JP2012112072A - Fiber structure, composite fiber structure, cushioning material, acoustic material and heat insulation material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fiber structure and a composite fiber structure with less environmental load as well as good pressure-resistant distribution and light weight and less bottoming feeling when it is used as a cushioning material, and with extremely good performance as well as less see-through appearance and less quality variation when it is used as an acoustic material or a heat insulation material, and to provide the cushioning material, the acoustic material and the heat insulation material using the same.SOLUTION: A fiber structure comprises a main fiber and a heat-adhesive short fiber at a weight ratio of 90/10 to 10/90 that are arranged in a thickness direction of the fiber structure. The fiber structure has a scattered thermally-fused point at which the heat-adhesive short fibers are crossed with each other and/or a scattered thermally-fused point at which the heat-adhesive short fiber and the main fiber are crossed. A polyester-based recovered fiber is contained as the main fiber.

Description

  The present invention can not only reduce the environmental load, but also when used as a cushioning material, the pressure distribution is good and lightweight, and there is little feeling of bottoming. When used, the present invention relates to a fiber structure, a composite fiber structure, a cushioning material, a sound absorbing material, and a heat insulating material, which have extremely good performance, no sense of see-through, and little quality variation.

  Conventionally, as a cushioning material, sound-absorbing material, heat insulating material, etc., after blending heat-adhesive short fibers and ordinary polyester fibers, heat treatment is performed once or the fiber material is inserted into a mold or the like without heat treatment, and then heat treatment is performed. The fiber structure obtained by doing this, and further, the fiber structure in which fibers are arranged in the thickness direction are used (for example, see Patent Document 1, Patent Document 2, and Patent Document 3). .

  On the other hand, in recent years, in order to reduce environmental load, it has been proposed to configure a fiber structure using repellent fibers (see, for example, Patent Document 4, Patent Document 5, and Patent Document 6). A repellent fiber is a fiber product that has been recovered from used clothing, etc., and has been cut back and returned to short fibers using a repellent facility. Naturally, synthetic fibers, etc. are usually randomly selected as fibers. It is a mixed thing.

JP-A-8-318066 JP 2010-144362 A JP 2001-207366 A JP 2001-316963 A JP 2004-27383 A JP-A-8-260312

  The purpose of the present invention is not only to reduce the environmental load, but also when used as a cushioning material, the pressure distribution is good and lightweight, and the feeling of bottoming is low, and it is used as a sound absorbing material and a heat insulating material. In some cases, the present invention provides a fiber structure, a composite fiber structure, a cushioning material, a sound absorbing material, and a heat insulating material, which have extremely good performance, no sense of see-through, and little variation in quality.

  The present invention relates to a polyester repellent fiber as a main fiber in a fiber structure composed of main fibers and heat-adhesive short fibers, and these main fibers and heat-adhesive short fibers arranged in the thickness direction of the fiber structure. When fibers are used, not only can the environmental load be reduced, but when the fiber structure is used as a cushioning material, the pressure distribution is good and light, and the feeling of bottoming is reduced. When the structure is used as a sound-absorbing material or a heat-insulating material, it has been found that the performance is extremely good and there is no sense of see-through, and that the variation in quality is reduced, and the present invention has been completed by further intensive studies. .

  Thus, according to the present invention, “the main fiber and the heat-adhesive short fiber are blended so that the weight ratio is 90/10 to 10/90, and the heat-adhesive short fibers are heat-sealed in a crossed state. And / or the heat-bonding short fibers and the main fibers are scattered, and the main fibers and the heat-bondable short fibers have a fiber structure. There is provided a fiber structure that is arranged in the thickness direction of the body, wherein the main fiber includes polyester-based repellent fibers.

In that case, it is preferable that the said polyester-type repulsion fiber contains the polyester-type repulsion fiber whose single fiber fineness is 50 dtex or more. Moreover, it is preferable that 10 weight% or more of polyester type | system | group rebellious fiber whose single fiber fineness is 50 dtex or more is contained with respect to the total weight of a polyester-type repulsive fiber. Further, the heat-adhesive short fiber is composed of a heat-adhesive component and a non-heat-adhesive component, and the heat-adhesive component has a melting point lower by 40 ° C. or more than the polymer component constituting the non-heat-adhesive component. It is preferable to have. Moreover, it is preferable that the average density of a fiber structure exists in the range of 5-60 kg / m < ³ >. Moreover, it is preferable that the thickness of a fiber structure exists in the range of 2-200 mm.

  Moreover, according to this invention, the composite fiber structure by which the sheet-like thing with a thickness of 0.01 mm or more is bonded to the said fiber structure is provided. Such a composite fiber structure is preferably subjected to hot pressing.

Moreover, according to this invention, the cushion material which uses the said fiber structure or composite fiber structure is provided.
Moreover, according to this invention, the sound-absorbing material formed using the said fiber structure or composite fiber structure is provided.
Moreover, according to this invention, the heat insulating material which uses the said fiber structure or composite fiber structure is provided.

  According to the present invention, not only can the environmental load be reduced, but also when used as a cushioning material, the pressure distribution is good and lightweight, and there is little feeling of bottoming, and it was used as a sound absorbing material and a heat insulating material. In some cases, a fiber structure, a composite fiber structure, a cushioning material, a sound absorbing material, and a heat insulating material can be obtained that have extremely good performance, no sense of see-through, and little quality variation.

It is a figure for demonstrating the direction of the arrangement | sequence of a heat bondable composite staple fiber or an inelastic staple fiber in a fiber structure. It is a figure which shows typically a mode that the sheet-like object is bonded together to the fiber structure through the contact bonding layer.

Hereinafter, embodiments of the present invention will be described in detail. It is important that the main fibers used in the present invention include polyester-based repellent fibers.
Here, the repellent fiber is a fiber product that has been recovered from used clothing, etc., and is cut back and returned to short fibers using a repellent facility. The fibers are usually natural fibers, synthetic fibers, etc. Are randomly mixed.

  The polyester type repellent fibers used in the present invention can be obtained by sorting, collecting and recycling them. Since work clothes, curtain fabrics, car skins, etc. are mainly made of polyester-based materials, those produced in the manufacturing process can be used, or the fabrics that have been sorted and collected can be disassembled and rebound. The hair can be used. In addition, in this manufacturing process, using the thing which has a problem in quality, such as a long fiber, a short fiber, and dyeing | staining generate | occur | produced before making a fabric.

  Polyester terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyhexamethylene terephthalate, polytetramethylene terephthalate, poly-1,4-dimethylcyclohexane terephthalate, polyethylene naphthalate, polypivalolactone, Preferable examples include rebellious fibers made of polylactic acid (PLA), stereocomplex polylactic acid, or copolymers thereof, or rebellious composite fibers containing the polymer component as at least one component. In addition, a coloring agent, various stabilizers, an ultraviolet absorber, a thickening branching agent, a matting agent, and other various improving agents may be blended in such a polymer.

  There is no limitation on the single fiber fineness in the polyester-based repellent fiber, but if a polyester-based repetitive fiber having a single fiber fineness of 50 dtex or more (more preferably 50 to 300 dtex) is included, the fiber structure is used as a cushioning material. When the fiber structure is used as a sound absorbing material or a heat insulating material, the effect of reducing settling in the thickness direction is preferably improved. In particular, when 50 dtex or more (more preferably 50 to 300 dtex) of polyester repellent fibers are contained in an amount of 10 wt% or more (more preferably 10 to 50 wt%) with respect to the total weight of the polyester repellent fibers. The effect is further improved, which is more preferable.

  Moreover, in the said polyester-type repellent fiber, it is preferable that it is in the range of 10-100 mm as fiber length. If the fiber length is less than 10 mm, sufficient rigidity may not be obtained. Moreover, in a card | curd process, it becomes a factor of omission between rollers and there exists a possibility that workability may worsen. On the contrary, if the fiber length is longer than 100 mm, process stability may be impaired, and at the same time, a nep (pillar) is likely to occur, and the appearance and texture may be deteriorated.

  Next, the constitution of the heat-adhesive short fiber may be a single component, but preferably a heat-adhesive composite short fiber comprising two or more components of a heat-adhesive component and a non-heat-adhesive component is preferable. In that case, it is preferable that a thermoadhesive component has melting | fusing point lower 40 degreeC or more than the polymer component which comprises a non-thermoadhesive component. If this temperature difference is less than 40 ° C., the adhesion is insufficient, and there is a risk that the fiber structure will be dull and difficult to handle.

  Here, examples of the polymer arranged as the heat-adhesive component include polyurethane elastomers, polyester elastomers, inelastic polyester polymers and copolymers thereof, polyolefin polymers and copolymers thereof, polyvinyl alcohol polymers, and the like. Examples of polyurethane elastomers include low melting point polyols having a molecular weight of about 500 to 6000, such as dihydroxy polyether, dihydroxy polyester, dihydroxy polycarbonate, dihydroxy polyester amide, and the like, and organic diisocyanates having a molecular weight of 500 or less, such as p, p'-diphenylmethane diisocyanate, tolylene diisocyanate, isophorone diisocyanate hydrogenated diphenylmethane isocyanate, xylylene isocyanate, , 6-diisocyanate methyl caproate, hexamethylene diisocyanate, molecular weight of 500 or less chain extender, for example a polymer obtained by a reaction between glycol aminoalcohol or triol.

  Among these polymers, particularly preferred is a polyurethane using polytetramethylene glycol, poly-ε-caprolactam or polybutylene adipate as a polyol. Examples of the organic diisocyanate in this case include p, p'-bishydroxyethoxybenzene and 1,4-butanediol.

  In addition, as a polyester-based elastomer, a polyetherester copolymer obtained by copolymerizing thermoplastic polyester as a hard segment and poly (alkylene oxide) glycol as a soft segment, more specifically, terephthalic acid, isophthalic acid, phthalic acid Alicyclic dicarboxylic acids such as naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid, diphenyl-4,4′-dicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, succinic acid, oxalic acid, At least one dicarboxylic acid selected from aliphatic dicarboxylic acids such as adipic acid, sebacic acid, dodecanedioic acid, dimer acid, or ester-forming derivatives thereof, 1,4-butanediol, ethylene glycol trimethylene glycol, Tetramethylene glycol, Aliphatic diols such as tamethylene glycol, hexamethylene glycol neopentyl glycol, decamethylene glycol, or alicyclic diols such as 1,1-cyclohexanedimethanol, 1,4-cyclohexanedimethanol, tricyclodecane methanol, or the like At least one diol component selected from ester-forming derivatives and the like, and polyethylene glycol, poly (1,2- and 1,3-polypropylene oxide) glycol, poly (tetramethylene oxide) having an average molecular weight of about 400 to 5000 ) Consists of at least one of poly (alkylene oxide) glycols such as glycols, copolymers of ethylene oxide and propylene oxide, copolymers of ethylene oxide and tetrahydrofuran, etc. It can be mentioned terpolymer.

  In particular, from the viewpoint of adhesiveness, temperature characteristics, and strength, a block copolymer polyether ester having polybutylene terephthalate as a hard component and polyoxybutylene glycol as a soft segment is preferable. In this case, the polyester portion constituting the hard segment is polybutylene terephthalate in which the main acid component is terephthalic acid and the main diol component is a butylene glycol component. Of course, part of this acid component (usually 30 mol% or less) may be substituted with another dicarboxylic acid component or oxycarboxylic acid component, and part of the glycol component (usually 30 mol% or less) is also butylene. It may be substituted with a dioxy component other than the glycol component. Further, the polyether portion constituting the soft segment may be a polyether substituted with a dioxy component other than butylene glycol.

  Copolyester polymers include aliphatic dicarboxylic acids such as adipic acid and sebacic acid, aromatic dicarboxylic acids such as phthalic acid, isophthalic acid and naphthalenedicarboxylic acid and / or fats such as hexahydroterephthalic acid and hexahydroisophthalic acid. A co-polymer containing a predetermined number of cyclic dicarboxylic acids and aliphatic or alicyclic diols such as diethylene glycol, polyethylene glycol, propylene glycol, and paraxylene glycol, with addition of oxyacids such as parahydroxybenzoic acid as desired. Polymerized esters and the like can be mentioned. For example, polyesters obtained by adding and copolymerizing isophthalic acid and 1,6-hexanediol in terephthalic acid and ethylene glycol can be used. Polylactic acid or the like can also be used. Furthermore, as the polyester component, biopolyester using raw materials made from plants may be used.

Examples of the polyolefin-based polymer include low density polyethylene, high density polyethylene, and polypropylene.
Among the above heat-adhesive components, polyester-based elastomers are particularly preferable for cushion applications. For sound absorption and heat insulation, a copolyester polymer is particularly preferable. In addition, various stabilizers, ultraviolet absorbers, thickening branching agents, matting agents, coloring agents, other various improving agents, and the like may be blended in the above-described polymer as necessary.

  In the heat-bonded composite short fibers, the non-adhesive component is represented by polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalene dicarboxylate (PEN), polylactic acid (PLA), and copolymers thereof. Polyester such as nylon 6, nylon 6 and nylon 66, other polyolefins, acrylic, and the like are exemplified, and polyester is preferably exemplified. In that case, it is preferable that the heat-adhesive component occupies at least a half of the surface area. The weight ratio of the heat-adhesive component and the non-adhesive component is preferably in the range of 30/70 to 70/30 as a composite ratio. The form of the heat-adhesive composite short fiber is not particularly limited, but the heat-adhesive component and the non-adhesive component are preferably side-by-side and core-sheath types, more preferably the core-sheath type. In this core-sheath-type heat-adhesive composite short fiber, the non-adhesive component becomes the core and the heat-adhesive component becomes the sheath, but the core may be concentric or eccentric. In addition, environmental impact is further reduced by using polyester that has been material recycled by bottle recycling or a polymer that has been chemically recycled. Furthermore, as the polyester, a biopolyester using raw materials made from plants may be used.

In such a heat-adhesive composite short fiber, the single fiber diameter is preferably in the range of 20 to 50 μm. The fiber length is preferably cut to 10 to 100 mm.
Moreover, it is preferable that crimps, such as a mechanical crimp by a normal indentation crimper system, are given to such heat-adhesive composite short fibers.

  In the fiber structure of the present invention, the total weight of the polyester-based repellent fiber fiber and the polyester-based heat-bonded composite short fiber (adhesive composite short fiber containing at least a polyester component as one component) is 60% or more relative to the fiber structure weight ( More preferably, it is 60 to 100%). If the weight ratio is less than 60% by weight, the high strength, easy moldability, flame retardancy, etc., which are the characteristics of polyester fibers, may not be exhibited.

In the fiber structure of the present invention, the main fiber including the polyester-based repellent fiber fiber and the heat-adhesive short fiber are mixed so that the weight ratio is 90/10 to 10/90, and the heat-adhesive short fiber is obtained. Fixing points thermally fused in a state where the fibers intersect with each other and / or fixing points thermally fused in a state where the heat-adhesive short fibers and the main fibers intersect with each other, and the main body This is a fiber structure in which fibers and heat-bondable short fibers are arranged in the thickness direction of the fiber structure.
Here, “arranged in the thickness direction” means that the total number of fibers arranged in parallel to the thickness direction of the fiber structure is (B) and the thickness direction of the fiber structure is On the other hand, when (A) is the total number of fibers arranged vertically, B / A is 1.5 or more.

  That is, the fibers constituting the conventional fiber structure are arranged in the direction perpendicular to the thickness direction of the fiber structure, that is, in the plane direction, whereas in the present invention, the constituent fibers are the thickness of the fiber structure. Since the fibers are arranged in parallel to the vertical direction, it is possible to obtain a fiber structure having excellent cushion feeling, high resilience, light weight, and good moldability. When the constituent fibers are arranged in the plane direction of the fiber structure, the effect of the present invention is not sufficiently achieved, which is not preferable. In particular, polyester-based fibers are fibers that are generally more rigid than natural fibers, but when they are repetitive fibers, they contain a short fiber length, so that they are perpendicular to the thickness direction of the fiber structure (thickness direction and horizontal). It is difficult to increase the bulk. However, by arranging the fibers contained in the fiber structure in the thickness direction of the fiber structure, even if the fiber has a short fiber length, the contribution ratio of the rigidity of the fiber itself is high, and the bulk is increased and the weight is reduced. Can be achieved.

  The method for producing such a fiber structure is not particularly limited, and any conventionally known method may be arbitrarily adopted. For example, after blending non-heat-adhesive composite short fibers and heat-adhesive composite short fibers and spinning them as a uniform web with a roller card, heat-treat the web while folding it into an accordion to form a fixing point by heat fusion The method of making it preferable is illustrated. For example, a device disclosed in Japanese Translation of PCT International Publication No. 2002-516932 (for example, commercially available Strut equipment manufactured by Struto Corporation) may be used.

The average density of the fiber structure thus obtained is preferably in the range of 5 to 60 kg / m ³ . If the density is less than 5 kg / m ³ , sufficient rigidity may not be obtained. On the contrary, when the average density exceeds 60 kg / m ³ , it becomes plate-shaped and not only becomes difficult to be molded thereafter, but also has poor cushioning properties and becomes hard, which may not be used as a fiber structure. There is also a risk of weight increase.

  In the fiber structure of the present invention, the thickness of the entire fiber structure is preferably in the range of 2 to 200 mm (more preferably 3 to 100 mm). When the thickness is within this range, the cushioning property is also excellent, so it is suitable as a vehicle seat for automobile wading, furniture cushions, bed mattresses, type futons, and automobiles, bullet trains, trains, etc. Can be used. Furthermore, it is preferable that the thickness is within this range because it exhibits not only excellent sound absorption / characteristics but also excellent rigidity.

  In such a fiber structure, not only can the environmental load and the production cost be reduced by using the polyester-based repellent fibers, but the polyester-based repellent fibers include fibers having various single fiber finenesses. Therefore, when used as a cushioning material, it has a good pressure distribution and is lightweight, has little bottoming, and does not show through. Will be less. In addition, since the fiber strength of polyester fibers is high compared to the strength of natural fibers such as cotton and wool, in the fluff process and fiber structure manufacturing process, cotton falling down under the equipment due to fiber cutting or fluffing up from the equipment Compared with the repellent fibers mainly composed of natural fibers, the number is greatly reduced. In addition, since the uniformity of the polyester-based repellent fibers is superior to the natural fiber repellent fibers, the spot weight is reduced in the product when the fiber structure is obtained. Moreover, since the heat setting property of the polyester fiber is easy, when the fiber structure is used to form a molded product, the moldability is improved. Moreover, a flame retardance can also be improved by using a polyester-type fiber. In addition, since the collected polyester-based repelled fibers are generally colored, it is possible to prevent the white polyester from being seen through when a low-weight skin fabric is bonded.

  Such a fiber structure may be subjected to normal dyeing or raising. Furthermore, known functional processing such as water repellent processing, flameproof processing, flame retardant processing, and negative ion generation processing may be added.

Next, the composite fiber structure of the present invention is a composite fiber structure in which a sheet-like material having a thickness of 0.01 mm or more is bonded to the fiber structure.
Here, as such a sheet-like material, a non-woven fabric by a direct spinning method such as melt blow, spun bond or flash bond, a non-woven fabric by a short fiber structure by an airlaid or card method, a needle punched product thereof, and an adhesive fiber were mixed. There are heat-treated or hot-pressed nonwoven fabrics, sheets obtained by combining these, films, woven and knitted fabrics, and sheets obtained by hot-pressing the fibrous structure of the previous period. By laminating these sheet-like materials, in general, the repellent fiber is a step of repelling the fiber with a cloth or the like, and also includes a product with a very short fiber length, so when arranged in the thickness direction of the fiber structure, Although the entanglement between the fibers is weakened, the strength in the arranged direction is increased by bonding the sheet-like material. Moreover, it is possible to prevent the fibers of the fiber structure in which the fibers are arranged in the thickness direction from being scattered. Furthermore, by laminating these sheet-like materials, it is possible to increase ventilation resistance and increase sound absorption by membrane vibration. Furthermore, by laminating the sheet material and the fiber structure, compression in the thickness direction is possible. The hardness will be greatly increased.

The thickness of the sheet-like material is preferably 0.01 mm to 5 mm (more preferably 0.1 to 2 mm) in consideration of strength, economy, and workability when used as a wall material. The apparent density is preferably in the range of 100 to 500 kg / m ³ .

As the material constituting the sheet-like material, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalene dicarboxylate (PEN), polylactic acid (PLA) and polyesters typified by these copolymers, Synthetic fibers or films composed of polyamides such as nylon 6 and nylon 66, other polyolefins, acrylics, modacrylic, etc., natural fibers such as silk, cotton, hemp, wool, rayon fibers, and anti-fibers containing these fibers And hair fibers. Among these, a polyester-based sheet is preferable from the viewpoint of easy recyclability and moldability.
Note that the sheet-like material may be arranged on the back surface, the side surface, and the inner layer of the fiber structure in addition to one surface.

  As a method of bonding the fiber structure and the sheet-like material, a method of heating and pressing the fiber structure and the sheet-like material, a method of mechanically joining with a needle or the like, or via an adhesive layer There is a method of bonding. The adhesive layer is preferably a non-woven fabric made of a hot-melt type resin or a low-melting resin fiber that is first melt-bonded by heat in the form of powder, sheet, net, or the like. At that time, the composition of the low melting point resin or the low melting point resin fiber may be a urethane type resin, an acrylic type resin or the like, but a polyester type adhesive or adhesive sheet is preferred from the viewpoint of recyclability. Furthermore, it is also preferable to heat-press in the process before or after bonding the fiber structure and the sheet-like material.

  Further, when the fiber structure and the sheet-like material are bonded together, the sheet-like material may be bonded as it is in the state of the fiber structure obtained by the manufacturing method, and the fiber structure is bonded in the thickness direction. After slicing with a slicer facility or the like approximately perpendicularly or obliquely as necessary, the sheet-like material may be bonded.

  Next, the cushion material of the present invention is a cushion material using the fiber structure or the composite fiber structure. Such a cushion material includes polyester-type fluff fibers having various single fiber fineness as main fibers, and the constituent fibers are arranged in the thickness direction. There will be less feeling.

  In addition, the sound absorbing material of the present invention is a sound absorbing material using the fiber structure or the composite fiber structure. Such a sound-absorbing material includes, as the main fiber, polyester-type fluff fibers having various single fiber fineness and various colors, and the constituent fibers are arranged in the thickness direction, so that the performance is extremely high. It is good and dirt is not noticeable, and there is little variation in quality.

  Moreover, the heat insulating material of this invention is a heat insulating material which uses the said fiber structure or composite fiber structure. Such a heat insulating material includes polyester fiber fibers having various single fiber fineness and various colors as main fibers, and the constituent fibers are arranged in the thickness direction. It is good and dirt is not noticeable, and there is little variation in quality.

  Next, although the Example and comparative example of this invention are explained in full detail, this invention is not limited by these. In addition, each measurement item in an Example was measured with the following method.

(1) Melting point Using a differential thermal analyzer 990 manufactured by Du Pont, measured at a temperature increase of 20 ° C./min, and obtained a melting peak. If the melting temperature is not clearly observed, the melting point is the temperature at which the polymer softens and starts to flow (softening point) using a trace melting point measuring device (manufactured by Yanagimoto Seisakusho). In addition, the average value was calculated | required by n number 5.

(2) B / A
The fiber structure is cut in the thickness direction, and in the cross section, the total number of fibers (0 ° ≦ θ ≦ 45 ° in FIG. 2) arranged parallel to the thickness direction is (B), and the fibers B / A was calculated with (A) being the total number of fibers (45 ° <θ ≦ 90 ° in FIG. 2) arranged perpendicular to the thickness direction of the structure. In addition, the measurement of the number was carried out by observing 30 fibers for each of 10 arbitrary positions with a transmission optical microscope, and counting the number.

(3) Sound absorption characteristics (sound absorption rate)
The sound absorption coefficient was a normal incident sound absorption coefficient according to JIS-A1405, and was measured by a two-microphone method using a multichannel analysis system 3550 type (software: BZ5087 type 2-channel analysis software) manufactured by Bruel & Kjar. The sound absorption rate was compared at 1000 Hz, 2000 Hz, and 4000 Hz.

(4) Thickness (mm) of fiber structure, composite fiber structure, sheet-like material
It was measured according to JIS K6401.

(5) Hardness (N) of fiber structure and composite fiber structure
It was measured according to JIS K6401. In addition, the numerical value of Table 1 is a value at the time of 25% compression of thickness.

(6) Moldability A mold having an inner diameter of 60 mm, a height of 20 mm, and a thickness of 5 mm was used, and a fiber structure or a composite fiber structure was hot-drawn for 180 seconds at a mold temperature of 190 ° C. The appearance of this sample was observed and evaluated according to the following criteria.
Third grade: The height excluding the thickness exceeded 15 mm, and the surface was cleanly molded.
2-3: The height excluding the thickness exceeds 15 mm, but some wrinkles are observed on the surface.
Grade 2: Wrinkles are observed on the surface at a height of about 5 to 15 mm excluding the thickness.
Level 1-2: The height excluding the thickness is about 5 to 15 mm, and the surface is considerably wrinkled.
First grade: The height excluding the thickness is less than 5 mm, and the mark of the mold is made.

(7) Cushioning property Ratio (50% compression hardness / 25% compression hardness) of 50% compression hardness and 25% compression hardness was calculated as an index of cushioning property. The smaller the ratio is, the better the cushioning property is, and 7.0 or less is acceptable.

[Example 1]
Core / sheath type thermo-adhesive composite short fiber having a single yarn fineness of 6.6 dtex and a fiber length of 51 mm using a thermoplastic polyetherester elastomer having a melting point of 154 ° C. as a sheath component and a melting point of 230 ° C. polybutylene terephthalate as a core component A (core / sheath ratio = 60/40: weight ratio) and a used polyester curtain are collected, and a polyester-based anti-fiber fiber B is prepared using cutting and anti-hair equipment, and (A: B) 30 : After blending at a weight ratio of 70, pass through the roller card, crosslay, and roller card in this order, and then use a struto machine struto equipment to fold the web and arrange most of the fibers in the thickness direction (B / A = 4.7) After that, a fiber structure was obtained by heat-bonding the fibers in a heat treatment furnace at a temperature of 200 ° C. The ratio of fibers having a single fiber fineness of 50 dtex or more to the total weight of the polyester anti-hair fibers included in the polyester anti-fiber fibers was 32% by weight. In the obtained fiber structure, the thickness was 10 mm and the density was 12 kg / m ³ .

Next, after applying polyester powder in an amount of 30 g / m ² to an automobile seat cover jersey knit (400 g / m ² basis weight, 1.5 mm thickness) obtained by a conventional method, The fiber structure was overlaid, the powder was heated with far infrared rays, and both were bonded between the belts heated up and down to obtain a composite fiber structure having a total thickness of 6.5 mm as shown in FIG. . The 25% compression hardness was 34N, and the 50% compression hardness was 200N. Further, when 50% compression hardness / 25% compression hardness was calculated as an index of cushioning property, it was 5.9, and the cushioning property was good.
When this composite fiber structure was used as a fiber wadding for a passenger car seat (cushion material), the texture was excellent in cushioning properties and was preferable as a fiber wadding for a passenger car seat.

[Example 2]
In Example 1, instead of the jersey knit, a black woven fabric having a basis weight of 90 g / m ² and a thickness of 1 mm was bonded. When this composite fiber structure was used as a fiber wadding (cushion material) for a passenger car ceiling, the cushioning property was good and the fabric was thin, but it was preferable without a sense of sheer.

[Example 3]
70% by weight of polyester-based repellent fibers used in Example 1, heat-bonded fibers, an amorphous copolymer polyester having a melting point of 110 ° C. was disposed in the sheath component, and ordinary polyethylene terephthalate was disposed in the core component. , Teijin Fibers Ltd. core-sheath-type heat fusion composite fiber (2.2 dtex × 51 mm, single fiber cross-sectional shape: round cross section) 30% by weight is opened and blended, and then passed in the order of roller card, crosslay, and roller card. Next, using a Struto equipment manufactured by Struto, the web was folded and most of the fibers were arranged in the thickness direction (B / A = 4.7), and then heat-treated at 170 ° C., with a basis weight of 540 g / m. ^2. After obtaining a fiber structure having a thickness of 25 mm, a sound absorbing material was obtained. The evaluation results are shown in Table 1.

[Example 4]
In Example 3, the ratio of the fiber blending was 60% by weight for the polyester-based repellent fibers, 30% by weight for the heat-sealing fibers, and ordinary polyester fibers (single fiber fineness 13 dtex, fiber length 64 mm, single fiber cross-sectional shape) : Hollow round cross section) 10% was opened and blended. After that, a fiber structure having a basis weight of 545 g / m ² and a thickness of 25 mm was obtained through the same steps as in Example 3, and then used as a sound absorbing material. The evaluation results are shown in Table 1. In particular, the low frequency sound absorption was good.

[Example 5]
On the fiber structure of Example 3, a 0.3 mm-thick spunbond nonwoven fabric (Precize (trade name), manufactured by Asahi Kasei Co., Ltd.) is simultaneously wound and heated using a belt-type laminating equipment. Crimping and cooling were performed to prepare a fiber structure. The evaluation results are shown in Table 1.

[Example 6]
A fiber structure having a fiber composition of 200 g / m ² and a thickness of 15 mm was obtained by the same fiber blending as in Example 3. It was pressed into a 1 mm sheet by a belt-type heating press, and the fiber structure of Example 3 and the 1 mm sheet were bonded together using polyester powder. The evaluation results are shown in Table 1. Furthermore, when the needle punched nonwoven fabric was bonded, the cushioning property was good and it could be used as a car floor.

[Comparative Example 1]
In Example 1, instead of the fiber structure, a needle punched nonwoven fabric (weighing 300 g / m ² , thickness 5 mm) made of only natural fiber-filled anti-hair fibers was used, and the fabric was bonded in the same manner. It was created. The obtained composite fiber sheet had a feeling of bottoming and was poor in cushioning properties. Further, the total weight was 730 g / m ² and was heavy.

[Comparative Example 2]
After using 75% by weight of repellent fibers made from general clothing and using 25% by weight of the heat-adhesive fibers used in Example 3, the cross-laid nonwoven fabric was used in the card process, cross-lay process and heat treatment process. Produced. The nonwoven fabric had a basis weight of 1300 g / m ² and a thickness of 21 mm. The evaluation results are shown in Table 1.

[Example 7]
In Example 1, the fur apparatus was repeated many times so that the fiber ratio of 50 dtex or more contained in the fur fiber was less than 10% with respect to the total weight of the fur fiber. When the fibers were used and subjected to the card process through the same process as in Example 1, there was much cotton falling and it was difficult to form a sheet. Furthermore, when the composite fiber structure was obtained by pasting the fabric through the same steps as in Example 1, the composite fiber structure had a greater feeling of bottoming than that obtained in Example 1, The cushioning property was poor.

[Comparative Example 3]
In Example 1, a polyethylene terephthalate containing 0.4 wt% of titanium oxide was spun and stretched by a conventional method instead of the polyester-based repulsive fiber B, and a round cross section having a single yarn fineness of 1.7 dtex and a fiber length of 51 mm Polyethylene terephthalate fiber (non-elastic crimped short fiber, titanium oxide amount 0.4 wt%) was used. Otherwise, the fabric was bonded in the same manner as in Example 1 to produce a composite fiber structure. In the obtained composite fiber structure, the 25% compression hardness was 43N. The 50% compression hardness was 330 N. When 50% compression hardness / 25% compression hardness was calculated as an index of cushioning property, it was 7.7 and the cushioning property was poor. As a product, it is soft but has a feeling of bottoming, and the cut section cross section looks white, so that the appearance quality is low.

  According to the present invention, not only can the environmental load be reduced, but also when used as a cushioning material, the pressure distribution is good and lightweight, and there is little feeling of bottoming, and it was used as a sound absorbing material and a heat insulating material. In some cases, fiber structures, composite fiber structures, cushioning materials, sound absorbing materials, and heat insulating materials are obtained that have extremely good performance, no sense of sheerness, and little variation in quality, and their industrial value is extremely great.

1: Main fiber or heat-adhesive composite short fiber 2: Thickness direction of fiber structure 3: Arrangement direction of main fiber or heat-adhesive composite short fiber 4: Fiber structure 5: Fabric 6: Adhesive layer 7: Fiber structure body

Claims (11)

The main fiber and the heat-adhesive short fiber are blended so that the weight ratio is 90/10 to 10/90, and the fixing point and / or the heat-bonded heat-bonded state in which the heat-adhesive short fibers intersect with each other. The heat-bonding short fibers and the main fibers are interspersed with the heat-bonded fixing points, and the main fibers and the heat-bonding short fibers are arranged in the thickness direction of the fiber structure. A fiber structure comprising:
The fiber structure characterized in that the main fiber includes polyester-based repellent fibers.   The fiber structure according to claim 1, wherein the polyester-based repelled fibers include polyester-based repelled fibers having a single fiber fineness of 50 dtex or more.   3. The fiber structure according to claim 1, wherein the polyester fiber having a single fiber fineness of 50 dtex or more is contained in an amount of 10% by weight or more based on the total weight of the polyester fiber.   The heat-adhesive short fiber is composed of a heat-adhesive component and a non-heat-adhesive component, and the heat-adhesive component has a melting point lower by 40 ° C. or more than the polymer component constituting the non-heat-adhesive component, The fiber structure according to any one of claims 1 to 3. The fiber structure in any one of Claims 1-4 whose average density of a fiber structure exists in the range of 5-60 kg / m < ³ >.   The fiber structure according to any one of claims 1 to 5, wherein the thickness of the fiber structure is within a range of 2 to 200 mm.   A composite fiber structure obtained by bonding a sheet-like material having a thickness of 0.01 mm or more to the fiber structure according to any one of claims 1 to 6.   The composite fiber structure according to claim 7, which is subjected to hot pressing.   The cushion material formed using the fiber structure in any one of Claims 1-6, or the composite fiber structure of Claim 7 or Claim 8.   A sound absorbing material using the fiber structure according to any one of claims 1 to 6, or the composite fiber structure according to claim 7 or claim 8.   The heat insulating material which uses the fiber structure in any one of Claims 1-6, or the composite fiber structure of Claim 7 or Claim 8.

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