JP2011051137A - Combined molding - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a combined molding which has flame retardancy, prevents an expansion-molded resin from exuding to the surface of a reinforcing material, the reinforcing material of which has flexibility and which prevents the generation of an abnormal sound. <P>SOLUTION: The combined molding has the expansion-molded resin and a crimped filament-spunbonded nonwoven fabric being the reinforcing material of the expansion-molded resin. The crimped filament-spunbonded nonwoven fabric is formed by using, at the least, a polypropylene-based crimped filament having 0.5-10 dtex fineness and 2-40 pieces/25 mm number of crimps, is thermocompression-bonded at 2-15% partial thermocompression bonding rate, and has 50-200 g/m<SP>2</SP>basis weight, 0.5-2.0 mm thickness, 0.1-150 cm<SP>3</SP>/cm<SP>2</SP>/second air permeability and ≥20 oxygen index (LOI) when measured according to JIS-K-7201. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a composite molded body having a foam molding resin and a crimped long fiber spunbond nonwoven fabric which is a reinforcing material for the foam molding resin. More specifically, the present invention can be used as a sheet for automobiles, furniture and the like, a cushion molded body, etc., and the reinforcing material has flexibility that can be easily adapted to a concavo-convex mold for foam molding and to the surface of the reinforcing material of foam molded resin. Further, the present invention relates to a composite molded body that can prevent the generation of abnormal noise due to friction between the composite molded body and the mounting steel material.

  Conventionally, polyurethane foams excellent in elasticity, moisture retention, light weight and the like have been used as cushion bodies for seats of automobiles and furniture. The polyurethane foam is obtained, for example, by injecting a polyurethane resin stock solution into a molding concavo-convex mold and foam molding. The obtained cushion body is attached to a mounting steel material such as a spring, a frame, and a pipe. However, there is a problem that abnormal noise is generated due to vibration during use and friction between the cushion body and the mounting steel material. In order to prevent the generation of such abnormal noises, a method has been proposed in which these mounting steel materials are integrated with the surface of the cushion body using felt, nonwoven fabric or the like during molding.

Patent Document 1 proposes a method using a laminate composed of a nonwoven fabric having a coarse structure and a nonwoven fabric having a dense structure, and Patent Document 2 discloses a method using a nonwoven fabric having a high basis weight of 110 to 800 g / m ^2. Is provided.

  In the above method, it is possible to prevent the resin liquid from oozing out to the surface of the nonwoven fabric and to impart rigidity to the cushion body. However, the above method has problems that the nonwoven fabric is not easily adapted to the concavo-convex mold and that the effect of preventing abnormal noise is low.

  Patent Document 3 provides a technique of using a crimped long fiber nonwoven fabric that has been partially thermocompression bonded as a reinforcing material base fabric for foam molding. Although this technology aims to suppress the seepage of the resin used for foam molding, there is a problem that the reinforcing material base for foam molding does not have the flame retardancy particularly required for applications such as automobile interior materials. .

JP-A-6-171003 JP-A-2-258332 JP 2000-62061 A

  The present invention solves the above-described problems, and is a composite molded body of a foam molded resin and a nonwoven fabric that is a reinforcing material for the foam molded resin. Exudation is prevented, and the reinforcing material is flexible enough to fit into the rugged mold for foam molding, and prevents abnormal noise due to friction between the composite molded product and the mounting steel of the composite molded product An object of the present invention is to provide a composite molding that can be produced.

  As a result of intensive studies to solve the above problems, the present inventors have found that the above problems can be solved by using a non-woven fabric in which crimped long fibers rich in bulkiness and flexibility are used. The invention has been completed. That is, the present invention is as follows.

[1] A composite molded body having a foam molding resin and a crimped long fiber spunbond nonwoven fabric that is a reinforcing material of the foam molding resin,
The crimped long fiber spunbonded nonwoven fabric is composed of at least a polypropylene-based crimped long fiber having a fineness of 0.5 to 10 dtex and a number of crimps of 2 to 40 pieces / 25 mm,
The crimped long fiber spunbond nonwoven fabric is thermocompression bonded with a partial thermocompression bonding rate of 2 to 15%,
The crimped long fiber spunbond nonwoven fabric is measured according to a basis weight of 50 to 200 g / m ² , a thickness of 0.5 to 2.0 mm, a gas permeability of 0.1 to 150 cm ³ / cm ² / sec, and JIS-K-7201. A composite molded article having an oxygen index (LOI) of 20 or more.
[2] The composite molded body according to [1], wherein the crimped long fiber spunbonded nonwoven fabric contains 0.1 to 10% by mass of a flame retardant.
[3] The composite molded article according to the above [1] or [2], wherein the content of the polypropylene-based crimped long fibers in the crimped long-fiber spunbonded nonwoven fabric is 70 to 100% by mass.
[4] The composite molded body according to any one of [1] to [3], wherein the crimped long fiber spunbonded nonwoven fabric has a bending resistance of 15 cm or less.
[5] The composite molded body according to any one of [1] to [4], wherein the crimped long fiber spunbonded nonwoven fabric has a breaking elongation of 70% or more.
[6] The composite molded body according to any one of [1] to [5], wherein the foam molding resin is a urethane foam molding resin.

  The composite molded body of the present invention is flame retardant, and since the reinforcing material is formed using crimped long fibers having high bulkiness and flexibility, the reinforcing material is easy to fit into the concavo-convex mold for foam molding, Further, seepage of the foam molding resin to the reinforcing material surface is prevented. Moreover, according to this invention, generation | occurrence | production of the noise by the friction etc. with the composite molding body of this invention formed as a foaming molding sheet | seat, a cushion body, etc., and the attachment steel material of this composite molding body can be prevented. Therefore, the composite molded body of the present invention can be suitably used for a wide range of applications such as vehicle interior materials.

The present invention is a composite molded body having a foam molding resin and a crimped long fiber spunbond nonwoven fabric that is a reinforcing material of the foam molding resin, wherein the crimped long fiber spunbond nonwoven fabric has a fineness of 0.5 to It is composed of at least a polypropylene-based crimped long fiber having 10 dtex and 2-40 crimps / 25 mm, and the crimped long fiber spunbond nonwoven fabric is thermocompression bonded at a partial thermocompression rate of 2-15%. The crimped long fiber spunbond nonwoven fabric has a basis weight of 50 to 200 g / m ² , a thickness of 0.5 to 2.0 mm, a gas permeability of 0.1 to 150 cm ³ / cm ² / sec, and JIS-K-7201. A composite molded body having an oxygen index (LOI) of 20 or more measured according to the above is provided. The crimped long fiber spunbonded nonwoven fabric used as a reinforcing material in the present invention has flame retardancy and is excellent in flexibility and bulkiness as described in detail below.

  In the polypropylene-based crimped long fibers constituting the crimped long-fiber spunbonded nonwoven fabric (also referred to as “crimped long-fiber nonwoven fabric” in the present specification), the fineness is 0.5 to 10 dtex, preferably 1 to 6 dtex. . When the fineness is less than 0.5 dtex, exudation of the resin liquid to the surface of the reinforcing material is reduced, but physical properties such as strength and elongation of the crimped long fiber nonwoven fabric are lowered, and the cost is increased. On the other hand, when the fineness exceeds 10 dtex, the resin liquid is likely to ooze out to the surface of the reinforcing material, and the bending resistance becomes large. However, problems such as an increase in rigidity of the composite molded body formed as a cushion body or the like arise. The fineness is a value calculated from a number average fiber diameter of 20 fibers obtained by taking a 500 times magnified photograph with a microscope.

  The polypropylene-based crimped long fiber only needs to include a polypropylene structure exceeding 50% by mass. Polypropylene-based crimped continuous fibers have the advantage of excellent spinnability. The polypropylene-based crimped continuous fiber may be a core-sheath type composite fiber containing polypropylene, a side-by-side type composite fiber, or the like.

  The crimped long fiber nonwoven fabric may be formed using only the polypropylene-based crimped long fiber, but may contain other components as long as the effects of the present invention are not impaired. Other components include polyester fibers (for example, polyethylene terephthalate, polybutylene terephthalate, polymethylene terephthalate), fatty acid polyester fibers (for example, polylactic acid), polyamide fibers (for example, nylon 6). , Nylon 610, nylon 66) and fibers made of a copolymer of these polymers, and crimped long fibers and non-crimped long fibers made of polyphenylene sulfide fibers. More specifically, for example, for the purpose of improving the carbon neutral ratio, a polylactic acid fiber can be contained as the other component.

  The content of the polypropylene-based crimped long fibers in the crimped long-fiber nonwoven fabric is preferably 70 to 100% by mass. When the said content rate is less than 70 mass%, there exists a tendency for the effect of the softness | flexibility provision by using a polypropylene-type crimped continuous fiber to be small. The content is more preferably 80 to 100% by mass, and still more preferably 90 to 100% by mass. The said content rate is realizable by adjusting the mass ratio of each component which comprises this nonwoven fabric at the time of manufacture of a crimped continuous fiber nonwoven fabric.

  In addition, the fiber cross section of the polypropylene-based crimped long fiber may be a round cross section or an irregular cross section such as a Y shape, a V shape, a U shape, an I shape, a C shape, a cross shape, a star shape, or a combination thereof. . Resins are prevented from seeping out due to bulkiness, flexibility and steric hindrance, and 5% reduction in intermediate stress, which is difficult to achieve with a round cross-section, is possible when spinning at the same spinning speed range. From the viewpoint of being, it is preferable that the fiber cross section is an irregular cross section. In particular, by adding flame retardants, stabilizers, etc. to polypropylene resin and making the fiber cross section atypical, a 5% intermediate that is not seen in the round cross section shape in the same spinning speed region without reducing productivity. Reduction of stress can be realized. The reason why the 5% intermediate stress can be reduced is not clear, but by adding flame retardants, stabilizers, etc. and making it atypical cross section, it becomes easy to express the structural difference of the fiber cross section in the spinning process. It is assumed that the stress can be reduced. The fiber cross-sectional shape is particularly preferably L-shaped and V-shaped.

  The perimeter of the irregular cross section is 1.3 times or more of the perimeter of the round cross section having the same area as the atypical cross section in that the resin seepage preventing effect, the 5% intermediate stress reduction effect, and the shape followability are good. It is preferably 1.4 times or more, and the flatness expressed by the ratio of the long side to the short side of the rectangle circumscribing the irregular cross-sectional shape is preferably 1.3 or more, more preferably 1.4 or more, more preferably 1.5 or more.

  The circumference and flatness of the above-mentioned cross section are measured by measuring the yarn length from image analysis or pasting the yarn on the cross-section photo from the cross-sectional photo by an optical microscope or scanning electron microscope (SEM). It can be calculated by law.

  As the polypropylene-based crimped long fibers, those of a single type or fineness may be used, but those of different or different finenesses may be mixed or laminated as described later. The polypropylene-based crimped continuous fiber is preferably composed of a single polymer component from the viewpoint of costs such as spinnability and productivity. Moreover, it is preferable to laminate | stack and use this crimped continuous fiber from viewpoints, such as bulkiness and a softness | flexibility.

  Crimping can be manifested by forming structural differences in the fiber cross section in the cooling zone during spinning. Moreover, you may express a crimp using a latent crimped staple as a polypropylene-type crimped continuous fiber.

  The number of crimps of the polypropylene-based crimped long fibers is 2 to 40/25 cm. The number of crimps is a value observed under a load of 2 mg / dtex before partial thermocompression bonding and without external restraining force. The crimp in the polypropylene-based crimped long fiber is typically helical. The number of crimps is preferably 5 to 30 pieces / 25 mm. When the number of crimps is 2/25 cm or more, the bulkiness of the crimped long-fiber nonwoven fabric in the present invention is good, and abnormal noise generated by friction between a composite molded body such as a cushion body and a mounting steel material In addition, it is possible to obtain the effect of suppressing the resin and the effect of suppressing the seepage of the resin, the flexibility is good, and the shape following property to the molding die is good. On the other hand, when the number of crimps is 40 pieces / 25 cm or less, the yarn breakage at the time of spinning is reduced, and an effect of stable production can be obtained.

  When the polypropylene-based crimped long fiber is crimped in a spiral shape, the spiral crimp diameter is preferably 0.5 to 1.0 mm, and more preferably 0.6 to 1.0 mm. When the helical crimp diameter is less than 0.5 mm, the structural difference in the fiber cross section for the expression of crimp is large and the strength tends to decrease. On the other hand, when the helical crimp diameter exceeds 1.0 mm, the bulkiness tends to decrease.

  Note that the number of crimps and the spiral crimp diameter are as follows: the nonwoven fabric is collected before partial thermocompression bonding, and 10 fibers of 20 cm are collected from the nonwoven fabric so as not to be deformed. In a state where the load is suspended, the number of crimps between 25 mm and the outer diameter of the crimped portion are counted using a magnifying glass, and are obtained as an average value of n = 10. The number of crimps and the spiral crimp diameter can be preferably measured by an optical microscope or a magnifier from the viewpoint of ease of measurement.

  In the present invention, the crimped continuous fiber nonwoven fabric is thermocompression bonded so that the partial thermocompression bonding rate is 2 to 15%. The partial thermocompression bonding rate is preferably 3 to 12%. In this specification, the partial thermocompression bonding rate of the crimped continuous fiber non-woven fabric is the area ratio of the thermocompression bonding per unit area of the surface of the non-woven fabric. If the partial thermocompression bonding rate is less than 2%, the frequency of thermocompression bonding between fibers is small, and sufficient handling and strength cannot be obtained. On the other hand, when the partial thermocompression bonding rate exceeds 15%, the thermocompression bonding frequency between the fibers is high, and it is difficult to follow the shape of the concavo-convex mold with a high bending resistance and a hard texture. The partial thermocompression bonding ratio is the percentage of the area of the thermocompression bonding part to the sum of the thermocompression bonding part and the non-crimping part directly by image analysis from the surface photograph of the nonwoven fabric surface by an optical microscope or scanning electron microscope (SEM). It is a value measured by a method for obtaining, or a method for obtaining a percentage of the mass of the thermocompression bonding portion relative to the mass sum of the thermocompression bonding portion and the non-thermocompression bonding portion by cutting out the portion thermocompression bonded in the surface photograph.

In addition, it is preferable that the area per location of the said thermocompression bonding part is 0.1-5.0 mm < ² >, and it is more preferable that it is 0.2-3.0 mm < ² >. When the area is less than 0.1 mm ² , there is less fiber-to-fiber bonding and physical strength such as friction strength tends to be low, and when it exceeds 5.0 mm ² , the area of the thermocompression bonding portion is large and the texture is hard. Tend. Moreover, it is preferable that the minimum space | interval of a thermocompression bonding part is 1-10 mm, and it is more preferable that it is 2-8 mm. When the minimum distance is less than 1 mm, there is a tendency that the thermocompression bonding portions are many and the texture is hard. Moreover, it is preferable to distribute a thermocompression bonding part uniformly on the whole surface of a nonwoven fabric surface.

  The depth of the concave portion of the thermocompression bonding portion (that is, the depression formed by thermocompression bonding by hot embossing roll processing or the like) is preferably 0.2 to 2.0 mm, more preferably 0.3 to 1.5 mm. preferable. When the depth is less than 0.2 mm, there is a tendency that the bonding of the thermocompression bonding portion is small, and when the depth exceeds 2.0 mm, processing by an embossing roll or the like tends to be difficult.

  The area of the above-mentioned thermocompression bonding part is a method of obtaining the area of the thermocompression bonding part by image analysis from a surface photograph of the nonwoven fabric surface by an optical microscope or a scanning electron microscope (SEM), or a part that is thermocompression bonded by the surface photograph. Is a value measured by a method of converting from cutout mass measurement. On the other hand, the minimum interval is the shortest of the distances between one thermocompression bonding part and another thermocompression bonding part existing around it from a surface photograph of the nonwoven fabric by an optical microscope or a scanning electron microscope (SEM). It is a value measured by the method of finding things. Further, the depth of the concave portion is determined from the photograph of the cross section of the nonwoven fabric including the minimum thickness portion (usually the center portion of the thermocompression bonding portion) of the thermocompression bonding portion by an optical microscope or a scanning electron microscope (SEM). It is a value measured by determining the absolute value of the difference between the minimum thickness and the thickness of the non-thermocompression bonded portion.

  As a method for realizing the above-mentioned area, minimum interval, and recess depth of the thermocompression bonding portion, thermocompression bonding using an embossing roll having a convex portion having a size and a shape corresponding to the size and shape of the thermocompression bonding portion. Typically employable.

The basis weight of the crimped long fiber nonwoven fabric is 50 to 200 g / m ² . When the weight per unit area is less than 50 g / m ² , when a composite molded body such as a cushion body is formed, the resin liquid is likely to ooze out and the cushion body has little reinforcing effect. If the basis weight exceeds 200 g / m ² , it is difficult for the resin liquid to ooze out, but it is difficult to follow the shape of the mold for molding, the molding processability is inferior, and the cushion body has increased rigidity. Arise. The said basis weight becomes like this. Preferably it is 60-150 g / m < ² >, More preferably, it is 60-100 g / m < ² >.

  The thickness of the crimped long fiber nonwoven fabric is 0.5 to 2.0 mm. When the thickness is less than 0.5 mm, the resin liquid is likely to ooze out and the composite material has little reinforcing effect. On the other hand, when the thickness exceeds 2.0 mm, it is difficult for the resin liquid to ooze out, but it is difficult to follow the shape of the mold for molding, the molding processability is inferior, and the rigidity of the composite molded body increases. The thickness is preferably 0.7 to 1.5 mm. The said fabric weight and thickness are the values measured by the method prescribed | regulated by JIS-L-1906.

  The above-mentioned crimped long fiber non-woven fabric is obtained by, for example, partially crimping a crimped long fiber web expressed by a known spunbond method under cooling conditions directly under the spinning nozzle with a hot embossing roll, or latent crimped long fibers. The web can be produced by crimping by heat treatment and partially thermocompression bonding with a hot embossing roll.

The air permeability of the crimped long-fiber nonwoven fabric is 0.1 to 150 cm ³ / cm ² / sec, preferably 0.5 to 130 cm ³ / cm ² / sec. When the air permeability is less than 0.1 cm ³ / cm ² / sec, the resin liquid is difficult to exude, but the nonwoven fabric is densified and has a hard texture. On the other hand, when the said air permeability exceeds 150 cm < ³ > / cm < ² > / sec, it becomes easy to ooze out the resin liquid. The said air permeability is a value calculated | required according to the fragile form method of JIS-L-1906.

  The crimped continuous fiber nonwoven fabric has an oxygen index (LOI) measured according to JIS-K-7201 of 20 or more, preferably 21 or more. If the oxygen index is less than 20, the flame retardancy is not sufficient, such as failure in the horizontal combustion test of the combustion test of automobile interior materials (JIS D1201 FMVSS N0.302). The upper limit of the oxygen index is not particularly limited, but from the viewpoint of productivity, the oxygen index is preferably 40 or less, and more preferably 30 or less.

  Examples of means for setting the oxygen index to 20 or more include, for example, containing a flame retardant in a polypropylene-based crimped continuous fiber, containing a stabilizer, and using a flame retardant and a stabilizer in combination. It is done. The content of the flame retardant in the crimped continuous fiber nonwoven fabric, more preferably the content of the flame retardant in the polypropylene-based crimped continuous fiber, is preferably 0.1 to 10.0% by mass, more preferably 0.00. It is 2-5.0 mass%, More preferably, it is 0.3-3.0 mass%. A polypropylene-based crimped long fiber containing a flame retardant can be produced, for example, by spinning a resin previously kneaded with a flame retardant, or by applying a flame retardant to the surface of the crimped long fiber. A crimped continuous fiber non-woven fabric layer having excellent resistance is obtained. When the above contents of the flame retardant are each less than 0.1% by mass, the flame retardancy tends to be low, and when it exceeds 10.0% by mass, the flame retardancy is increased, but the strength of the fiber is decreased. Tend.

  Flame retardants include non-halogen phosphates such as trimethyl phosphate, triethyl phosphate, tributyl phosphate, triphenyl phosphate, tricresyl phosphate, special phosphate esters such as aliphatic polyphosphate, aromatic polyphosphate, and the like. Brominated flame retardants such as halogenated phosphoric acid esters, decabromodiphenyl oxide, octabromodiphenyl oxide, etc., melamine flame retardants, guanidine phosphate derivatives, phosphorous nitrogen compounds, aluminum hydroxide, magnesium hydroxide, calcium carbonate 1 type, or 2 or more types, such as inorganic fillers, etc. can be used. In particular, the reaction product of peroxidized 4-butylamino-2,2,6,6-tetramethylperidine and 2,4,6-trichloro-1,3,5-triazine is reacted with cyclohexane. Reaction product of N, N′-bis (3-aminopropyl) ethylenediamine and 1,3,5-triazine-2,4,6- (1H, 3H, 5H) A compound of trione and 1,3,5-triazine 2,4,6-triamine, and a melamine flame retardant such as melamine polyphosphate are preferably used. Furthermore, flame retardancy can also be improved by using, for example, a stabilizer such as NOR (N-alkoxy) sterically hindered amine as a stabilizer for preventing the polypropylene resin from being decomposed.

  Polypropylene crimped filaments are various additives usually added to polypropylene resins, such as phenolic and thioether-based antioxidants, light stabilizers, heat stabilizers, ultraviolet absorbers, pigments, inorganic fillers, An organic filler or the like can be contained within a range that does not impair the object of the present invention.

  The crimped long fiber nonwoven fabric is prepared by mixing a predetermined amount of each of the above-mentioned various additives that are usually added to a polypropylene resin composition having a desired composition according to the purpose and, if necessary, a normal polypropylene resin. Mixing using an apparatus such as a super mixer, a ribbon blender, a Banbury mixer, etc., and using a commonly used single screw extruder, twin screw extruder, Brabender or roll, etc., a melt kneading temperature of 150 ° C. to 250 ° C., preferably 180 ° It can be obtained by melt-kneading pelletizing at a temperature of from 230C to 230C.

  The bending resistance of the crimped long fiber nonwoven fabric is preferably 15 cm or less. When the bending resistance exceeds 15 cm, the texture becomes hard and the reinforcing material is not easily adapted to the concavo-convex mold for foam molding, and the moldability and the rigidity of the composite molded body tend to be low. The bending resistance is more preferably 12 cm or less, still more preferably 10 cm or less. On the other hand, from the viewpoint of handleability, the bending resistance is preferably 1 cm or more, more preferably 2 cm or more, and further preferably 3 cm or more. The bending resistance is a value measured according to JIS-L-1960, 45 ° cantilever method.

  The breaking elongation of the crimped continuous fiber nonwoven fabric is preferably 70% or more. When the elongation at break is 70% or more, the shape following property to the concavo-convex mold is good. The breaking elongation is more preferably 75% or more, and further preferably 80% or more. On the other hand, the breaking elongation is preferably 200% or less, more preferably 150% or less, and still more preferably 130% or less from the viewpoint of maintaining the shape.

The 5% intermediate stress value in terms of basis weight of the crimped long fiber nonwoven fabric is preferably 0.6 N / 5 cm or less, and in this case, the shape following property to the concavo-convex mold is good. The above-mentioned basis weight converted 5% intermediate stress value is obtained as a value obtained by dividing the intermediate stress at 5% elongation in tensile strength measurement by the basis weight. The 5% intermediate stress value in terms of the basis weight is more preferably 0.55 N / 5 cm or less, and further preferably 0.5 N / 5 cm or less. The 5% intermediate stress value in terms of basis weight is expressed by the following equation.
{5% intermediate stress value in terms of basis weight (N / 5 cm) = (5% intermediate stress (N / 5 cm)) / (weight per unit area (g / m ² ))}

  The fact that the above-mentioned breaking elongation of the crimped long-fiber non-woven fabric is 70% or more and that the above-mentioned basis weight conversion 5% intermediate stress value is 0.6 N / 5 cm or less is that the reinforcing material is familiar with the shape of the molding die. It is particularly suitable when the composite molded body of the present invention is used for urethane mold molding for automobile seats because it is easy to follow and conforms to the concavo-convex mold.

  The elongation at break and the 5% intermediate stress value are constant length tensile tests in each of the warp direction (that is, the winding direction, that is, the length direction of the nonwoven fabric) and the transverse direction (that is, the direction perpendicular to the warp direction) of the nonwoven fabric. It is a value measured by tensile strength measurement using a machine, and the above ranges of elongation at break and 5% intermediate stress value mean that both the values measured in the vertical direction and the horizontal direction are within the above range. .

The average apparent density of Mekuchijimicho fiber nonwoven fabric is preferably a 0.05~0.18g / cm ^3, more preferably 0.06~0.15g / cm ^3. If the average apparent density is less than 0.05 g / cm ^3, tend to resin exudation increases, if it exceeds 0.18 g / cm ^3, there is a tendency that shape-formable decreases. The average apparent density is calculated from the following formula, from the basis weight and thickness of the nonwoven fabric:
(Average apparent density) = (weight per unit area) / (thickness)
Is a value calculated according to The average apparent density can be controlled by changing the fineness of the fiber, the number of crimps, the basis weight, and the like.

  The crimped long fiber nonwoven fabric of the present invention may have a laminated structure composed of two or more layers of crimped long fiber nonwoven fabric. In this case, each layer can be of the same or different fineness composed of the same or different polymer components. When the crimped long fiber nonwoven fabric of the present invention is composed of two or more layers of crimped long fiber nonwoven fabric, the partial thermocompression bonding rate may be different for each layer, and the partial crimping rate of each layer is preferably 2 to 15%, More preferably, it is 3 to 13%, and further preferably 5 to 12%. However, the thermocompression bonding is typically performed by hot embossing roll processing or the like as will be described later, and it is preferable that the entire laminate is thermocompression bonded in a state where two or more layers of crimped continuous fiber nonwoven fabrics are laminated. In this case, the partial thermocompression bonding rates of the respective layers are the same.

  Moreover, it is preferable that the interlayer of two or more crimped long-fiber nonwoven fabric layers is joined by thermocompression bonding so that the partial thermocompression bonding rate is 2 to 15%. When the partial thermocompression bonding rate is less than 2%, the frequency of thermocompression bonding between fibers tends to be low, and the handleability and strength tend to be low. On the other hand, when the partial thermocompression bonding rate exceeds 15%, the frequency of thermocompression bonding between the fibers is high, and the shape tends to be difficult to follow the concave-convex mold with a high bending resistance and a hard texture. The partial thermocompression bonding ratio is more preferably 3 to 13%, still more preferably 5 to 12%. The partial thermocompression bonding between the layers can be realized simultaneously with the partial thermocompression bonding of each layer, typically by thermocompression bonding of the entire laminate in which two or more crimped long fiber nonwoven fabric layers are laminated.

The laminated structure composed of two or more crimped long-fiber nonwoven fabric layers can be, for example, a dense structure. For example, the average apparent a layer of coarse structure of density 0.03~0.12g / cm ^3, a layer of dense structure than the coarse structure average apparent density of 0.08~0.35g / cm ³ Can be formed.

  The reinforcing material in the composite molded body of the present invention can further include another layer laminated on at least one surface of the above-described crimped long fiber nonwoven fabric. Examples of other layers include non-crimped long-fiber nonwoven fabrics and synthetic resin films. The non-crimped long-fiber non-woven fabric gives an effect of suppressing the seepage of the resin liquid used for foam molding to the non-woven fabric surface. The fineness of the non-crimped long fibers constituting the non-crimped long-fiber nonwoven fabric is preferably 0.5 to 5 dtex, more preferably 0.7 to 4 dtex. When the fineness is less than 0.5 dtex, the flexibility is high, but the bulkiness tends to be low, and when it exceeds 5 dtex, the bulkiness is high, but the flexibility tends to be low. Further, the fiber cross section of the non-crimped long fiber is preferably a round cross section from the viewpoint of a dense configuration.

  Non-crimped long fibers can also be used for the purpose of improving the leachability of the resin to the reinforcing material surface during molding from the viewpoint of fiber dispersibility, fiber density, and the like. Non-crimped long fibers can be produced by the same method as the above-described crimped long fibers, except that crimps are not expressed.

  In the present invention, the crimped continuous fiber non-woven fabric and the non-crimped continuous fiber nonwoven fabric may form the above-described dense structure. For example, the crimped continuous fiber nonwoven fabric has the above-mentioned rough structure, The long fiber nonwoven fabric can have the dense structure.

  The synthetic resin film provides an advantage of better preventing the resin from exuding to the surface of the reinforcing material. Synthetic resin films include low density polyethylene, linear low density polyethylene, medium density polyethylene, high density polyethylene, ethylene-vinyl acetate copolymer, ethylene-α-olefin copolymer, other ethylene resins, polypropylene As the resin, polybutene resin, and olefin resin, one or more of ethylene-acrylic acid copolymer and ethylene-methyl acrylate copolymer can be used in combination. Furthermore, a microporous film formed by adding an inorganic filler such as calcium carbonate, calcium sulfate, barium sulfate or the like to an olefin-based resin and drawing it can be used.

  The thickness of the synthetic resin film is preferably 20 to 70 μm, more preferably 30 to 60 μm, from the viewpoint of moldability. In particular, in order to perform a preferable heat sealing process, it is preferable to use a laminated film composed of a plurality of types of films having a melting point difference of 10 to 50 ° C. As a laminated | multilayer film, what contains a low density polyethylene resin, ethylene-vinyl acetate copolymer resin, a polyamide-type resin etc. is used, for example.

  The synthetic resin film can be laminated in contact with the crimped long fiber nonwoven fabric and / or the non-crimped long fiber nonwoven fabric, but is preferably laminated in contact with the crimped long fiber nonwoven fabric from the viewpoint of mold followability. As a preferable layer configuration, a configuration in which crimped long-fiber nonwoven fabric / synthetic resin film / non-crimped long-fiber nonwoven fabric are laminated in this order can be given.

  Composite sheets of crimped long-fiber non-woven fabric and non-crimped long-fiber non-woven fabric and / or synthetic resin film are resin extrusion laminating method, tandem extrusion laminating method, dry laminating method such as urethane resin and ester resin, hot melt It can be formed by a powder resin laminating method, a hot melt resin curtain spraying method or the like, and a heat laminating method by contacting a heating roll. The adhesive force between the crimped long fiber nonwoven fabric or the non-crimped long fiber nonwoven fabric and the synthetic resin film is preferably 10 N / 25 mm or more, more preferably 15 N to 100 N / 25 mm. The adhesive force is a value measured by a 180 degree peel test method.

  Examples of the foam molding resin in the present invention include polyurethane resin, polyester resin, polyvinyl chloride resin, polyethylene resin and the like, and urethane foam molding resin is particularly preferable from the viewpoints of flexibility, durability, cushioning properties and the like. Specific examples of the urethane foam molding resin include foam molding by reacting a polyol component with an isocyanate heated to a temperature of 100 to 200 ° C.

  The composite molded body of the present invention is obtained by attaching a crimped continuous fiber non-woven fabric to an inner concavo-convex portion of a foam molding die, and then injecting a foam resin stock solution such as a urethane resin solution into an integral molding, for example, for automobiles and furniture. It can be formed as a cushion body for a seat. The composite molded body of the present invention may be formed of only a foam molded resin, a crimped long fiber nonwoven fabric, and an arbitrary non-crimped long fiber nonwoven fabric and / or a synthetic resin film. It may be combined.

  The present invention will be described based on examples. The measurement method is as follows.

(1) Fineness (dtex):
A 500 times magnified photograph was taken with a microscope, and the fineness was calculated from the number average fiber diameter of 20 fibers.

(2) Number of crimps and spiral crimp diameter:
A non-woven fabric was sampled before partial thermocompression bonding, and 10 single yarns of 20 cm were collected from the nonwoven fabric so as not to be deformed. Then, a weight of 2 mg / dtex of fiber was suspended on one side of the single yarn, and the width was 25 mm. The number of crimps and the outer diameter of the crimped portion were counted using a magnifying glass, and the average value of n = 10 was determined as the number of crimps and the spiral crimp diameter.

(3) Weight per unit area (g / m ² ):
A sample of 20 cm in length and 25 cm in width was cut out at three places to measure the mass, and an average value at three places was converted into a mass per unit. (Conforms to JIS-L-1906)

(4) Thickness (mm):
According to JIS-L-1906, 10 places were measured with a load of 10 kPa with a pressurizer having a diameter of 10 mm, and the average value was taken as the thickness.

(5) Area per partial thermocompression bonding part, interval between partial thermocompression bonding parts, and partial thermocompression bonding rate:
<The area per partial thermocompression bonding part and the space | interval of a partial thermocompression bonding part>
A partial thermocompression bonding part is cut out by n = 10 one by one from an enlarged photograph of the nonwoven fabric surface using a Keyence Co. (VE-8800) scanning electron microscope, and the mass is measured. It was measured as the area per piece. On the other hand, the minimum distance between one partial thermocompression bonding part and the nearest other partial thermocompression bonding part existing around it is obtained, and this is obtained with n = 10 for different partial thermocompression bonding parts, and the average value thereof Was measured as the interval between the partial thermocompression bonding portions.
<Partial thermocompression bonding rate>
From the magnified photograph of the nonwoven fabric surface using a Keyence Corporation (VE-8800) scanning electron microscope, the ratio of the area of the partial thermocompression bonding portion to the total area of the nonwoven fabric was calculated with a 30-fold field of view.
Partial thermocompression rate = (total area of partial crimped part) / (total area of non-woven fabric)

(6) Breathability:
The measurement was performed according to the fragile method of the general long fiber nonwoven fabric test method of JIS-L-1906.

(7) Oxygen index:
It measured according to the oxygen index measuring method of JIS-K-7201.

(8) Bending softness: Determined according to JIS-L-1906 45 ° cantilever method.

(9) Elongation at break (%):
Using a constant-length tensile tester, cut a sample width of 5 cm and a length of 30 cm, measure the tensile elongation at three vertical and horizontal positions at a gripping interval of 20 cm and a tensile speed of 10 cm / min, and determine the vertical and horizontal elongation at break. The average value for each of three locations was taken as the elongation at break.

(10) 5% intermediate stress value in terms of basis weight (N / 5 cm):
Using a constant-length tensile tester, cut a sample width of 5 cm and a length of 30 cm, measure the tensile strength at three vertical and horizontal positions at a gripping interval of 20 cm and a tensile speed of 10 cm / min, and measure the stress at 5% elongation. The average value for each of the three locations was taken as 5% intermediate stress, and the value obtained by dividing this by the basis weight was taken as the 5% intermediate stress value in terms of basis weight.

(11) Average apparent density (g / cm ³ ):
Average apparent density = (weight per unit area) / (thickness)
It calculated | required according to the formula of.

[Example 1]
Using a spunbond melt spinning machine, a polypropylene resin (PP) containing 1.5% by mass of a phosphoric ester-based flame retardant {1,3-phenylenebis (2,6 dimethylphenyl phosphate): manufactured by Asahi Denka Kogyo} , Melting point 165 ° C.) is discharged from the odd-shaped nozzle spout, and the yarn is cooled from the side by a cooling device from a position 130 mm below the spout, thereby causing a difference in the structure of the yarn due to the cooling difference. Polypropylene crimped long fiber (fineness: 3 dtex, number of crimps: 23 pieces / 25 mm, spiral crimped diameter: 0.7 mm) having a V-shaped fiber cross section (weight per unit) 100 g / m ² ) was obtained.

Partially thermocompression-bonding roll in which the above-described crimped long fiber web is combined with an embossing roll and a surface smoothing roll in which convex portions having an area of 1.2 mm ² on the entire surface are staggered with a minimum spacing of 4.6 mm. (The temperature was 135 ° C., the linear pressure was 300 N / cm, and the partial thermocompression bonding rate was 8%) to obtain a crimped continuous fiber non-woven fabric partially thermocompression bonded.

The properties of the obtained crimped long-fiber nonwoven fabric are as follows: area per thermocompression bonding part: 1.2 mm ² , minimum distance between thermocompression bonding parts: 4.6 mm, partial thermocompression bonding rate: 8%, basis weight: 100 g / m ² , Thickness: 0.82 mm, Breathability: 35 cm ³ / cm ² / sec, Oxygen Index (LOI): 25, Bending Softness: 7.5 cm, Elongation at Break: Vertical 85% Horizontal 110%, 5% Intermediate Stress Value: 35 N / 5 cm in the vertical direction, 7 N / 5 cm in the horizontal direction, 5% intermediate stress value in terms of basis weight: Vertical 0.35 N / 5 cm, horizontal 0.07 N / 5 cm, average apparent density: 0.12 g / cm ³ .

  Using the obtained crimped long fiber nonwoven fabric, a seat sheet for an automobile was molded. As a result of attaching the non-woven fabric to the inside of the foaming mold, there was a soft texture, good shape followability to the mold, and good mounting to the mold. Next, a two-component type urethane resin was injected into the mold and foamed. The obtained composite molded body was released from the molding die, and the resin exuded on the surface of the nonwoven fabric was observed, but no resin exuded. In addition, when the presence or absence of abnormal noise due to friction was examined by sitting and moving on a seat, it was found that a good composite molded product was obtained with no abnormal noise.

[Example 2]
In the production of the crimped continuous fiber nonwoven fabric of Example 1, as a flame retardant, peroxidized N-butyl-2,2,6,6-tetramethyl-4-piperidineamine and 2,4,6,- A flame retardant (Ciba) which is a reaction product of a product obtained by reacting a reaction product of trichloro-1,3,5, -triazine with cyclohexane and N, N′-bis (3-aminopyrrolyl) ethylenediamine (Specialty Chemicals Co., Ltd.) 1.0 mass%, and the polypropylene crimped continuous fiber web has a basis weight of 70 g / m ² , the number of crimps: 17 pieces / 25 mm, and the spiral crimped diameter: 0. A crimped continuous fiber non-woven fabric was obtained in the same manner as in Example 1 except that the spinning conditions were changed to 7 mm and a fineness of 2 dtex.

The properties of the obtained nonwoven fabric were as follows: area per thermocompression bonding part: 1.2 mm ² , minimum distance between thermocompression bonding parts: 4.6 mm, partial thermocompression bonding rate: 8%, basis weight: 70 g / m ² , thickness: 0.60 mm, Breathability: 55 cm ³ / cm ² / sec, Oxygen index: 24, Bending softness: 5.3 cm, Elongation at break: Vertical 85% Horizontal 110%, 5% Intermediate stress: Vertical 19N / 5cm Horizontal 4N The intermediate stress value of 5% in terms of basis weight: vertical 0.27 N / 5 cm, horizontal 0.04 N / 5 cm, and average apparent density: 0.12 g / cm ³ .

  Using the obtained crimped long fiber nonwoven fabric, a seat sheet for an automobile was molded. As a result of attaching the non-woven fabric to the inside of the foaming mold, there was a soft texture, good shape followability to the mold, and good mounting to the mold. Next, a two-component type urethane resin was injected into the mold and foamed. The obtained composite molded body was released from the molding die, and the resin exuded on the surface of the nonwoven fabric was observed, but no resin exuded. In addition, when the presence or absence of abnormal noise due to friction was examined by sitting and moving on a seat, it was found that a good composite molded product was obtained with no abnormal noise.

[Examples 3 and 4]
(Polypropylene crimp) in the same manner as in Example 2 except that the flame retardant content in Example 2 was changed to 0.5 mass% (Example 3) and 0.3 mass% (Example 4). In Example 3, the fine fiber has a fineness: 2 dtex, a number of crimps: 16 pieces / 25 cm, and a helical crimp diameter: 0.7 mm. In Example 4, a fineness: 2 dtex, the number of crimps: 15 pieces / 25 cm. , Spiral crimped diameter: 0.8 mm), a crimped continuous fiber web and a crimped continuous fiber nonwoven fabric were obtained. The properties of the obtained crimped long fiber nonwoven fabric are as follows.

Example 3: Area per thermocompression bonding part: 1.2 mm ² , Minimum distance between thermocompression bonding parts: 4.6 mm, partial thermocompression bonding rate: 8%, basis weight: 70 g / m ² , thickness: 0.6 mm, Breathability: 54 cm ³ / cm ² / sec, oxygen index (LOI): 22, bending resistance: 5.5 cm, elongation at break: vertical 89% horizontal 116%, 5% intermediate stress value: vertical 23 N / 5 cm, horizontal 3.5 N / 5 cm, basis weight converted 5% intermediate stress value: vertical 0.32 N / 5 cm, horizontal 0.05 N / 5 cm, average apparent density: 0.12 g / cm ³
Example 4: Area per thermocompression bonding part: 1.2 mm, Minimum interval between thermocompression bonding parts: 4.6 mm, partial thermocompression bonding rate: 8%, basis weight: 70 g / m ² , thickness: 0.57 mm, ventilation Property: 56 cm ³ / cm ² / sec, oxygen index (LOI): 21, bending resistance: 6.0 cm, elongation at break: vertical 86% horizontal 115%, 5% intermediate stress value: vertical 28 N / 5 cm, horizontal 4 N / 5 cm, 5% intermediate stress value in terms of basis weight: Vertical 0.4 N / 5 cm Horizontal 0.06 N / 5 cm, Average apparent density: 0.12 g / cm ³

  Using the crimped long-fiber nonwoven fabric obtained in Examples 3 and 4, a seat sheet for an automobile was molded. As a result of attaching the non-woven fabric to the inside of the foaming mold, there was a soft texture, good shape followability to the mold, and good mounting to the mold. Next, a two-component type urethane resin was injected into the mold and foamed. The obtained composite molded body was released from the molding die, and the resin exuded on the surface of the nonwoven fabric was observed, but no resin exuded. In addition, when the presence or absence of abnormal noise due to friction was examined by sitting and moving on a seat, it was found that a good composite molded product was obtained with no abnormal noise.

[Comparative Example 1]
Using a spunbond melt spinning machine, polypropylene resin (PP, melting point 165 ° C.) is discharged from the spinning nozzle, and the yarn is cooled from the side using a cooling device under the spinning nozzle. A polypropylene non-crimped long fiber web having a weight per unit area of 100 g / m ² (fineness of 3 dtex) was obtained.

Partial thermocompression-bonding roll (temperature: 135 ° C., linear pressure: 300 N / mm), which is a combination of embossing rolls and surface smoothing rolls that have staggered arrangement of convex parts with an area of 1.2 mm ² on the entire surface with a minimum spacing of 4.6 mm (cm, partial thermocompression rate 8%), the non-crimped long fiber web was passed through to obtain a partially non-crimped polypropylene non-crimped long-fiber nonwoven fabric.

The characteristics of the obtained non-crimped long-fiber nonwoven fabric were as follows: area per thermocompression bonding part: 1.2 mm, minimum distance between thermocompression bonding parts: 4.6 mm, partial thermocompression bonding rate: 8%, basis weight: 100 g / m ² , Thickness: 0.42 mm, Breathability: 25 cm ³ / cm ² / sec, Oxygen Index (LOI): 17, Bending Softness: 13.5 mm, Elongation at Break: Vertical 50% Horizontal 65%, 5% Intermediate Stress Value: Vertical 85 N / 5 cm, horizontal 35 N / 5 cm, basis weight conversion 5% intermediate stress value: Vertical 0.85 N / 5 cm Horizontal 0.35 N / 5 cm, average apparent density: 0.24 g / cm ³ .

  Using the obtained non-woven fabric, a molding process for a seat sheet for an automobile was performed. As a result of attaching the nonwoven fabric to the inside of the foam molding die, the texture was hard, the shape following property to the die was poor, and the nonwoven fabric was poorly attachable to the die, resulting in poor molding processability. Next, a two-component type urethane resin was injected into the mold and foamed. The obtained composite molded body was released from the molding die, and the presence or absence of the urethane resin on the nonwoven fabric surface was observed. However, a composite molded product having a particularly poor shape was obtained.

  The composite molded body of the present invention is flame retardant and comprises a reinforcing material using crimped fibers rich in bulkiness and flexibility, so that a urethane foam resin such as a vehicle seat is molded. The resin-reinforcing material composite molded body is preferably used. The reinforcing material used in the composite molded body of the present invention can easily follow the concavo-convex mold and can prevent the resin used for foam molding from seeping out onto the reinforcing material surface. Therefore, according to this invention, generation | occurrence | production of the noise by the friction etc. of composite molded bodies, such as a foaming molding sheet | seat and a cushion body, and attachment steel material can be prevented. Therefore, the composite molded body of the present invention can be suitably used for a wide range of applications such as vehicle interior materials.

Claims (6)

A composite molded body having a foam molding resin and a crimped long fiber spunbond nonwoven fabric that is a reinforcing material of the foam molding resin,
The crimped long fiber spunbonded nonwoven fabric is composed of at least a polypropylene-based crimped long fiber having a fineness of 0.5 to 10 dtex and a number of crimps of 2 to 40 pieces / 25 mm,
The crimped long fiber spunbond nonwoven fabric is thermocompression bonded with a partial thermocompression bonding rate of 2 to 15%,
The crimped long fiber spunbond nonwoven fabric is measured according to a basis weight of 50 to 200 g / m ² , a thickness of 0.5 to 2.0 mm, a gas permeability of 0.1 to 150 cm ³ / cm ² / sec, and JIS-K-7201. A composite molded article having an oxygen index (LOI) of 20 or more.   The composite molded body according to claim 1, wherein the crimped long fiber spunbonded nonwoven fabric contains 0.1 to 10% by mass of a flame retardant.   The composite molded body according to claim 1 or 2, wherein a content of the polypropylene-based crimped long fibers in the crimped long-fiber spunbonded nonwoven fabric is 70 to 100% by mass.   The composite molded body according to any one of claims 1 to 3, wherein the crimped long fiber spunbonded nonwoven fabric has a bending resistance of 15 cm or less.   The composite molded body according to any one of claims 1 to 4, wherein the crimped long fiber spunbonded nonwoven fabric has a breaking elongation of 70% or more.   The composite molded body according to claim 1, wherein the foam molding resin is a urethane foam molding resin.