other, and then a central portion (a portion 50 mm from the support) between the supports is subjected to a speed wedge by a pressure wedge. Pressure was applied downward at 20 mm / min. This pressurized state was detected by a tensile tester (Tensilon UCT-500, manufactured by Orientec), and the load at the point where the load became maximum (maximum point load) was measured and recorded. The results are shown in Table 2 below.

<< Table 2 >> Non-woven fabric laminated body sagging amount Maximum point load sample (mm) (N / 25 mm width) 1 13.5 5.6 2 16.0 4.9 3 18.5 4.4 4 18.7 3.9

[0075]

The nonwoven fabric laminate of the present invention comprises a simple entangled nonwoven fabric having a high average tensile strength or an entangled nonwoven fabric having a higher average tensile strength produced from the simple entangled nonwoven fabric. The rigid layer secures the rigidity,
Since the weight is reduced by the bulky layer whose apparent density is lower than that of the rigid layer, it has sufficient rigidity despite its light weight. Moreover, since the interior material for automobiles of the present invention is obtained by forming the above-described nonwoven fabric laminate into a desired shape, it has sufficient rigidity despite its light weight.

Claims (10)

[Claims] 1. An entangled nonwoven fabric in which the average value of the tensile strength in the longitudinal direction and the tensile strength in the transverse direction measured in a state of a simple entangled nonwoven fabric whose shape is maintained only by entanglement of fibers is 150 N / 50 mm width or more. A nonwoven fabric laminate comprising: a rigid layer formed of a nonwoven fabric having a lower apparent density than the rigid layer; 2. The rigid layer has an apparent density of 0.15 g / cm ^3.
The nonwoven fabric laminate according to claim 1, which is less than. 3. The rigid layer has a thickness of 0.8 mm or more.
The nonwoven fabric laminate according to claim 1 or 2. 4. The nonwoven fabric laminate according to claim 1, wherein a difference between an apparent density of the rigid layer and an apparent density of the bulky layer is 0.14 g / cm ³ or less. 5. The nonwoven fabric according to claim 1, wherein heat-fusible fibers are contained as fibers constituting the rigid layer, and the heat-fusible fibers are fused. Laminate. 6. The nonwoven fabric according to claim 1, wherein the fibers constituting the bulky layer include heat-fusible fibers, and the heat-fusible fibers are fused. Laminate. 7. The nonwoven fabric laminate according to claim 1, wherein the fibers constituting the rigid layer and / or the bulky layer include irregular cross-section fibers and / or hollow fibers. 8. The nonwoven fabric laminate according to claim 1, wherein the fibers constituting the rigid layer and the fibers constituting the bulky layer substantially consist only of polyester fibers. 9. The method according to claim 1, wherein a skin layer is further laminated.
The nonwoven fabric laminate according to any one of Items 1 to 8. 10. An automotive interior material obtained by molding the nonwoven fabric laminate according to any one of claims 1 to 9.