JP2004360142A - Nonwoven fabric, interior materials and method for producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an inexpensive nonwoven fabric that is resistant to breakage caused by pulling because the fabric undergoes no embrittlement by exposure to heat from the production process and can retain the strength even when the unit weight of the fabric is low and is not restricted to the fiber length, different from the wet process. <P>SOLUTION: The backing fiber comprising carbon fiber as inorganic fiber 5, polypropylene fiber as water-insoluble thermoplastic organic fiber 6 and polyvinyl alcohol fiber as water-soluble organic fiber 7 are mixed and the resultant fiber assembly is needle punched whereby a fabric sheet is formed. Then, the water-soluble organic fiber 7 is softened or fused and solidified by drying whereby the contact points between the fibers in the fiber assembly are connected. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a nonwoven fabric using inorganic fibers, an interior material in which the nonwoven fabric is laminated on an interior material main body (for example, for a vehicle or a building), and a method for producing the same.
[0002]
Problems to be solved by the prior art and the invention
In interior materials for vehicles such as automobiles, especially for ceiling materials, heat insulation, vibration damping, soundproofing, moldability, light weight, etc. are regarded as important, and molded ceiling materials are conventionally used for resin felt and cardboard. Although those impregnated with a phenol resin have been used, they have a drawback in that although they have rigidity, they have a large basis weight.
Therefore, at present, there is known an interior material in which a nonwoven fabric made of an inorganic fiber such as glass fiber or carbon fiber is attached as a reinforcing material to the surface of a polyurethane foam and integrated. However, since inorganic fibers such as glass fibers and carbon fibers are expensive, there is a problem that the mixing ratio is directly reflected in the cost and the cost is increased.
[0003]
Alternatively, a resin sheet or a non-woven fabric composed of inorganic fibers and thermoplastic organic fibers is heated and fused to the surface of a mat in which inorganic fibers and fibers made of polyolefin-based polypropylene or polyethylene resin are mixed. There is known an interior material which is integrated with the interior. Patent Literatures include, for example, an interior material obtained by laminating and fusing a thermoplastic organic resin film to a mat of inorganic fibers (see Patent Literature 1), and a mat composed of inorganic fibers and thermoplastic resin fibers having inorganic fibers on the surface thereof. An interior material in which a layer made of a thermoplastic resin is fused (see Patent Literature 2), a fiber-reinforced heat in which a mixed fiber mat of a reinforcing fiber such as an inorganic fiber and a thermoplastic organic fiber is heated and pressed to melt the thermoplastic organic fiber. An interior material using a plastic sheet (see Patent Literature 3), a mat-like material having a different mixing ratio of inorganic fiber and thermoplastic organic fiber are stacked and integrally heated and heated above the melting point of the thermoplastic organic fiber. A laminated body (see Patent Document 4) is known.
These mixed fiber mats are made by melting thermoplastic organic fibers at the time of thermocompression bonding during the production of the mats and fusing the inorganic fibers together. Therefore, for example, a light and thin mat having a basis weight of less than about 150 g / m ^2. In the case of manufacturing, when a mold occurs during the heat compression bonding, if the mold is pulled out in the transport direction or the like, it is easily broken and the strength is weakened. For this reason, it was difficult to obtain a continuous molded body, so that a heterogeneous molded body joined in the middle was obtained. Therefore, in order to produce a uniform non-woven fabric as a continuous molded body that has sufficient strength against pull-out, it was necessary to have a thickness such that the basis weight became 150 g / m ² or more. In addition, a mat having a high basis weight requires a large amount of expensive inorganic fibers, and thus has a problem that the cost increases.
[0004]
Looking at the manufacturing method of nonwoven fabrics widely, not limited to interior materials, a wet papermaking method is known as a method of not bonding fibers by heating. However, in this wet papermaking method, it is preferable to use short fibers having a fiber length of 25 mm or less, and a nonwoven fabric made of short fibers has few contact intersections between the fibers and tends to have low toughness due to lack of toughness. Conversely, when the wet papermaking method is attempted using fibers having a fiber length of 25 mm or more, the fibers are entangled with each other, secondary aggregation occurs, dispersibility is deteriorated, and it is difficult to stably produce a uniform nonwoven fabric. It becomes. Furthermore, thermoplastic organic fibers having a specific gravity of 1 or less, for example, polypropylene fibers having a specific gravity of 0.91, cannot be stirred and dispersed in the wet papermaking process because they float in water, and are barriers to the weight reduction of the nonwoven fabric. .
[0005]
An object of the present invention is to solve the above-mentioned problems and to bond base fibers and the like using water-soluble organic fibers, so that there is no weakening due to heat at the time of manufacturing. An object of the present invention is to provide a low-priced nonwoven fabric which can maintain its strength even with a small amount of nonwoven fabric and is not limited in fiber length as in the wet papermaking method. In addition, since the non-woven fabric plays a role as a reinforcing material for the interior material by layering the non-woven fabric with the strength kept on the interior material body and integrally molding the interior material, the interior material with high elasticity and high strength is used. To provide.
[0006]
In addition, in fields other than interior materials, there are examples of using water-soluble organic fibers in the production of nonwoven fabrics, for clothing (for example, see Patent Document 5), cushion materials (for example, see Patent Document 6), printed wiring. Applications (for example, see Patent Document 7) and artificial leather (for example, see Patent Document 8) are known. In this case, the water-soluble organic fibers are used to increase the texture and bulk of the product, and their production method is mainly to fuse other fibers together by heating and then to wash them with water. The water-soluble organic fibers are eluted and removed at the same time as the water-soluble organic fibers are entangled with each other by performing the water entanglement treatment, and the water itself is hardly contained in the product itself. It does not provide an opportunity to bond the fibers using water-soluble organic fibers.
[0007]
[Patent Document 1]
JP-A-64-77664 [Patent Document 2]
Japanese Patent Application Laid-Open No. 02-80652 [Patent Document 3]
JP-A-61-130345 [Patent Document 4]
JP 09-123327 A [Patent Document 5]
JP 07-316962 A [Patent Document 6]
JP 2000-192358 A [Patent Document 7]
JP 2001-192555 A [Patent Document 8]
Japanese Patent Application Laid-Open No. 05-33256
[Means for Solving the Problems]
In order to achieve the above object, the present invention employs the following means (1-1) (1-2) (2-1) (2-2) (3) (4).
(1-1) A fiber aggregate formed by mixing a base fiber containing at least one selected from inorganic fibers, heat-resistant organic fibers and natural fibers with a water-soluble organic fiber is formed into a cloth by needle punching. A non-woven fabric in which the water-soluble organic fibers are softened or melted by water and dried and solidified after being formed, so that the contact points between the fibers of the fiber assembly are bonded.
[0009]
(1-2) A fiber assembly in which a base fiber containing at least one selected from inorganic fibers, heat-resistant organic fibers and natural fibers, a water-soluble organic fiber and a water-insoluble thermoplastic organic fiber are mixed. Is formed into a cloth shape by needle punching, and then the water-soluble organic fibers are softened or melted with the addition of elution loss due to water and solidified by drying, so that the contact points between the fibers of the fiber assembly are bonded. Non-woven fabric.
[0010]
The basis weight of the nonwoven fabric of the means (1-1) and (1-2) is not particularly limited, but is preferably 15 g / m ² or more and less than 150 g / m ² .
[0011]
(2-1) A base fiber containing at least one selected from inorganic fibers, heat-resistant organic fibers and natural fibers and a water-soluble organic fiber are mixed to form a fiber aggregate, and the fiber aggregate is subjected to needle punching. A method for producing a nonwoven fabric, in which a water-soluble organic fiber is softened or melted with water and dried and solidified after being shaped into a cloth, thereby bonding the contact points between the fibers of the fiber assembly to produce the nonwoven fabric.
[0012]
(2-2) A base fiber containing at least one selected from inorganic fibers, heat-resistant organic fibers and natural fibers, a water-soluble organic fiber and a water-insoluble thermoplastic organic fiber are mixed to form a fiber aggregate. After the fiber aggregate is shaped into a cloth by needle punching, the contact points between the fibers of the fiber aggregate are dried and solidified by softening or melting the water-soluble organic fibers with elution and reduction by adding water. A method for manufacturing a nonwoven fabric that is manufactured by bonding.
The heating temperature for drying and solidifying is not particularly limited. However, it is preferable that the water-soluble organic fiber is dried and solidified by heating at a temperature lower than the melting point of the water-insoluble thermoplastic fiber at the time of pressurization and drying.
[0013]
In the production method of the means (2-1) and (2-2), the fiber aggregate is subjected to dehydration treatment and pressure treatment after the softening or melting of the water-soluble organic fiber and before the solidification, although not particularly limited. Is preferred.
[0014]
(3) An interior material in which the nonwoven fabric of the above-mentioned means (1-1) or (1-2) is overlaid and integrated with the interior material body.
[0015]
The following (1), (2), and (3) can be exemplified as a mode in which the interior material is integrated.
{Circle around (1)} An aspect in which the fusion film sandwiched between the nonwoven fabric and the interior material main body is melted by heating to integrate the nonwoven fabric with the interior material body.
{Circle around (2)} A mode in which the nonwoven fabric and the interior material main body are bonded by spraying an adhesive spray on at least one of the surface of the nonwoven fabric to be overlapped and the surface of the interior material main body.
{Circle around (3)} In particular, in the case of the means (1-2), a nonwoven fabric made of the nonwoven fabric is overlaid on the interior material main body, and the nonwoven fabric and the interior material main body are fused by fusion of the water-insoluble thermoplastic organic fiber and the interior material main body. An integrated mode.
[0016]
(4) A method for producing an interior material in which the nonwoven fabric produced by the production method according to the means (2-1) or (2-2) is overlaid and integrated with the interior material body.
[0017]
The following methods (1), (2) and (3) can be exemplified as a method of integrating the interior materials.
{Circle around (1)} A method in which a fusion film sandwiched between a nonwoven fabric and an interior material main body is melted by heating to integrate the nonwoven fabric with the interior material body.
{Circle over (2)} A method of spraying an adhesive spray on at least one of the surface of the nonwoven fabric to be overlapped and the surface of the interior material main body, and bonding the nonwoven fabric and the interior material main body.
{Circle around (3)} Particularly in the case of (2-2), the nonwoven fabric manufactured by the manufacturing method using the nonwoven fabric is superimposed on the interior material body, heated to a temperature higher than the melting point of the water-insoluble thermoplastic organic fiber, and then cooled. A method of integrating a nonwoven fabric and an interior material body by fusing the water-insoluble thermoplastic organic fiber and the interior material body.
[0018]
The modes of the constituent elements in the above (1-1) (1-2) (2-1) (2-2) (3) and (4) are exemplified below.
"Base fiber" can be exemplified as inorganic fibers, such as glass fibers, metal fibers, ceramic fibers, carbon fibers, mineral fibers including basalt fibers, and heat-resistant organic fibers such as aramid fibers, polyethylene terephthalate, and polypropylene fibers. Fibers to which a liquid crystal polymer is added can be exemplified, and natural fibers include hemp, cotton, coconut, bamboo, kenaf, wool, silk and the like, and at least one or a combination of two or more selected from these can be exemplified. Among them, carbon fibers are not particularly limited, but carbon fibers are preferable because of their advantages of high elastic modulus, high strength, light weight, and incineration. The average fiber length of the base fiber is not particularly limited, but is preferably from 25 to 200 mm, since the contact intersection point between the fibers for keeping the toughness and strength of the nonwoven fabric high can be sufficiently obtained. Further, assuming that the fiber aggregate is 100% by weight, the ratio of the base fiber is not particularly limited, but is preferably 30 to 50% by weight.
[0019]
Examples of the “water-insoluble thermoplastic organic fibers” include fibers made of olefin-based polyethylene, polypropylene, low-melting polyester, and the like, and one or a combination of two or more selected from these. Among them, although not particularly limited, polypropylene fibers having a low specific gravity are preferable. Further, assuming that the fiber aggregate is 100% by weight, the ratio of the water-insoluble thermoplastic organic fibers is not particularly limited, but is preferably 30 to 50% by weight.
[0020]
The “water-soluble organic fiber” is not particularly limited, but a fiber made of polyvinyl alcohol (water-soluble vinylon) can be exemplified. Assuming that the fiber aggregate is 100% by weight, the ratio of the water-soluble organic fibers in the fiber aggregate before the water treatment is not particularly limited, but is preferably 10 to 40% by weight. By mixing a large amount of the water-soluble organic fibers into the fiber aggregate, an effect is obtained in which the fiber surface is easily entangled with fibers that are slippery and easily breakable, such as carbon fibers used as a base fiber, and are used for needle punching. A good needle mat can be obtained without using a needle having a barb depth of 0.11 mm to 0.18 mm and no kick-up.
Further, the ratio of the water-soluble organic fibers in the dried and solidified nonwoven fabric after the water treatment is not particularly limited, assuming that the nonwoven fabric in which the water-soluble organic fibers are dried and solidified is 100% by weight, but is preferably 5 to 35% by weight. The dried and solidified water-soluble organic fiber is considered to have a function of bonding the contact points of the fibers of the fiber assembly with the adhesive layer by forming an adhesive layer, so that the amount of the water-soluble fiber is reduced by elution so as to be less than 5%. If the amount is too large, the function of adhering the fibers is too weak, so that the contact points between the fibers tend to separate, and if the amount of the water-soluble fiber is 35% or more, the strength is significantly reduced under high humidity.
The ratio of the water-soluble organic fibers contained in the fiber aggregate before the water treatment and the dried and solidified nonwoven fabric after the water treatment may or may not change. When it changes, it can be exemplified that the water-soluble organic fiber is mainly dissolved in water and the content of the water-soluble organic fiber is reduced with the elution loss.
[0021]
“Hydration” refers to adding water to the fiber, and is not particularly limited to that method. For example, there are a method of adding liquid water and a method of humidification.
[0022]
The material of the “interior material main body” is not particularly limited, and examples thereof include a reinforced resin material containing inorganic fibers and natural fibers, a foamed polyurethane, a composite resin material with a liquid crystal polymer, and the like. A foam, a honeycomb structure, and the like when using a fiber-reinforced composite material or foamed polyurethane can be exemplified. Specifically, polyurethane foam, a fibrous mat composed of glass fibers and resin fibers can be exemplified, and the resin fibers used for the fibrous mat are polyolefin-based polypropylene, polyethylene terephthalate, polyethylene resin, polyethylene copolymer resin. At least one or more fibers using the selected resin can be exemplified.
The field to which the "interior material" is applied is not particularly limited, and is applicable to any type of interior material. However, particularly suitable fields include those for vehicles and buildings, and those for vehicles. And ceiling materials for automobiles.
[0023]
In the above means (3) and (4), the mode of overlapping the nonwoven fabric on the interior material main body is not particularly limited, but the mode of overlapping the nonwoven fabric on both surfaces so as to sandwich the interior material main body, and the method of applying the nonwoven fabric on one surface of the interior material main body. A mode in which only the nonwoven fabric is stacked and a mode in which the nonwoven fabric is laminated inside the interior material body can be exemplified. Further, a nonwoven fabric or a resin sheet, which is not the present invention, may be integrated on the surface of the laminated nonwoven fabric or the surface of the interior material body on which the nonwoven fabric is not laminated.
Examples of the fusion film include polypropylene, polyethylene terephthalate, and polyethylene resin, and examples of the adhesive include polyisocyanate.
[0024]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, as shown in FIG. 1 and FIG. 2, an embodiment in which the present invention embodies a nonwoven fabric 1 a, an interior material 2, and a manufacturing method thereof will be described. The materials, configurations, numerical values, and the like described in the embodiments are merely examples, and can be changed as appropriate.
[0025]
This nonwoven fabric 1a is composed of a base fiber of carbon fiber having an average fiber length of 55 mm as the inorganic fiber 5, a water-soluble vinylon fiber (Kuraron K-II) manufactured by Kuraray Co., Ltd. as the water-soluble organic fiber 7, After the fiber aggregate formed by blending polypropylene fibers as the water-soluble thermoplastic organic fibers 6 is shaped into a cloth by needle punching, the water-soluble organic fibers 7 are softened or melted by the addition of water with elution and weight loss. By drying and solidifying, the contact points between the fibers of the fiber assembly are bonded. The nonwoven fabric 1a has a water-soluble vinylon fiber content of 5% by weight, assuming that the total amount of the nonwoven fabric 1a is 100% by weight, and is a flat plate shape having a basis weight of about 125 g / m ² and a thickness of about 0.2 mm.
[0026]
The interior material 2 has a nonwoven fabric 1a in which a glass fiber and a polypropylene fiber as an interior material main body 3a having a void are overlapped on one surface of a composite mat material having a basis weight of 700 g / m ² , each of which is 50% by weight, to constitute the nonwoven fabric 1a. The polypropylene fiber as the water-insoluble thermoplastic organic fiber 6 and the polypropylene fiber constituting the interior material main body 3a are melted, the nonwoven fabric 1a becomes a nonwoven fabric 1b, and the interior material main body 3a is formed of the interior material main body 3b. The nonwoven fabric 1b and the interior material main body 3b are integrated by each fusion.
[0027]
The nonwoven fabric 1a and the interior material 2 are manufactured by the following method.
Assuming that the ratio of each fiber is 100% by weight, the carbon fiber as the inorganic fiber 5 is 40% by weight, the polypropylene fiber as the water-insoluble thermoplastic organic fiber 6 is 40% by weight, A water-soluble vinylon fiber as the conductive organic fiber 7 is mixed at 20% by weight.
This fiber aggregate is shaped into a cloth by needle punching to prepare a mat 10 having a basis weight of 150 g / m ² as shown in FIG. Next, the mat 10 is completely impregnated in warm water, and the water-soluble vinylon fibers are softened or melted by dissolution and weight loss with water, and dewatered by roller squeezing to make the water content 300 g / m ² . Next, at a heating temperature of 120 ° C. for 2 minutes, pressurization is performed by a hot press machine with a vertical gap adjusted to 0.15 mm by a gauge, and dehydration discharge and compression are simultaneously performed to dry and solidify the water-soluble vinylon fiber. As shown in FIG. 1 (b), a nonwoven fabric 1a was formed by forming an adhesive layer. By making the dried and solidified water-soluble vinylon fibers into an adhesive layer, the contact points between the carbon fibers and the polypropylene fibers are adhered by the adhesive layer.
In the drying and solidification process following the addition and dehydration, some unnecessary water-soluble vinylon fibers in the cloth-like fiber aggregate are eluted to the outside to reduce the weight of the cloth-like fiber aggregate and to form a final nonwoven fabric. Can be adjusted, and the basis weight, which is difficult to manufacture by needle processing, can be set to 15 g / m ² or more and less than 150 g / m ² . The heating temperature, time and pressure during drying and solidification are set according to the material used and the desired hardness. If the heating temperature is higher than the melting temperature of the polypropylene fibers, a harder fibrous sheet can be obtained. Further, by increasing the heating temperature (for example, to 160 ° C.), the crystallization of the softened or melted water-soluble vinylon fiber when it is dried and solidified can be increased, and the water-soluble vinylon fiber can be modified to have moisture absorption resistance and water absorption resistance. it can.
[0028]
This nonwoven fabric 1a is overlaid on one surface of a composite mat material having a weight per unit area of 700 g / m ² in which glass fiber and polypropylene fiber as the interior material body 3a having voids are each 50% by weight, and the non-water-soluble thermoplastic organic fibers 6 are used. Heating between 190 ° C heating plate for 7 minutes so that the temperature of the nonwoven fabric 1a and the overlapping portion of the composite mat material and the nonwoven fabric 1a become about 190 ° C which is higher than the melting point (164 to 170 ° C) of a certain polypropylene fiber. I do. Thereafter, the laminated mats are pressed with cold press from both sides facing each other, so that the polypropylene fibers constituting the nonwoven fabric 1a and the polypropylene fibers constituting the interior material body 3a are melted, and the fibers are fused to each other. The nonwoven fabric 1b and the interior material main body 3b are integrally molded to form a flat interior material 2 for a vehicle.
FIG. 1C shows a state in the nonwoven fabric 1b after being integrated with the interior material body 3b. As shown in FIG. 2, the interior material 2 for a vehicle is used as a ceiling material 4 of an automobile, with the interior material 2 being an interior material body 3 b, a nonwoven fabric 1 b, It is used so that it becomes the order of the surface material 17 inside a vehicle.
[0029]
According to the nonwoven fabric 1b, the interior material 2 and the method for producing them according to the present embodiment, the following effects (1) to (5) can be obtained.
{Circle around (1)} Since the remaining water-soluble organic fibers 7 that have been reduced in dissolution amount are dried and solidified to form an adhesive layer, the contact points between the fibers can be bonded to each other. It is a manufacturing method that can be manufactured even if it is used.Since there is no weakening due to heat at the time of manufacturing, it is hard to be broken even if it is heated and pressed to a predetermined irregular shape or pulled out in the transport direction when a mold occurs. , So that it can be continuously and integrally molded.
{Circle around (2)} Even in the case of a nonwoven fabric having a low basis weight, since the manufacturing method is such that a uniform nonwoven fabric can be easily obtained while maintaining the strength, the ratio of the inorganic fibers 5 to be contained is reduced and the cost can be reduced.
{Circle around (3)} By forming the nonwoven fabric 1b containing the water-insoluble thermoplastic organic fibers 6, the elasticity is high and the crimp is apt to be provided, so that the interior material 2 has the effect of increasing the sound absorbing performance.
{Circle around (4)} The nonwoven fabric 1b containing the water-insoluble thermoplastic organic fibers 6 provides an adhesive effect of integrating the nonwoven fabric 1a and the interior material body 3 in a dot manner by thermocompression bonding. Second, moisture absorption resistance, strength under high humidity, dimensional stability and shape maintenance can be secured. In particular, since the interior material 2 for a vehicle is formed by press-molding a mixed mat of a base fiber and a thermoplastic fiber, it is possible to stack and integrally mold the mat. Since this integration is performed by melting polypropylene fibers contained in both the nonwoven fabric 1a and the interior material main body 3a, the odor due to the volatile gas at high temperature of the solvent or the organic resin can be reduced. The environment and the space where the product is used can be kept comfortable.
{Circle around (5)} The nonwoven fabric 1b is superimposed on the interior material main body 3a to form the interior material 2 integrally formed by fusion, so that the nonwoven fabric 1b serves as a reinforcing material, and has high elasticity and high strength. It can be 2.
[0030]
Note that the present invention is not limited to the above embodiment, and can be embodied with appropriate modifications without departing from the spirit of the invention.
(1) As shown in FIG. 3A, the fusion film 11 is sandwiched between the nonwoven fabric 1a and the interior material main body 3a, melted by heating, and integrated with the nonwoven fabric 1b and the interior material main body 3.
(2) As shown in FIG. 3B, the surface of the nonwoven fabric 1a is sprayed with a spray of an adhesive 12 to bond the nonwoven fabric 1a and the interior material body 3a.
[0031]
【The invention's effect】
As described above in detail, according to the present invention, since there is no weakening due to heat at the time of production, it is hard to be broken even under tension, and the strength can be maintained even with a nonwoven fabric having a low basis weight, and wet papermaking. Unlike the method, the length of the fiber is not limited, and an excellent effect that a low-priced nonwoven fabric can be provided is exhibited.
[0032]
Furthermore, according to the ninth, tenth, eleventh, or twelfth aspect of the present invention, the nonwoven fabric is a reinforcing material for the interior material by forming a nonwoven fabric having high strength over the interior material body and integrally forming the interior material. Therefore, an excellent effect that an interior material having high elasticity and high strength can be provided can be provided.
[Brief description of the drawings]
FIG. 1 shows an embodiment of the present invention, in which (a) a cross-sectional view of a mat and an enlarged view of a fiber, (b) a cross-sectional view of a nonwoven fabric and an enlarged view of a fiber, and (c) a cross-sectional view of an interior material and are integrated. FIG.
FIG. 2 is a partial cross-sectional view of the vehicle ceiling material of the embodiment.
FIG. 3 shows a modification of the present invention, in which (a) is a cross-sectional view of an interior material integrated using a fusion film, and (b) is a cross-sectional view of an interior material integrated using an adhesive. .
[Explanation of symbols]
1a, 1b Nonwoven fabric 2 Interior material 3a, 3b Interior material body 5 Inorganic fiber 6 Water-insoluble thermoplastic organic fiber 7 Water-soluble organic fiber 10 Mat

Claims (12)

After a fiber aggregate formed by blending a base fiber containing at least one selected from inorganic fibers, heat-resistant organic fibers and natural fibers and a water-soluble organic fiber is shaped into a cloth by needle punching, A nonwoven fabric in which the water-soluble organic fibers are softened or melted by water and dried and solidified, whereby the contact points between the fibers of the fiber assembly are bonded. A base fiber containing at least one selected from inorganic fibers, heat-resistant organic fibers and natural fibers, and a fiber assembly formed by mixing a water-soluble organic fiber and a water-insoluble thermoplastic organic fiber are subjected to needle punching. A nonwoven fabric in which, after being shaped into a cloth, the water-soluble organic fibers are softened or melted with the addition of elution and reduced in weight with water and solidified by drying, so that the contact points between the fibers of the fiber aggregate are bonded. Basis weight 15 g / ^{m 2} or more 150 g / ^{m 2} less than a is claim 1 or 2 wherein the nonwoven fabric. The nonwoven fabric according to claim 1, 2 or 3, wherein the base fiber mainly comprises carbon fiber having an average fiber length of 25 to 200 mm. A base fiber containing at least one selected from inorganic fibers, heat-resistant organic fibers, and natural fibers is mixed with a water-soluble organic fiber to form a fiber aggregate, and the fiber aggregate is formed into a cloth by needle punching. A method for producing a nonwoven fabric, wherein the nonwoven fabric is produced by shaping and then softening or melting the water-soluble organic fiber with water and drying and solidifying the water-soluble organic fiber to bond the contact points between the fibers of the fiber assembly. Mixing a base fiber containing at least one selected from inorganic fibers, heat-resistant organic fibers and natural fibers with a water-soluble organic fiber and a water-insoluble thermoplastic organic fiber to form a fiber aggregate; Is formed into a cloth by needle punching, and then the water-soluble organic fibers are softened or melted together with the elution and weight loss by adding water and solidified by drying to adhere the contact points between the fibers of the fiber assembly. Manufacturing method of non-woven fabric. 7. The method for producing a nonwoven fabric according to claim 6, wherein the water-soluble organic fibers are dried and solidified by heating and heating at a temperature lower than the melting point of the water-insoluble thermoplastic fibers during the pressurization. The method for producing a nonwoven fabric according to claim 5, 6 or 7, wherein the fiber aggregate is subjected to dehydration treatment and pressure bonding treatment after softening or melting and before solidification of the water-soluble organic fiber. An interior material in which the nonwoven fabric according to claim 1, 2, 3, or 4 is overlaid and integrated with the interior material body. An interior material in which the nonwoven fabric according to claim 2 is overlaid on an interior material body, and the nonwoven fabric and the interior material body are integrated by fusion of the water-insoluble thermoplastic organic fiber and the interior material body. A method for producing an interior material, wherein the nonwoven fabric produced by the production method according to claim 5, 6, 7, or 8 is overlaid on and integrated with the interior material body. The non-woven fabric produced by the production method according to claim 6 or 7, which is superimposed on the interior material body, heated to a temperature equal to or higher than the melting point of the water-insoluble thermoplastic organic fiber, and then cooled to form the non-water-soluble thermoplastic organic fiber. A method of manufacturing an interior material in which the nonwoven fabric and the interior material body are integrated by fusing the interior material body.

Images