JP2013076179A - Nonwoven fabric for reinforcement of foam molded article - Google Patents

Nonwoven fabric for reinforcement of foam molded article Download PDF

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Publication number
JP2013076179A
JP2013076179A JP2011215960A JP2011215960A JP2013076179A JP 2013076179 A JP2013076179 A JP 2013076179A JP 2011215960 A JP2011215960 A JP 2011215960A JP 2011215960 A JP2011215960 A JP 2011215960A JP 2013076179 A JP2013076179 A JP 2013076179A
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Prior art keywords
nonwoven fabric
fiber
reinforcing
layer
stress
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Inventor
Hiroyuki Sakamoto
浩之 坂本
Hideo Isoda
英夫 磯田
Shinichiro Inatomi
伸一郎 稲富
Takashi Koida
貴史 恋田
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Toyobo Co Ltd
東洋紡株式会社
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    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326Condensation or reaction polymers
    • D04H1/435Polyesters
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005Synthetic yarns or filaments
    • D04H3/009Condensation or reaction polymers
    • D04H3/011Polyesters
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H5/00Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/08Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of fibres or yarns

Abstract

PROBLEM TO BE SOLVED: To provide a reinforcement material of foam molded article, which is especially suitable for the reinforcing material of a spring receiver, capable of obtaining a foamed urethane mold with no breakage or bleeding, good finished shape, improved function of damping noise due to such as scratching, bending or folding action, and improved abrasion resistance by improving nonwoven fabric strength and further with excellent shape retention property, while maintaining handleability and excellent mold followability as a reinforcing material of foam molded article.SOLUTION: A reinforcing material of foam molded article comprises: a nonwoven fabric layer of staple fibers; and a nonwoven fabric layer of filaments to form a laminate. The nonwoven fabric layer of filaments partially forms a densely crimped part with the nonwoven fabric layer of staple fibers. Both layers are partially entangled with each other. The staple fibers composing the nonwoven fabric of staple fibers penetrate the nonwoven fabric layer of filaments to form a projected fiber structure. The reinforcing material has a 5% elongation stress of 10-30 N/5cm in a vertical direction and a 5% elongation stress of 5-25 N/5cm in a horizontal direction. The difference between a 5% elongation stress and a 30% elongation stress satisfies a value of 25 (N/5cm) or less in a vertical direction, and the difference between the 30% elongation stress and a 40% elongation stress satisfies a value of 25 (N/5cm) or less in a vertical direction.

Description

本発明は、本発明は、取扱性と発泡成形性に優れた発泡成形品補強用不織布に関する。更には、発泡成形時の耐滲み出し性に特に優れ、成形品は機能性に優れ、軽量化も可能な発泡成形品補強用不織布に関する。   The present invention relates to a non-woven fabric for reinforcing a foam molded article, which is excellent in handleability and foam moldability. Further, the present invention relates to a non-woven fabric for reinforcing a foam molded product, which is particularly excellent in resistance to bleeding during foam molding, the molded product has excellent functionality and can be reduced in weight.
近年、座席等のクッション材として、発泡ウレタン成形体が広く用いられており、一般的に、発泡ウレタン成形体の成形時に補強材が一体化されたものが用いられている。かかる補強材は、発泡ウレタン成形体と金属スプリング(以後、「バネ」と記載する場合もある)の間に位置して、金属スプリングのクッション作用を均等に分散すると共に、金属スプリングから受ける摩擦から発泡ウレタン成形体を保護するという役割を担うものである。そして、消費者が求める品質が高度になるにつれ、座席等の使用時に、補強材に滲み出したウレタンと金属スプリングの摩擦により発する擦過音を解消する制音性の要望が高まっている。そこで、これに応える補強材として、嵩高層と緻密層とを有し、嵩高層側にウレタンを含浸させ、緻密層でウレタンの滲み出しを防止する補強材が特許文献1で提案されている。この方法では、発泡層が緻密層面にまで達して、緻密層が薄いため滲み出し防止効果が不十分で滲み出しによる擦過音の増大や緻密層の強度不足による耐久性が劣る問題がある。   In recent years, urethane foam molded bodies have been widely used as cushion materials for seats and the like, and generally, a material in which a reinforcing material is integrated at the time of molding a foamed urethane molded body is used. Such a reinforcing material is located between the urethane foam molded body and the metal spring (hereinafter sometimes referred to as “spring”), and evenly disperses the cushioning action of the metal spring, and from the friction received from the metal spring. It plays a role of protecting the urethane foam molded body. As the quality demanded by consumers becomes higher, there is a growing demand for sound control that eliminates scratching noise caused by friction between urethane and metal springs that have oozed into the reinforcing material when a seat or the like is used. Therefore, as a reinforcing material that responds to this, Patent Document 1 proposes a reinforcing material that has a bulky layer and a dense layer, impregnates the bulky layer with urethane, and prevents the urethane from seeping out in the dense layer. This method has a problem that the foamed layer reaches the dense layer surface and the dense layer is thin, so that the effect of preventing bleeding is insufficient, and the durability of the dense layer is inferior due to an increase in scratching sound due to the bleeding and insufficient strength of the dense layer.
特許文献1の改良法として、嵩高層(基材層)の目付を大きくした提案が特許文献2及び特許文献3で提案されている。この方法でも、特許文献1と同様に、発泡層が緻密層面にまで達して、緻密層からの滲み出し防止効果が不十分で滲み出しにより、擦過音が増大する問題がある。   As an improved method of Patent Document 1, Patent Document 2 and Patent Document 3 propose proposals that increase the basis weight of the bulky layer (base material layer). Even in this method, similarly to Patent Document 1, the foamed layer reaches the dense layer surface, and there is a problem that the effect of preventing the exudation from the dense layer is insufficient and the abrasion noise increases due to the exudation.
高目付単層不織布の片面を熱圧着し、圧着面をバネ受け面として使用する方法が特許文献4及び特許文献5で提案されている。かかる方法では、発泡層が緻密層面にまで達して、緻密層が薄いため滲み出し防止効果が不十分で滲み出しによる擦過音の増大や緻密層の強度不足による耐久性が劣る問題がある。また、片面を充分熱圧着させて剛直化する必要から、複雑で凹凸が大きい深絞り形状の発泡ウレタン成形において、成形型への追従性が不充分となり、欠肉や皺の発生を充分防止することができない問題が残っている。   Patent Documents 4 and 5 propose a method in which one surface of a high-weight single-layer nonwoven fabric is thermocompression bonded and the pressure-bonded surface is used as a spring receiving surface. In such a method, the foamed layer reaches the dense layer surface, and the dense layer is thin, so that the effect of preventing bleeding is insufficient, and there is a problem that durability due to increased abrasion noise due to bleeding and insufficient strength of the dense layer is inferior. In addition, since it is necessary to make one side sufficiently thermocompression-bonded and rigid, deep-drawn urethane foam molding with complex and large irregularities has insufficient followability to the mold and sufficiently prevents the occurrence of undercuts and wrinkles. There remains a problem that can not be.
低モジュラス素材として、捲縮ポリプロピレン繊維不織布にエンボス加工して発泡成形用補強材とする提案が特許文献6に提案されている。この方法は、捲縮発現した嵩高な層にエンボス加工で部分圧着部を形成する方法で、単層では、圧着部は滲み出し性が改良されるが、非圧着部は滲み出し易い問題がある。また、発泡成形体と補強材の一体化が不十分になり、剥離の発生や柔軟素材のため強度が低くなり耐久性にも問題がある。   As a low modulus material, Patent Document 6 proposes a foamed reinforcing material by embossing a crimped polypropylene fiber nonwoven fabric. This method is a method of forming a partial pressure-bonding part by embossing on a crimped bulky layer. In the case of a single layer, the pressure-bonding part improves the bleeding property, but the non-pressure-bonding part has a problem of easy bleeding. . Further, the integration of the foamed molded body and the reinforcing material becomes insufficient, and the strength is lowered due to the occurrence of peeling or a flexible material, and there is a problem in durability.
熱圧着加工した長繊維不織布からなる緻密層と嵩高層を積層してニードルパンチ交絡処理した、緻密層を発泡層側に用いる方法が特許文献7で提案されている。この方法では、発泡剤の滲み出しは抑制されるが、剛直性の増加により金型追随性が低下して欠肉や皺の発生を充分防止することができない問題及び発泡体との接合が不充分で剥離しやすい問題が残っている。   Patent Document 7 proposes a method using a dense layer on the foamed layer side, which is obtained by laminating a dense layer and a bulky layer made of a long-fiber nonwoven fabric subjected to thermocompression bonding and performing needle-punching entanglement treatment. Although this method suppresses oozing out of the foaming agent, there is a problem that mold followability is lowered due to an increase in rigidity, and it is not possible to sufficiently prevent occurrence of thinning and wrinkles, and bonding with the foam is not possible. The problem remains sufficient and easy to peel off.
同様の方法ではあるが、緻密層を中間層に用いる方法が特許文献8及び特許文献9で提案されているが、特許文献7と同様の問題がある。   Although the method is similar, a method using a dense layer as an intermediate layer is proposed in Patent Document 8 and Patent Document 9, but has the same problem as Patent Document 7.
圧着長繊維不織布を緻密層とし、長繊維ウエッブを嵩高層として積層交絡して柔軟性を改良する方法が特許文献10で提案されている。この方法は、柔軟性付与により金型追随性は改良されるが、長繊維ウエッブの交絡度が不充分で、耐摩耗性が劣り、不織布強度も低いため発泡成形品補強材としての耐久性に問題がある。   Patent Document 10 proposes a method for improving the flexibility by laminating and encircling a bonded long-fiber nonwoven fabric as a dense layer and a long-fiber web as a bulky layer. This method improves the mold followability by providing flexibility, but the entanglement degree of the long fiber web is insufficient, the wear resistance is inferior, and the nonwoven fabric strength is low, so that it is durable as a foam molded article reinforcement. There's a problem.
長繊維不織布と短繊維ウエッブを積層し、水流交絡により一体化して破裂強度を高めた不織布を用いる方法が特許文献11に提案されている。この方法は、水流交絡による柔軟性の付与で金型への型添性は向上するが、短繊維に熱接着成分を使用した場合、剛性は上がるが脆くなり耐久性が劣る。また、短繊維ウエッブを長繊維不織布に積層交絡させているため、短繊維ウエッブ層の耐磨耗性が劣り、不織布強力も低いため、発泡成形品補強材としての耐久性が悪くなる問題がある。補強材にネット状物を併用すると、金型追随性も低下して仕上がり形状が劣る問題も出る。   Patent Document 11 proposes a method of using a nonwoven fabric in which a long fiber nonwoven fabric and a short fiber web are laminated and integrated by hydroentanglement to increase the burst strength. In this method, the moldability is improved by imparting flexibility by hydroentanglement. However, when a thermal adhesive component is used for the short fiber, the rigidity increases but the brittleness is deteriorated and the durability is inferior. In addition, since the short fiber web is laminated and entangled with the long fiber nonwoven fabric, the abrasion resistance of the short fiber web layer is inferior and the strength of the nonwoven fabric is low. . When a net-like material is used in combination with the reinforcing material, the mold followability is lowered and the finished shape is inferior.
実公昭62−26193号公報Japanese Utility Model Publication No. 62-26193 特許2976394号公報Japanese Patent No. 2976394 特許3048435号公報Japanese Patent No. 3048435 特開平2−258332号公報JP-A-2-258332 特許2611422号公報Japanese Patent No. 2611422 特開2009−167570号公報JP 2009-167570 A 特許2990207号公報Japanese Patent No. 2990207 特許2990208号公報Japanese Patent No. 2990208 特開2007−331259号公報JP 2007-33159 A 特許3883008号公報Japanese Patent No. 3883008 特開2005−212204号公報JP-A-2005-212204
従来技術としては、成形性、補強材機能及び取扱性を同時に満たす提案はなされていない。
本発明は従来技術を背景になされたもので、発泡成形品補強用として、取扱性を維持して、金型追随性に優れ、成形品は、破れや滲み出しがなく、仕上がり形状が良好で、擦過、屈曲、屈折音などの制音機能や耐磨耗性に優れ、更には不織布強度を向上させて保形耐久性にも優れた発泡成形品を得ることができる発泡成形品補強用不織布を提供することを課題とする。
As a prior art, no proposal has been made to simultaneously satisfy the moldability, the reinforcing material function, and the handleability.
The present invention has been made against the background of the prior art, and as a foam molded product reinforcement, it maintains its handleability and has excellent mold followability, and the molded product has no tear or oozing and has a good finished shape. Non-woven fabric for reinforcing foam molded products, which is excellent in sound-damping functions such as abrasion, bending, refraction, and abrasion resistance, and further can improve the strength of the nonwoven fabric to obtain foam molded products with excellent shape retention durability. It is an issue to provide.
本発明者らは上記課題を解決するため、鋭意研究した結果、バネ受け面となる被覆層を制音機能と耐磨耗機能の優れた嵩高な短繊維不織布層とし、発泡体と接する基材層は発泡剤遮断機能をもつ緻密圧着部を有する長繊維不織布層で構成し、該被覆層と該基材層を交絡接合して、基材層面に突出繊維構造を形成した結果、構造体全体が柔軟化することが可能となることを知見した。また、30〜40%の低伸度域での伸張応力を特定範囲に設定することで、取扱性を維持して、優れた金型追随性を付与することが可能となることを知見した。さらには、突出繊維構造のアンカー効果で発泡体と補強材の接合を強固にし、補強材の強力も高めることで、成形品の耐久性を向上させ得ることも知見し、本発明に到達した。   As a result of intensive studies to solve the above-mentioned problems, the present inventors have made a coating layer serving as a spring receiving surface into a bulky short fiber nonwoven fabric layer having excellent sound damping function and wear resistance function, and a substrate in contact with the foam As a result of forming a protruding fiber structure on the surface of the base material layer, the layer is composed of a long-fiber nonwoven fabric layer having a dense pressure-bonding part having a foaming agent blocking function, and entangled the covering layer and the base material layer. It has been found that can be made flexible. Further, it has been found that by setting the tensile stress in a low elongation range of 30 to 40% within a specific range, it is possible to maintain handleability and to impart excellent mold followability. Furthermore, it has been found that the durability of the molded product can be improved by strengthening the bonding between the foam and the reinforcing material by the anchor effect of the protruding fiber structure and increasing the strength of the reinforcing material.
即ち、本発明は、以下の通りである。
(1)短繊維不織布層と、部分的に緻密圧着部を形成した長繊維不織布層が積層され、短繊維不織布層と長繊維不織布層は部分的に交絡絡合されており、短繊維不織布層を形成する繊維が長繊維不織布層を貫通して突出繊維構造を形成しており、縦方向の5%伸張時応力(ST5m)が10〜30N/5cmであり、横方向の5%伸張時応力(ST5c)が5〜25N/5cmであり、縦方向の5%伸張時応力(ST5m)と縦方向の30%伸張時応力(ST30m)との差(ΔST5m−ST30m)及び、縦方向の30%伸張時応力(ST30m)と縦方向の40%伸張時応力(ST40m)との差(ΔST30m−ST40m)が下記式を満足する発泡成形品補強用不織布。
ΔST5m−ST30m≦25(N/5cm) ・・・式1
ΔST30m−ST40m≦25(N/5cm) ・・・式2
(2)ポリエステル繊維からなり、目付当りの縦方向の強度(DTm)及び横方向の強度(DTc)が1.6N/5cm以上で、目付当りの縦方向と横方向の強度の和(DTm+DTc=DTt)が3.5N/5cm以上である(1)に記載の発泡成形品補強用不織布。
(3)短繊維不織布を構成する繊維は、少なくとも2種類の短繊維を含有し、繊度が1.2〜3dtexの繊度の低い繊維(繊維A)と繊度が2〜4dtexの繊度の高い繊維(繊維B)を含有し、繊維Aと繊維Bの繊度差(ΔD)と繊維Aと繊維Bの質量混率(A/B)が下記式を満足する(1)または(2)に記載の発泡成形品補強用不織布。
繊度差(ΔD):0.5≦ΔD≦2(dtex) ・・・式3
混率(A/B):80/20〜30/70(質量%) ・・・式4
That is, the present invention is as follows.
(1) A short fiber nonwoven fabric layer and a long fiber nonwoven fabric layer partially formed with a dense compression bonded portion are laminated, and the short fiber nonwoven fabric layer and the long fiber nonwoven fabric layer are partially entangled, and the short fiber nonwoven fabric layer Forming a protruding fiber structure through the long-fiber nonwoven fabric layer, the 5% elongation stress (ST5m) in the longitudinal direction is 10 to 30 N / 5 cm, and the 5% elongation stress in the transverse direction. (ST5c) is 5 to 25 N / 5 cm, the difference (ΔST5m−ST30m) between the 5% stretching stress (ST5m) in the longitudinal direction and the 30% stretching stress (ST30m) in the longitudinal direction and 30% in the longitudinal direction. A non-woven fabric for reinforcing a foam molded article, wherein the difference (ΔST30m−ST40m) between the stress at stretching (ST30m) and the stress at 40% stretching in the longitudinal direction (ST40m) satisfies the following formula.
ΔST5m−ST30m ≦ 25 (N / 5 cm) Formula 1
ΔST30m−ST40m ≦ 25 (N / 5 cm) Equation 2
(2) Made of polyester fiber, the longitudinal strength per unit weight (DTm) and lateral strength (DTc) is 1.6 N / 5 cm or more, and the sum of the longitudinal and lateral strength per unit basis (DTm + DTc = The non-woven fabric for reinforcing a foam molded article according to (1), wherein DTt) is 3.5 N / 5 cm or more.
(3) The fibers constituting the short fiber nonwoven fabric include at least two types of short fibers, a fiber having a fineness of 1.2 to 3 dtex (fiber A) and a fiber having a fineness of 2 to 4 dtex ( Foam molding according to (1) or (2), which contains fiber B), the fineness difference (ΔD) between fiber A and fiber B, and the mass mixing ratio (A / B) between fiber A and fiber B satisfy the following formula: Non-woven fabric for product reinforcement.
Fineness difference (ΔD): 0.5 ≦ ΔD ≦ 2 (dtex) Formula 3
Mixing ratio (A / B): 80/20 to 30/70 (mass%) Formula 4
本発明は、取扱性を維持して、成形性とバネ受け機能を同時に満足する発泡成形品補強用不織布である。即ち、バネ受け面となる層(被覆層)を制音機能と耐磨耗機能及び易変形機能の優れた嵩高で緻密な短繊維不織布層とし、発泡体と接する層(基材層)は発泡剤遮断機能と発泡ガス抜け機能を有する緻密部を形成した長繊維不織布層で構成し、該被覆層と該基材層を交絡接合して、基材層面に突出繊維構造を形成することで、構造体全体を柔軟化させると共に、局部的な応力集中が掛かると伸張変形が容易化して、優れた金型追随性と突出繊維構造のアンカー効果で発泡体構造全体が一体化して耐久性も向上した、成形性、制音性、耐久性とも優れた発泡成形クッション材を得られる発泡成形品補強用不織布である。   The present invention is a non-woven fabric for reinforcing foam molded articles that maintains handleability and satisfies both moldability and a spring receiving function at the same time. That is, the layer (coating layer) that becomes the spring receiving surface is a bulky and dense short fiber nonwoven fabric layer having excellent sound damping function, wear resistance function and easy deformation function, and the layer in contact with the foam (base material layer) is foamed. By comprising a long fiber nonwoven fabric layer formed with a dense portion having an agent blocking function and a foaming gas escape function, entangled the coating layer and the base material layer to form a protruding fiber structure on the base material layer surface, Flexibility of the entire structure and expansion of the structure are facilitated by local stress concentration, and the entire foam structure is integrated and improved durability due to excellent mold followability and protruding fiber structure anchor effect. This is a non-woven fabric for reinforcing foam-molded articles, which can obtain a foam-molded cushion material excellent in moldability, sound damping and durability.
特に、不織布を引出す応力範囲は伸張を抑制し、伸度40%未満の低伸度域での応力を低くして成形加工時の金型追随性を著しく向上させ、破断強度を高くして、成形品としたときの耐久性を向上させた発泡成形品補強用不織布を提供することができる。   In particular, the stress range for drawing out the nonwoven fabric suppresses stretching, lowers the stress in a low elongation region with an elongation of less than 40%, remarkably improves the mold followability during molding, and increases the breaking strength. It is possible to provide a non-woven fabric for reinforcing a foamed molded product having improved durability when formed into a molded product.
本発明は、短繊維不織布層と、部分的に緻密圧着部を形成した長繊維不織布層が積層され、短繊維不織布層と長繊維不織布層は部分的に交絡絡合されており、短繊維不織布層を形成する繊維が長繊維不織布層を貫通して突出繊維構造を形成しており、縦方向の5%伸張時応力(ST5m)が10〜30N/5cmであり、横方向の5%伸張時応力(ST5c)が5〜25N/5cmであり、縦方向の5%伸張時応力と縦方向の30%伸張時応力(ST30m)との差(ΔST5m−ST30m)、及び縦方向の30%伸張時応力(ST30m)と40%伸張時応力(ST40m)との差(ΔST30m−ST40m)が下記式を満足する発泡成形品補強用不織布である。
ΔST5m−ST30m≦25(N/5cm) ・・・式1
ΔST30m−ST40m≦25(N/5cm) ・・・式2
なお、本発明では、長繊維不織布のMD方向を縦方向、CD方向を横方向とする。本発明では、長繊維不織布は、縦方向に繊維が配列されているので、繊維の配列方向が縦方向となる。繊維配列方向と直交する方向が横方向となる。
In the present invention, a short fiber nonwoven fabric layer and a long fiber nonwoven fabric layer partially formed with a dense press-bonded portion are laminated, and the short fiber nonwoven fabric layer and the long fiber nonwoven fabric layer are partially entangled and short fiber nonwoven fabric. The fibers forming the layer penetrate the long-fiber nonwoven fabric layer to form a protruding fiber structure, the stress at 5% elongation in the longitudinal direction (ST5m) is 10 to 30 N / 5 cm, and at the 5% elongation in the transverse direction The stress (ST5c) is 5 to 25 N / 5 cm, and the difference (ΔST5m−ST30m) between 5% longitudinal stress and 30% longitudinal stress (ST30m), and 30% longitudinal stretching. A non-woven fabric for reinforcing a foam molded article in which the difference (ΔST30m−ST40m) between the stress (ST30m) and the stress at 40% elongation (ST40m) satisfies the following formula.
ΔST5m−ST30m ≦ 25 (N / 5 cm) Formula 1
ΔST30m−ST40m ≦ 25 (N / 5 cm) Equation 2
In the present invention, the MD direction of the long-fiber nonwoven fabric is the vertical direction, and the CD direction is the horizontal direction. In the present invention, in the long-fiber nonwoven fabric, since the fibers are arranged in the vertical direction, the arrangement direction of the fibers is the vertical direction. The direction orthogonal to the fiber arrangement direction is the lateral direction.
本発明の発泡成形品補強用不織布は、被覆層を短繊維不織布層で構成することで、繊維の自由度大きくしてバネ形状に変形追随して密着し易くなり、バネ材との摩擦による擦れ音の発生を抑制する効果を付与する。そして、基材層である緻密圧着部を形成した長繊維不織布層に部分的な交絡絡合により、積層することで、短繊維不織布層を形成する繊維が長繊維不織布層を貫通し、長い突出繊維構造を多く形成するのを容易にしている。多くの長い突出繊維構造を形成することで、発泡体へのアンカー効果が高められ、発泡体と補強材との強固な一体化が可能となり、発泡成形品の変形や磨耗に対する耐久性を高めている。   The non-woven fabric for reinforcing foam-molded product of the present invention is composed of a short fiber non-woven fabric layer as a coating layer, so that the degree of freedom of the fibers is increased and the spring shape is easily followed by deformation and friction, and friction with the spring material. The effect of suppressing the generation of sound is given. And the fibers forming the short fiber nonwoven fabric layer penetrate through the long fiber nonwoven fabric layer and are long protruding by being laminated by partial entanglement with the long fiber nonwoven fabric layer formed with the dense crimping portion as the base material layer. It is easy to form a lot of fiber structure. By forming many long protruding fiber structures, the anchoring effect to the foam is enhanced, and the foam and the reinforcing material can be strongly integrated, and the durability against deformation and wear of the foam molded product is enhanced. Yes.
被覆層に長繊維不織布層を用いた場合、嵩高性の低下で制音効果の低減と、交絡処理による突出繊維構造の形成が著しく少なくなり、発泡体との一体化が不充分になり、耐久性が低下して剥離を生じる場合があり好ましくない。   When a long-fiber nonwoven fabric layer is used for the covering layer, the bulkiness is reduced, the sound-damping effect is reduced, and the formation of protruding fiber structures due to the entanglement process is remarkably reduced, resulting in insufficient integration with the foam and durability. It is not preferable because the properties may deteriorate and peeling may occur.
本発明の被覆層である短繊維不織布層は、少なくとも基材層である長繊維不織布層と部分的に交絡絡合一体化され、長繊維不織布層を貫通した突出繊維構造を形成している。   The short fiber nonwoven fabric layer that is the coating layer of the present invention is partially entangled and integrated with at least the long fiber nonwoven fabric layer that is the base material layer to form a protruding fiber structure that penetrates the long fiber nonwoven fabric layer.
長繊維不織布層と交絡絡合一体化していない場合、被覆層である短繊維不織布層と基材層である長繊維不織布層が剥離しやすく、被覆機能の耐久性が劣り好ましくない。また、短繊維不織布層が交絡処理されていない場合は短繊維不織布層が崩壊するので好ましくない。長繊維不織布層が発泡剤と接合性が不良な素材の場合は、突出繊維構造を形成していないと発泡体との一体化も困難になり好ましくない。   When the long fiber nonwoven fabric layer and the long fiber nonwoven fabric layer are not entangled and entangled, the short fiber nonwoven fabric layer as the coating layer and the long fiber nonwoven fabric layer as the base material layer easily peel off, and the durability of the coating function is inferior. Moreover, since the short fiber nonwoven fabric layer collapse | disintegrates when the short fiber nonwoven fabric layer is not entangled, it is not preferable. In the case where the long fiber nonwoven fabric layer is a material having poor bonding properties with the foaming agent, integration with the foam becomes difficult unless a protruding fiber structure is formed.
本発明の発泡成形品補強用不織布は、基材層に部分的に緻密圧着部を形成した長繊維不織布層を用いている。長繊維不織布層は基材層として、発泡成形時に補強材表面への発泡剤の漏れを遮断する遮断層として機能させる必要、及び、成形加工時の金型追随性の確保と発泡時のガス抜け性を維持して成形品の浮きを防止のため、独立したドット状圧着部を形成し、短繊維不織布層と積層一体化するための交絡処理により取扱性を維持して成形性を損なわないよう柔軟化させている。   The nonwoven fabric for reinforcing foam-molded products of the present invention uses a long-fiber nonwoven fabric layer in which a dense press-bonded portion is partially formed on a base material layer. The long fiber nonwoven fabric layer needs to function as a barrier layer that blocks leakage of the foaming agent to the surface of the reinforcing material during foam molding, as well as ensuring mold followability during molding and outgassing during foaming In order to maintain moldability and prevent floating of the molded product, an independent dot-shaped crimping part is formed, and handling property is maintained by entanglement processing for laminating and integrating with the short fiber nonwoven fabric layer so as not to impair the moldability. It is flexible.
基材層に短繊維不織布層を用いた場合は、発泡時の遮断層機能が失われ、基材層を通過した発泡剤は被覆層表面にまで達して、発泡剤の滲み出しを生じて、成形品の品位の低下に止まらず、発泡成形品補強用不織布との擦れによる摩擦音発生による制音性の低下、磨耗による成形品の損傷発生による耐久性の低下を生じるので好ましくない。   When the short fiber nonwoven fabric layer is used for the base material layer, the function of the barrier layer at the time of foaming is lost, the foaming agent that has passed through the base material layer reaches the surface of the coating layer, and the foaming agent oozes out, Not only is the quality of the molded product lowered, but it is not preferable because the sound-damping property is lowered due to the generation of frictional noise due to rubbing with the nonwoven fabric for reinforcing a foamed molded product, and the durability is lowered due to the occurrence of damage to the molded product due to wear.
基材層に長繊維不織布層を用いた場合でも、部分的に緻密圧着部分を形成していない場合、例えばニードルパンチ交絡や水流交絡などによる緻密圧着部分を形成していない場合は、上述と同様に、発泡剤の滲み出し等による品位の低下や制音性の低下、耐久性の低下を生じ好ましくない。また、長繊維不織布層が全面に緻密圧着されている場合、及びそれに近い緻密圧着領域が形成されている場合、積層交絡処理による開孔だけでは通気性が不充分となり、発泡時のガス抜け不良による成形品の浮きを発生、剛直性の増加により変形し難くなり金型追随性が悪くなり成形性が損なわれるので好ましくない。   Even when a long-fiber nonwoven fabric layer is used as the base material layer, when a dense crimping part is not partially formed, for example, when a dense crimping part by needle punch entanglement or hydroentanglement is not formed, the same as described above Further, it is not preferable because it causes deterioration of the quality due to the exudation of the foaming agent, deterioration of the sound damping property, and durability. Also, when the long-fiber nonwoven fabric layer is densely crimped on the entire surface, and when a dense crimping region close to it is formed, the air permeability is insufficient only by the opening by the laminating entanglement process, and the gas escape failure during foaming It is not preferable because the molded product floats due to the above, and it becomes difficult to be deformed due to the increase in rigidity and the mold followability is deteriorated and the moldability is impaired.
本発明の発泡成形品補強用不織布の基材層に用いる長繊維不織布層の部分的に形成された緻密圧着部は、発泡剤の遮蔽機能と金型追随性を満たせば特には限定されないが、好ましくは、金型追随性が阻害されない独立したドット状圧着部を形成しており、圧着部の面積比率は8〜25%、より好ましくは10〜20%とすることで、遮蔽機能と金型追随性を同時に満足する性能を付与できる。   The dense press-bonded part of the long-fiber nonwoven fabric layer used for the base material layer of the nonwoven fabric for reinforcing foam molded article of the present invention is not particularly limited as long as it satisfies the shielding function of the foaming agent and the mold followability, Preferably, an independent dot-shaped crimping part that does not hinder mold followability is formed, and the area ratio of the crimping part is 8 to 25%, more preferably 10 to 20%, so that the shielding function and the mold are Performance that satisfies the following ability can be provided.
連続した圧着部が形成されている場合、不織布剛性が高くなり金型追随性が阻害される場合があり、好ましくない。   When the continuous crimping | compression-bonding part is formed, nonwoven fabric rigidity becomes high and a metal mold | die followability may be inhibited, and it is unpreferable.
独立したドット状圧着部の面積比が5%未満では、基材層としての力学特性が低下して、取扱性が劣り好ましくない。また、発泡剤の遮断機能も不足して発泡剤の滲みだしを生じる場合があり、面積比が40%を越えると伸張荷重への変形応答性が悪くなり、金型追随性が劣る場合があるので好ましくない。   When the area ratio of the independent dot-shaped crimping portions is less than 5%, the mechanical properties as the base material layer are deteriorated, and the handleability is inferior. In addition, the foaming agent may have insufficient barrier function and bleeding of the foaming agent may occur, and if the area ratio exceeds 40%, the deformation responsiveness to an extension load may be deteriorated and the mold following property may be inferior. Therefore, it is not preferable.
長繊維不織布層の部分圧着部の独立したドット状圧着部の単位面積は、小さ過ぎると接合点の強度低下により力学特性が低下して、縦方向の5%伸張時応力が10N/5cm未満となり、目付当りの強度も1.6N/5cmを下回り、取扱性と耐久性に問題が出る場合があるので好ましくない。ドット状圧着部の単位面積が大き過ぎると接合点は強固となるが、局所的な遮蔽カバー率の差が大きくなり滲みだしを生じる場合があり、また、変形時の金型追随性にも斑を生じて滲み出し、割れ、引き攣りなどを生じて形状の品位が劣る場合があり好ましくない。   If the unit area of the independent dot-shaped crimping part of the partial crimping part of the long-fiber nonwoven fabric layer is too small, the mechanical properties deteriorate due to the strength reduction of the joining point, and the stress at 5% elongation in the longitudinal direction becomes less than 10 N / 5 cm. The strength per unit weight is also less than 1.6 N / 5 cm, which may cause problems in handling and durability. If the unit area of the dot-shaped crimping part is too large, the joining point will be strong, but the difference in local shielding coverage will increase, and bleeding may occur, and the mold followability at the time of deformation will also be uneven. This is not preferable because it may cause oozing, cracking, and jerking, resulting in inferior shape quality.
本発明における長繊維不織布の部分圧着部の独立したドット状圧着部の単位面積は、好ましくは0.01〜2.5mm、より好ましくは0.02〜1.0mmである。 Independent unit area of the dot-shaped crimping portions of the portion crimped portion of the long-fiber nonwoven fabric in the present invention are preferably 0.01~2.5Mm 2, more preferably 0.02 to 1.0 mm 2.
本発明の独立した部分圧着部を形成する方法は、特には限定されない。本発明では公知の方法、例えば、エンボスローラー加工などが使用できる。
部分的に圧着繊維集合部の形状についても、独立したドットであれば特には限定されないが、好ましくは織目柄、ダイヤ柄、四角柄、亀甲柄、楕円柄、格子柄、水玉柄、丸柄などが例示できる。
独立したドット状圧着部を形成することで、独立した圧着繊維集合部が構成長繊維を強固に固定して力学特性を保持する接合点として働き、他の表面は、表面のみフラット化されていて、遮断層効果と構造固定効果及び適度な通気性を有しており、発泡成形による変形に、容易に追随できる機能と脱気機能が付与されている。
The method for forming the independent partial crimping portion of the present invention is not particularly limited. In the present invention, known methods such as embossing roller processing can be used.
The shape of the crimped fiber assembly part is not particularly limited as long as it is an independent dot, but preferably a texture pattern, diamond pattern, square pattern, turtle shell pattern, ellipse pattern, lattice pattern, polka dot pattern, round pattern Etc. can be exemplified.
By forming an independent dot-shaped crimping part, the independent crimping fiber assembly part functions as a joining point that firmly fixes the constituent long fibers and maintains the mechanical properties, and the other surfaces are flattened only on the surface It has a barrier layer effect, a structure fixing effect, and appropriate air permeability, and is provided with a function that can easily follow deformation caused by foam molding and a deaeration function.
本発明の発泡成形品補強用不織布は、被覆層の短繊維不織布層と基材層の長繊維不織布層が部分的に交絡絡合されており、短繊維不織布層を形成する繊維が長繊維不織布層を貫通して突出繊維構造を形成している。   The nonwoven fabric for reinforcing foam molded articles of the present invention has a short fiber nonwoven fabric layer as a coating layer and a long fiber nonwoven fabric layer as a base material layer partially entangled, and the fibers forming the short fiber nonwoven fabric layer are long fiber nonwoven fabrics. A protruding fiber structure is formed through the layers.
短繊維不織布層と長繊維不織布層は、一体化して補強材として機能させるため交絡絡合されており、さらに、短繊維不織布を形成する繊維が長繊維不織布層を貫通して突出繊維構造を形成して、短繊維不織布層をも保持した状態で、突出繊維構造が発泡層中に埋没されることで、発泡成形体が発泡層と補強材が強固に一体化して、変形や外圧にも構造全体が連動した変形で相互の機能を補足しあい、成形体の耐久性を向上させている。   The short fiber nonwoven fabric layer and the long fiber nonwoven fabric layer are entangled and entangled to function as a reinforcing material, and the fibers forming the short fiber nonwoven fabric penetrate the long fiber nonwoven fabric layer to form a protruding fiber structure. In addition, the protruding fiber structure is embedded in the foamed layer while holding the short fiber nonwoven fabric layer, so that the foamed molded body is firmly integrated with the foamed layer and the reinforcing material, so that it can also be deformed and structured under external pressure. The deformation of the whole complements each other's functions and improves the durability of the molded body.
被覆層を構成する繊維が基材層を貫通して突出繊維構造を形成していないと、アンカー効果による発泡層と補強層の強固な一体化が阻害され、補強層の剥離を生じる場合があり好ましくない。また、被覆層を構成する繊維が突出繊維構造を形成していない場合は、発泡層と基材層が強固に接合されていても、被覆層と基材層が強固に接合されていないと、被覆層が剥離する場合があり、構造全体が連動した変形で相互の機能を補足できなくなり、成形体の耐久性が劣るので好ましくない。
強固に接合されていても、熱接着成分を含む不織布を用いて一体化している場合は熱接着成分が伸縮性を持てないと構造体が脆くなり構造破壊を生じ耐久性が劣る問題があり好ましくない。
If the fibers constituting the coating layer do not penetrate the base material layer to form a protruding fiber structure, strong integration of the foamed layer and the reinforcing layer due to the anchor effect may be hindered, and the reinforcing layer may be peeled off. It is not preferable. Further, when the fibers constituting the coating layer do not form a protruding fiber structure, even if the foam layer and the base material layer are firmly joined, the coating layer and the base material layer are not firmly joined, The coating layer may be peeled off, and it is not preferable because the entire structure cannot be complemented by the interlocking deformation, and the durability of the molded body is inferior.
Even if it is firmly bonded, if it is integrated using a non-woven fabric containing a heat bonding component, the structure becomes brittle if the heat bonding component does not have stretchability, and there is a problem that the durability is inferior due to structural failure. Absent.
本発明の発泡成形品補強用不織布では、発泡体と接する長繊維不織布層面に突出繊維構造を形成していれば特には限定されないが、好ましくは、突出繊維構造の突出個数は、50〜250個/cmが好ましい。50個/cm未満では、交絡処理効果による柔軟化効果とポリウレタン等の発泡体との接着点及びポリウレタン中へのアンカー効果が不充分になり接合不良で剥離する場合もあり、300個/cmを越える場合、ウレタンとの接合性からは無数に有るのが望ましいが、長繊維不織布層が多孔化及び柔軟化し過ぎて、発泡剤遮蔽層効果が低下する場合や基材層が損傷や柔軟化して力学特性に問題が出る場合がある。なお、本発明における突出繊維構造の突出個数とは、1回の交絡処理により生じた1孔から複数本の繊維が突出した形態も1個として数える。
本発明のより好ましい突出繊維構造の突出個数は80〜200個/cm、最も好ましくは90〜150個/cmである。
In the nonwoven fabric for reinforcing foam molded product of the present invention, the protruding fiber structure is not particularly limited as long as the protruding fiber structure is formed on the surface of the long-fiber nonwoven fabric layer in contact with the foam, but preferably the protruding number of protruding fiber structures is 50 to 250. / Cm 2 is preferred. If it is less than 50 pieces / cm 2 , the softening effect due to the entanglement treatment effect, the adhesion point to the foamed material such as polyurethane and the anchor effect in the polyurethane may be insufficient, and there may be a case where peeling occurs due to poor bonding. In the case of exceeding 2 , it is desirable that there are innumerable in terms of bonding properties with urethane, but the long fiber nonwoven fabric layer is too porous and softened, and the foaming agent shielding layer effect is reduced, or the base material layer is damaged or flexible May cause problems in mechanical properties. In addition, the number of protrusions of the protruding fiber structure in the present invention is also counted as one in which a plurality of fibers protrude from one hole generated by one entanglement process.
The number of protrusions of the more preferable protruding fiber structure of the present invention is 80 to 200 / cm 2 , most preferably 90 to 150 / cm 2 .
本発明における突出繊維構造で形成された好ましいループを含む繊維長は2〜10mmである。繊維長が2mm未満ではアンカー効果が不足する場合があり、10mmを越える場合は、引っ掛かりによる型枠へのセット時作業性に問題が出る場合がある。
本発明のより好ましい繊維長は3〜8mmであり、最も好ましい繊維長は4〜7mmである。
The fiber length including the preferable loop formed with the protruding fiber structure in the present invention is 2 to 10 mm. If the fiber length is less than 2 mm, the anchor effect may be insufficient. If the fiber length exceeds 10 mm, there may be a problem in workability during setting to the mold by catching.
The more preferable fiber length of this invention is 3-8 mm, and the most preferable fiber length is 4-7 mm.
本発明での部分的交絡絡合処理は、交絡絡合処理により、長繊維不織布層と短繊維不織布層が柔軟一体化され、長繊維不織布層を貫通した短繊維不織布層を構成する繊維が突出繊維構造を形成されていれば、公知の水流交絡法、ニードルパンチ交絡法などが適用できるが、好ましくは、突出繊維構造の形成が容易なニードルパンチ法が推奨できる。   In the partial entanglement treatment in the present invention, the long fiber nonwoven fabric layer and the short fiber nonwoven fabric layer are flexibly integrated by the entanglement entanglement treatment, and the fibers constituting the short fiber nonwoven fabric layer penetrating the long fiber nonwoven fabric layer protrude. As long as the fiber structure is formed, a known water entanglement method, a needle punch entanglement method, or the like can be applied. Preferably, a needle punch method that can easily form a protruding fiber structure can be recommended.
ニードルパンチ条件は特には限定されないが、製法として、長繊維不織布層上に開繊ウエッブを積層して交絡処理する場合、積層されている短繊維不織布層では単繊維の繊度、カット長、断面形状等の特性や混繊状態、目付、不織布の拘束状態、及び、長繊維不織布層では目付、緻密度、構成繊維配列や単繊維特性等に影響されるので、バーブの種類やニードルパンチ条件の調整は必要だが、ペネ数50〜250本/cmの範囲で選択するのがよい。
ペネ数50本/cm未満では、短繊維不織布層と長繊維不織布層の一体化が不十分となり、被覆層が剥離して一体構造を維持できなくなる場合があり、ペネ数250本/cm以上では、長繊維不織布層の発泡剤遮断機能が低下して、成形時発泡剤漏れを生じる場合がある。交絡処理による揉み効果と損傷による不織布強力の低下を生じる場合がある。
好ましいペネ数は、80〜150本/cm、より好ましくは100〜130本/cmである。
Needle punch conditions are not particularly limited, but as a manufacturing method, when a spread web is laminated on a long-fiber nonwoven fabric layer and entangled, the single fiber fineness, cut length, and cross-sectional shape of the laminated short-fiber nonwoven fabric layer Because it is affected by the properties such as fiber mixing state, fabric weight, restrained state of nonwoven fabric, and fabric weight of nonwoven fabric layer, the fabric weight, density, constituent fiber arrangement, single fiber properties, etc., adjustment of barb type and needle punch conditions Is necessary, but it is preferable to select it within the range of 50 to 250 pens / cm 2 .
The penetrometer number fifty / cm less than 2, the integration of the short fiber nonwoven fabric layer and the long-fiber nonwoven fabric layer is insufficient, there is a case where the coating layer can not be maintained a unitary structure by peeling, penetrometer number 250 lines / cm 2 As described above, the foaming agent blocking function of the long-fiber nonwoven fabric layer may be lowered, and foaming agent leakage may occur during molding. The stagnation effect due to the entanglement treatment and the non-woven fabric strength may be reduced due to damage.
The number of pene is preferably 80 to 150 / cm 2 , more preferably 100 to 130 / cm 2 .
また、ニードルパンチの突出繊維構造形成効果は、針深度に依存しており、必要な突出繊維長を形成できる条件で、できるだけ浅くするのが好ましい。針深度が深いと開口径が大きくなり発泡剤の滲み出しを生じる場合があるので、最適条件を設定するのが望ましい。例えば、突出繊維長を3〜10mmとするには、積層した不織布厚みが荷重20g/cmで測定したとき約3mmでは、針深度は10〜16mmに設定するのが好ましい。 Further, the protruding fiber structure forming effect of the needle punch depends on the needle depth, and it is preferable to make it as shallow as possible under the condition that a necessary protruding fiber length can be formed. When the needle depth is deep, the opening diameter becomes large and the foaming agent may ooze out, so it is desirable to set the optimum conditions. For example, in order to set the protruding fiber length to 3 to 10 mm, the needle depth is preferably set to 10 to 16 mm when the thickness of the laminated nonwoven fabric is about 3 mm when measured with a load of 20 g / cm 2 .
本発明の発泡成形品補強用不織布は、縦方向の5%伸張時応力(ST5m)が10〜30N/5cmである。
縦方向の5%伸張時応力(ST5m)が10N/5cm以上とすることで、引出時の伸張応力での伸び、及び取付時の変形を抑制して取扱性を維持している。
10N/5cm未満では、引出時の伸張応力での伸びにより安定した裁断ができなくなり、また取付時に変形を生じてセットのやり直し等で取扱性が劣り、セット後変形に気付かない場合は製品不良になるので好ましくない。
縦方向の5%伸張時応力(ST5m)が30N/5cm以下とすることで、発泡成形時の金型追随性を良好に保つことができる。30N/5cmを越えると、発泡成形時の金型追随性が悪くなり、発泡成形品の仕上がり形状が劣るものとなる場合があり好ましくない。本発明での好ましい縦方向の5%伸張時応力(ST5m)は、10〜25N/5cmである。
The nonwoven fabric for reinforcing foam-molded articles of the present invention has a stress at 5% elongation (ST5m) in the longitudinal direction of 10 to 30 N / 5 cm.
By setting the stress at 5% elongation (ST5m) in the vertical direction to 10 N / 5 cm or more, the elongation due to the elongation stress at the time of pulling out and the deformation at the time of mounting are suppressed, and the handling property is maintained.
If it is less than 10 N / 5 cm, stable cutting will not be possible due to elongation due to the elongation stress at the time of drawing, and it will be deformed during installation and handling will be inferior due to re-setting, etc., and if you do not notice deformation after setting, it will be defective. This is not preferable.
When the 5% elongation stress (ST5m) in the vertical direction is 30 N / 5 cm or less, the mold followability during foam molding can be kept good. If it exceeds 30 N / 5 cm, the mold followability at the time of foam molding is deteriorated, and the finished shape of the foam molded product may be inferior. The preferred longitudinal stress (ST5m) in the longitudinal direction in the present invention is 10 to 25 N / 5 cm.
本発明の発泡成形品補強用不織布は、横方向の5%伸張時応力(ST5c)が5〜25N/5cmである。
横方向の5%伸張時応力(ST5c)を5N/5cm以上とすることで、取扱時の伸張変形を抑制して、セット性等の取扱性を維持している。5N/5cm未満では、取付時に変形を生じてセットのやり直し等で取扱性が劣り、セット後変形に気付かない場合は製品不良になるので好ましくない。
横方向の5%伸張応力(ST5c)を25N/5cm以下とすることで、発泡成形時の金型追随性を良好に保つことができる。25N/5cmを越えると、発泡成形時の金型追随性が悪くなり、発泡成形品の仕上がり形状が劣るものとなる場合があり好ましくない。本発明での好ましい横方向の5%伸張時応力(ST5c)は、10〜15N/5cmである。
The nonwoven fabric for reinforcing foamed molded products of the present invention has a 5% elongation stress (ST5c) in the transverse direction of 5 to 25 N / 5 cm.
By setting the stress at 5% elongation (ST5c) in the lateral direction to 5 N / 5 cm or more, expansion deformation during handling is suppressed, and handling properties such as setability are maintained. If it is less than 5 N / 5 cm, deformation is caused at the time of attachment, handling is inferior due to re-setting, etc., and if deformation is not noticed after setting, the product becomes defective, which is not preferable.
By setting the 5% elongation stress (ST5c) in the lateral direction to 25 N / 5 cm or less, the mold followability during foam molding can be kept good. If it exceeds 25 N / 5 cm, the mold followability at the time of foam molding is deteriorated, and the finished shape of the foam molded product may be inferior. In the present invention, the preferred lateral stress at 5% elongation (ST5c) is 10 to 15 N / 5 cm.
本発明の発泡成形品補強用不織布は、縦方向の5%伸張時応力(ST5m)と縦方向の30%伸張時応力(ST30m)との差(ΔST5−ST30m)、及び縦方向の30%伸張時応力(ST30m)と40%伸張時応力(ST40m)との差(ΔST30m−ST40m)が式1及び式2を満足する発泡成形品補強用不織布である。
ΔST5m−ST30m≦25(N/5cm) ・・・式1
ΔST30m−ST40m≦25(N/5cm) ・・・式2
The nonwoven fabric for reinforcing foam-molded articles of the present invention has a difference (ΔST5-ST30m) between a 5% longitudinal stress (ST5m) and a 30% longitudinal stress (ST30m), and a 30% longitudinal elongation. This is a non-woven fabric for reinforcing foam molded articles in which the difference (ΔST30m−ST40m) between the stress at time (ST30m) and the stress at 40% elongation (ST40m) satisfies Expressions 1 and 2.
ΔST5m−ST30m ≦ 25 (N / 5 cm) Formula 1
ΔST30m−ST40m ≦ 25 (N / 5 cm) Equation 2
本発明の発泡成形品補強用不織布は、発泡成形時の初期段階では、30%伸張変形までは塑性変形に近い低応力で均一な変形を容易にして、更に40%伸張変形までは低発泡応力で金型の大変形部分にまで型に添った均一な変形を可能とするため、縦方向の5%伸張時応力(ST5m)と縦方向の30%伸張時応力(ST30m)との差(ΔST5m−ST30m)は上記式1を満たす25N/5cm以下、縦方向の30%伸張時応力(ST30m)と40%伸張時応力(ST40m)との差(ΔST30m−ST40m)は上記式2を満たす25N/5cm以下とし、上記式1と式2を同時に満たすことで均質で良好な発泡成形性を付与している。   The non-woven fabric for reinforcing foamed articles of the present invention facilitates uniform deformation with low stress close to plastic deformation until 30% stretch deformation at the initial stage of foam molding, and further low foam stress until 40% stretch deformation. In order to enable uniform deformation along the mold up to the large deformation part of the mold, the difference (ΔST5m) between the 5% longitudinal stress (ST5m) and the 30% longitudinal stress (ST30m) in the vertical direction. -ST30m) is 25 N / 5 cm or less satisfying the above formula 1, and the difference (ΔST30m-ST40m) between the 30% stretch stress (ST30m) and the 40% stretch stress (ST40m) in the longitudinal direction is 25 N / By making the length 5 cm or less and satisfying the above formulas 1 and 2 at the same time, uniform and good foam moldability is imparted.
上記式1(ΔST5m−ST30m)が25N/5cmを越えると、発泡成形での補強材の初期変形が不均一となり、均質な補強材の成形体への被覆が阻害され、皺の発生や破れの原因となる場合がある。また、上記式2(ΔST30m−ST40m)が25N/5cmを越えると、補強材の金型の大変形部分への型添いが不均一になり、局所部分が無理な変形による破れを生じて発泡剤の滲み出しや変形不足による金型形状に仕上がらない問題を生じる場合があり好ましくない。
本発明の発泡成形品補強用不織布の好ましい(ΔST5m−ST30m)は20N/5cm以下、(ΔST30m−ST40m)は20N/5cm以下である。
If the above formula 1 (ΔST5m-ST30m) exceeds 25 N / 5 cm, the initial deformation of the reinforcing material in foam molding becomes non-uniform, and the coating of the uniform reinforcing material on the molded body is hindered, and wrinkles are generated or broken. It may be a cause. Further, if the above formula 2 (ΔST30m-ST40m) exceeds 25 N / 5 cm, the reinforcement is not uniformly applied to the large deformed portion of the mold, and the local portion is broken due to excessive deformation, and the foaming agent This is not preferable because it may cause a problem that the mold shape is not finished due to ooze out or deformation.
The preferred (ΔST5m-ST30m) of the nonwoven fabric for reinforcing foam-molded products of the present invention is 20 N / 5 cm or less, and (ΔST30 m-ST40 m) is 20 N / 5 cm or less.
本発明の発泡成形品補強用不織布の素材は、特には限定されないが、長繊維不織布層にモジュラスの低いポリプロピレンやポリエチレンを用いた場合、ST5mを10〜30N/5cm、及び、上記式1と式2を満たすことができない場合があり、また、後述する成形品の耐久性をより高く保つための、発泡成形品補強用不織布の目付当りの縦方向の強度(DTm)及び横方向の強度(DTc)が1.6N/5cm/(g/m)以上で、目付当りの縦方向と横方向の強度の和(DTm+DTc=DTt)が3.5N/5cm(g/m)以上を同時に満足することは不可能となるので、発泡成形品補強用不織布の素材は、ポリエステル繊維で構成される不織布が積層されたものが好ましい。 The material of the nonwoven fabric for reinforcing foamed molded products of the present invention is not particularly limited. However, when polypropylene or polyethylene having a low modulus is used for the long-fiber nonwoven fabric layer, ST5m is 10 to 30 N / 5 cm, and the above formula 1 and formula 2 may not be satisfied, and in order to keep the durability of the molded product described later higher, the longitudinal strength (DTm) and the lateral strength (DTc) per unit weight of the nonwoven fabric for reinforcing foam molded products ) Is 1.6 N / 5 cm / (g / m 2 ) or more, and the sum of the vertical and horizontal strength per unit weight (DTm + DTc = DTt) satisfies 3.5 N / 5 cm (g / m 2 ) or more simultaneously. Therefore, it is preferable that the nonwoven fabric for reinforcing foam molded articles is formed by laminating nonwoven fabrics composed of polyester fibers.
本発明でのポリエステルとは、芳香族ポリエステル、脂肪族ポリエステルをいい、好ましくは、耐熱性と力学特性がすぐれる芳香族ポリエステルが例示できる。
芳香族ポリエステルとしては、ポリブチレンテレフタレート(PBT)、ポリエチレンテレフタレート(PET)、ポリブチレンナフタレート(PBN)、ポリエチレンナフタレート(PEN)、ポリシクロヘキサンジメチルテレフタレート(PCHT)、ポリトリメチオレンテレフタレート(PTT)などのホモポリエステル及びそれらの共重合ポリエステルなどが例示できる。
本発明でのより好ましいポリエステルとしては、融点が220℃以上のポリエステルで、ガラス転移点温度が80℃以下のポリエステルが好ましく、ガラス転移点温度が70℃以下のポリエステルがより好ましい。好ましいポリエステルとしては、たとえば、ポリエチレンテレフタレート(PET)、ポリブチレンテレフタレート(PBT)、ポリトリメチオレンテレフタレート(PTT)及びそれらの共重合物や混合物などが例示でき、最も好ましいポリエステルとしては、ポリエチレンテレフタレート(PET)及びそれらの共重合ポリエステルが挙げられる。
なお、本発明では、特性を低下させない範囲で、必要に応じて、抗酸化剤、耐光剤、着色剤、抗菌剤、難燃剤、親水化剤などの改質剤も添加できる。
The polyester in the present invention refers to an aromatic polyester and an aliphatic polyester, and preferably an aromatic polyester having excellent heat resistance and mechanical properties.
Aromatic polyesters include polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polybutylene naphthalate (PBN), polyethylene naphthalate (PEN), polycyclohexanedimethyl terephthalate (PCHT), polytrimethylene terephthalate (PTT). Examples thereof include homopolyesters and copolyesters thereof.
As a more preferable polyester in the present invention, a polyester having a melting point of 220 ° C. or higher and a glass transition temperature of 80 ° C. or lower is preferable, and a polyester having a glass transition temperature of 70 ° C. or lower is more preferable. Examples of preferable polyesters include polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), and copolymers and mixtures thereof. As the most preferable polyester, polyethylene terephthalate ( PET) and their copolyesters.
In the present invention, modifiers such as an antioxidant, a light-proofing agent, a colorant, an antibacterial agent, a flame retardant, and a hydrophilizing agent can be added as needed without degrading the characteristics.
本発明の発泡成形品補強用不織布は、以下に記載の高い強力を保持させるため、ポリエステルからなる繊維で構成されるのが好ましい。
本発明の発泡成形品補強用不織布は、発泡成形時には、金型追随性を維持して成形でき、成形品となった後は、外力に対して不織布形態を保持して補強機能を発揮するために、目付当りの縦方向の強度(DTm)及び横方向の強度(DTc)が1.6N/5cm(g/m)以上を満足させる。
目付当りの縦方向の強度(DTm)及び横方向の強度(DTc)が1.6N/5cm(g/m)未満では、発泡成形時の金型追随性は良くなるが、成形品の外力に対する不織布形態を保持する機能が低下して形態破壊を生じ耐久性が劣る成形品となる場合があり好ましくない。この機能は、縦方向及び横方向共に満足しない場合は、力学特性が劣る方向から形態が破壊されていき耐久性が劣るものとなるので縦方向及び横方向共に満足しない場合は好ましくない。
The nonwoven fabric for reinforcing foam-molded articles of the present invention is preferably composed of fibers made of polyester in order to maintain the high strength described below.
The non-woven fabric for reinforcing foam-molded products of the present invention can be molded while maintaining mold followability at the time of foam-molding. After becoming a molded product, the non-woven fabric shape is maintained against the external force and exhibits a reinforcing function. In addition, the vertical strength per unit weight (DTm) and the horizontal strength (DTc) satisfy 1.6 N / 5 cm (g / m 2 ) or more.
When the longitudinal strength per unit weight (DTm) and the lateral strength (DTc) are less than 1.6 N / 5 cm (g / m 2 ), the mold followability during foam molding is improved, but the external force of the molded product It is not preferable because the function of retaining the nonwoven fabric form with respect to the resin may deteriorate, resulting in a morphological failure and a molded product having poor durability. If this function is not satisfied in both the vertical direction and the horizontal direction, the form is destroyed from the direction in which the mechanical properties are inferior and the durability is inferior.
本発明の発泡成形品補強用不織布のより好ましい目付当りの縦方向の強度(DTm)は1.7N/5cm(g/m)以上、横方向の強度(DTc)は1.9N/5cm(g/m)以上である。
好ましい目付当りの縦方向と横方向の強度の和(DTm+DTc=DTt)は3.5N/5cm(g/m)以上、より好ましくは3.6N/5cm(g/m)以上である。
More preferably, the non-woven fabric for reinforcing foamed articles of the present invention has a strength per unit weight (DTm) of 1.7 N / 5 cm (g / m 2 ) or more and a transverse strength (DTc) of 1.9 N / 5 cm ( g / m 2 ) or more.
The sum of the vertical and horizontal strength per unit weight (DTm + DTc = DTt) is preferably 3.5 N / 5 cm (g / m 2 ) or more, more preferably 3.6 N / 5 cm (g / m 2 ) or more.
本発明の発泡成形品補強用不織布の被覆層である短繊維不織布層を構成する繊維は、特には限定されないが、好ましくは、少なくとも2種類の短繊維を含有し、繊度が1.2〜3dtexの繊度の低い繊維(繊維A)と繊度が2〜4dtexの繊度の高い繊維(繊維B)を含有し、繊維Aと繊維Bの繊度差(ΔD)と繊維Aと繊維Bの質量混率(A/B)が式3と式4を同時に満たす発泡成形品補強用不織布である。
繊度差(ΔD):0.5≦ΔD≦2(dtex) ・・・式3
混率(A/B):80/20〜30/70(質量%) ・・・式4
Although the fiber which comprises the short fiber nonwoven fabric layer which is a coating layer of the nonwoven fabric for foam molded article reinforcement of this invention is not specifically limited, Preferably, it contains at least 2 types of short fiber, and the fineness is 1.2-3 dtex. The fiber (fiber A) having a low fineness and the fiber (fiber B) having a high fineness of 2 to 4 dtex are contained, the fineness difference (ΔD) between the fiber A and the fiber B, and the mass mixture ratio of the fibers A and B (A / B) is a non-woven fabric for reinforcing foam-molded articles satisfying the expressions 3 and 4 simultaneously.
Fineness difference (ΔD): 0.5 ≦ ΔD ≦ 2 (dtex) Formula 3
Mixing ratio (A / B): 80/20 to 30/70 (mass%) Formula 4
本発明の発泡成形品補強用不織布の被覆層である短繊維不織布層を構成する好ましい繊維は、繊維Aとして緻密な組織を形成でき、変形し易い1.2〜3dtexの短繊維と、繊維Bとして緻密さと変形のし易さを維持しながら、嵩高性を付与するために2〜4dtexの短繊維の2種類が少なくとも混繊されていることが好ましい。
繊維Aが1.2dtex未満では、成形品のバネ受け面での耐摩耗性が劣るので耐久性が悪くなる問題があり、3dtexを超えると変形し難くなり、不織布の伸張時応力が高くなる問題がある。繊維Bが2dtex未満では、繊維Aとの繊度差が少なくなり、嵩高さの付与できなくなり、繊維の組織内での自由度が低下して伸びにくくなる問題があり、4dtexを超えると、嵩高さは増加するが緻密な組織としての変形による伸び斑を発生して、低応力での伸びやすさが阻害される。
本発明でのより好ましい繊維Aの繊度は1.5〜2dtex、繊維Bの繊度は2.5〜3.5dtexである。
The preferred fibers constituting the short fiber nonwoven fabric layer that is the covering layer of the nonwoven fabric for reinforcing foamed molded products of the present invention are capable of forming a dense structure as the fiber A, and 1.2 to 3 dtex short fibers that are easily deformed, and the fiber B. It is preferable that at least two kinds of short fibers of 2 to 4 dtex are mixed in order to impart bulkiness while maintaining the density and ease of deformation.
If the fiber A is less than 1.2 dtex, the wear resistance on the spring receiving surface of the molded product is inferior, resulting in a problem of poor durability. If the fiber A exceeds 3 dtex, it becomes difficult to be deformed and the stress at the time of stretching of the nonwoven fabric is increased. There is. If the fiber B is less than 2 dtex, the difference in fineness from the fiber A is reduced, and the bulkiness cannot be imparted, and there is a problem that the degree of freedom in the fiber structure is lowered and it is difficult to stretch, and if it exceeds 4 dtex, the bulkiness is increased. Increases, but it causes stretch spots due to deformation as a dense structure, which hinders the ease of elongation at low stress.
In the present invention, the fineness of the fiber A is more preferably 1.5 to 2 dtex, and the fineness of the fiber B is 2.5 to 3.5 dtex.
繊維Aと繊維Bの繊度差(ΔD)は、上述の理由及び繊維同士のマイグレーションからは、式3を満足するのが好ましい。
繊度差(ΔD):0.5≦ΔD≦2(dtex) ・・・式3
繊度差(ΔD)が0.5dtex未満では、上述の嵩高性を付与できなくなるので、好ましくない。2dtexを超えると嵩高さは増加するが緻密な組織としての変形による伸び斑を発生して、低応力での伸びやすさが阻害される。
本発明でのより好ましい繊度差(ΔD)は0.5〜1.5dtexである。
The fineness difference (ΔD) between the fiber A and the fiber B preferably satisfies the expression 3 from the above reason and the migration between the fibers.
Fineness difference (ΔD): 0.5 ≦ ΔD ≦ 2 (dtex) Formula 3
If the fineness difference (ΔD) is less than 0.5 dtex, the above-described bulkiness cannot be imparted, which is not preferable. If it exceeds 2 dtex, the bulkiness increases, but elongation spots due to deformation as a dense structure occur, and the ease of elongation at low stress is hindered.
A more preferable fineness difference (ΔD) in the present invention is 0.5 to 1.5 dtex.
本発明では、繊維Aと繊維Bの質量混率(A/B)は、低応力下での発泡成形品補強用不織布とした時、低応力で変形の易やすさを維持するために、式4を満足するのが好ましい。
混率(A/B):80/20〜30/70(質量%) ・・・式4
繊維Aの質量混率が80質量%を超えると嵩高性が低下して、不織布組織の緻密化が進むので伸張時の低応力での伸び易さが阻害される場合があり、30質量%未満では嵩高性が増加し過ぎて、変形による伸び斑を発生して、低応力での伸びやすさが阻害され場合があり、好ましくない。
本発明でのより好ましい質量混率(A/B)は60/40〜40/60(質量%)である。
In the present invention, the mass mixture ratio (A / B) of the fiber A and the fiber B is expressed by the following formula 4 in order to maintain the ease of deformation at a low stress when a nonwoven fabric for reinforcing foam molded products under a low stress is used. It is preferable to satisfy
Mixing ratio (A / B): 80/20 to 30/70 (mass%) Formula 4
When the mass mixing ratio of the fiber A exceeds 80% by mass, the bulkiness is lowered and the nonwoven fabric structure is further densified, so that the ease of elongation at low stress during stretching may be hindered. The bulkiness is excessively increased, and elongation spots due to deformation are generated, which may hinder the ease of elongation at low stress, which is not preferable.
A more preferable mass mixture ratio (A / B) in the present invention is 60/40 to 40/60 (mass%).
本発明における短繊維不織布層は上述の好ましい短繊維を混繊してウエッブ化し、常法により所望の目付に積層後、交絡絡合処理して短繊維不織布層を形成する。交絡絡合処理して短繊維不織布層とすることで、積層加工時の作業性が向上する以外に、長繊維不織布層と積層交絡して作成した発泡成形品補強用不織布を用い、発泡成形した成形品は、バネ受け面の短繊維からなる被覆層の耐摩耗性が向上して構造破壊し難くいため耐久性も向上する。
短繊維不織布層とする場合の交絡絡合処理は、特には限定されないが、好ましくは、不織布構造を保持できて、長繊維不織布層と積層後、交絡絡合処理による突出繊維構造形成が容易な程度の交絡絡合処理が好ましい。交絡絡合処理し過ぎると、好ましい突出繊維構造の形成が困難となる場合があり好ましくない。
より好ましい交絡絡合処理法としては、ニードルパンチによる交絡絡合処理を予備交絡と本交絡処理して不織布化する方法がある。予備交絡処理は、ぺネ数20個/cm前後、本交絡処理はペネ数100〜150個/cm程度がより好ましい。
The short fiber nonwoven fabric layer in the present invention is formed by mixing the above-mentioned preferred short fibers into a web, and laminating to a desired basis weight by a conventional method, followed by entanglement treatment to form a short fiber nonwoven fabric layer. In addition to improving workability at the time of laminating by making the short fiber nonwoven fabric layer by entanglement entanglement treatment, foam molding was carried out using a nonwoven fabric for reinforcing foam molded products created by entanglement with the long fiber nonwoven fabric layer. The molded article has improved durability because the wear resistance of the coating layer made of short fibers on the spring receiving surface is improved and the structure is hardly broken.
The entanglement entanglement treatment in the case of the short fiber nonwoven fabric layer is not particularly limited, but preferably, the nonwoven fabric structure can be maintained, and after the lamination with the long fiber nonwoven fabric layer, the protruding fiber structure can be easily formed by the entanglement entanglement treatment. A degree of entanglement process is preferred. If the entanglement process is excessive, it may be difficult to form a preferable protruding fiber structure, which is not preferable.
As a more preferable entanglement method, there is a method in which the entanglement process by the needle punch is made into a nonwoven fabric by performing preliminary entanglement and main entanglement process. More preferably, the preliminary entanglement treatment has a number of penetrations of about 20 pieces / cm 2 , and the entanglement treatment has a number of penetrations of about 100 to 150 pieces / cm 2 .
ポリエステルからなる繊維で構成され、繊維Aと繊維Bが上述の好ましい条件を満たす短繊維不織布層で構成されると、理由は明確ではないが、本発明の発泡成形品補強用不織布が、縦方向の5%伸張時応力(ST5m)と縦方向の30%伸張時応力(ST30m)との差(ΔST5m−ST30m)及び、縦方向の30%伸張時応力(ST30m)と40%伸張時応力(ST40m)との差(ΔST30m−ST40m)が式1及び式2を満足することができる。
ΔST5m−ST30m≦25(N/5cm) ・・・式1
ΔST30m−ST40m≦25(N/5cm) ・・・式2
When the fiber A and the fiber B are composed of the short fiber nonwoven fabric layer satisfying the above-mentioned preferable conditions, the reason is not clear, but the foam molded article reinforcing nonwoven fabric of the present invention is formed in the longitudinal direction. The difference (ΔST5m−ST30m) between the 5% stretching stress (ST5m) and the 30% stretching stress (ST30m) in the longitudinal direction, and the 30% stretching stress (ST30m) and 40% stretching stress (ST40m) in the longitudinal direction. ) (ΔST30m−ST40m) can satisfy Expression 1 and Expression 2.
ΔST5m−ST30m ≦ 25 (N / 5 cm) Formula 1
ΔST30m−ST40m ≦ 25 (N / 5 cm) Equation 2
本発明の発泡成形品補強用不織布の目付は、規定する好ましい形態で力学特性を満たせば特には限定されないが、50〜180g/mが好ましい。目付が50g/m未満では、発泡剤の被覆機能も低下して滲み出しを発生する場合があり、また、力学特性が低くなり補強材機能も不充分になり成型品の耐久性が劣る場合がある。目付が180g/mを越えると、本発明に規定する縦方向の5%伸張時応力(ST5m)と縦方向の30%伸張時応力(ST30m)との差(ΔST5m−ST30m)及び、縦方向の30%伸張時応力(ST30m)と40%伸張時応力(ST40m)との差(ΔST30m−ST40m)が式1及び式2を満足することができなくなり、金型追随性が悪くなり、かつ、目付を大きくするとシート重量も増加して車両の軽量化を阻害する問題があり好ましくない。本発明の発泡成形品補強用不織布のより好ましい目付は60〜160g/m、さらに好ましくは80〜140g/mである。 The basis weight of the non-woven fabric for reinforcing foam-molded product of the present invention is not particularly limited as long as it satisfies the mechanical characteristics in a preferable form to be defined, but 50 to 180 g / m 2 is preferable. When the basis weight is less than 50 g / m 2 , the covering function of the foaming agent may be reduced and bleeding may occur, and the mechanical properties may be low and the reinforcing material function may be insufficient, resulting in poor durability of the molded product. There is. When the weight per unit area exceeds 180 g / m 2 , the difference (ΔST5m−ST30m) between the longitudinal stress of 5% (ST5m) and the longitudinal stress of 30% (ST30m) defined in the present invention and the longitudinal direction The difference (ΔST30m−ST40m) between the stress at 30% elongation (ST30m) and the stress at 40% elongation (ST40m) cannot satisfy the formulas 1 and 2, and the mold followability is deteriorated, and If the basis weight is increased, the weight of the seat is increased, and there is a problem that the weight reduction of the vehicle is hindered. The more preferable basis weight of the nonwoven fabric for reinforcing foam molded products of the present invention is 60 to 160 g / m 2 , and more preferably 80 to 140 g / m 2 .
なお、本発明の発泡成形品補強用不織布の被覆層である短繊維不織布層の目付は、短繊維不織布からなり、被覆機能と突出繊維構造が形成されていれば特には限定されないが、50〜120g/mが好ましい。50g/m未満では、被覆機能が低下する問題がある。120g/mを越えると発泡成形品補強用不織布の目付も増加して成型シートの軽量化を阻害する問題が生じる場合がある。より好ましい目付は60〜100g/mである。 The basis weight of the short fiber nonwoven fabric layer, which is a coating layer of the nonwoven fabric for reinforcing foam molded article of the present invention, is not particularly limited as long as it is made of a short fiber nonwoven fabric and has a covering function and a protruding fiber structure. 120 g / m 2 is preferred. If it is less than 50 g / m < 2 >, there exists a problem that a coating function falls. If it exceeds 120 g / m 2 , the basis weight of the non-woven fabric for reinforcing a foamed molded product may increase, which may cause a problem that impedes weight reduction of the molded sheet. A more preferable basis weight is 60 to 100 g / m 2 .
本発明の発泡成形品補強用不織布の基材層である長繊維不織布層の目付は、発泡剤の遮蔽機能を満たして、突出繊維構造を把持し、積層体とした時の力学特性が規定の範囲を満たせば特には限定されないが、20〜60g/mが好ましい。20g/m未満では発泡剤の遮蔽機能が満たせなくなり、力学特性も劣る場合があり、60g/mを越えると、伸張荷重への伸張変形依存性が悪くなり成形時に金型追随性が悪くなる場合があるので、適切な条件を設定するのが望ましい。本発明では、25〜45g/mがより好ましい。 The basis weight of the long-fiber nonwoven fabric layer, which is the base material layer of the nonwoven fabric for reinforcing foam molded articles of the present invention, satisfies the shielding function of the foaming agent, grips the protruding fiber structure, and defines the mechanical properties when a laminate is formed. Although it will not specifically limit if the range is satisfy | filled, 20-60 g / m < 2 > is preferable. If it is less than 20 g / m 2 , the shielding function of the foaming agent may not be satisfied, and the mechanical properties may be inferior. If it exceeds 60 g / m 2 , the dependency on the extension deformation due to the extension load becomes worse and the mold following ability becomes worse during molding. Therefore, it is desirable to set appropriate conditions. In this invention, 25-45 g / m < 2 > is more preferable.
本発明では、被覆層と基材層の2層構造とするのがより好ましいが、被覆層と基材層の間に中間層を積層一体化することもでき、中間層は、特には限定されないが、中間層を遮断層として用いることも可能である。
中間層を積層する場合、最上層となる被覆層の目付は、最下層の基材層面に突出繊維構造を形成でき、最上層となる被覆層でのバネ受け機能を満たせる目付であれば特には限定されないが、不織布目付を150g/m未満とする場合は、被覆層を50g/m、基材層と中間層を含めて100g/m未満となるよう設定するのが望ましい。
In the present invention, a two-layer structure of a coating layer and a base material layer is more preferable, but an intermediate layer can be laminated and integrated between the coating layer and the base material layer, and the intermediate layer is not particularly limited. However, it is also possible to use the intermediate layer as a blocking layer.
When the intermediate layer is laminated, the basis weight of the uppermost coating layer is particularly preferably a basis weight that can form a protruding fiber structure on the lowermost substrate layer surface and can satisfy the spring receiving function of the uppermost coating layer. but not limited, to the non-woven fabric having a basis weight of less than 150 g / m 2, the coating layer 50 g / m 2, it is desirable to set to be less than 100 g / m 2, including the base layer and the intermediate layer.
本発明の発泡成形品補強用不織布の見掛密度は本発明要件を満たせば特には限定されないが、好ましい見掛密度が0.05〜0.15g/cmである。見掛密度が0.05g/cm未満では、嵩高過ぎて、耐摩耗性が劣り耐久性が悪くなる場合があり好ましくない。見掛密度が0.15g/cmを越えると被覆層の嵩高さが無くなり、制音効果が悪くなる場合があり好ましくない。
本発明の発泡成形品補強用不織布のより好ましい見掛密度は0.06〜0.12g/cmである。
Although the apparent density of the nonwoven fabric for reinforcing foam molded articles of the present invention is not particularly limited as long as the requirements of the present invention are satisfied, the preferred apparent density is 0.05 to 0.15 g / cm 3 . If the apparent density is less than 0.05 g / cm 3, it is too bulky, which may be inferior in wear resistance and durability, which is not preferable. When the apparent density exceeds 0.15 g / cm 3 , the bulkiness of the coating layer is lost, and the sound damping effect may be deteriorated.
A more preferable apparent density of the nonwoven fabric for reinforcing foam molded products of the present invention is 0.06 to 0.12 g / cm 3 .
本発明の発泡成形品補強用不織布の被覆層となる短繊維不織布層の見掛密度は、本発明要件を満たせば特には限定されないが、0.02〜0.07g/cmが好ましく、0.02〜0.06g/cmがより好ましい。 The apparent density of the short fiber nonwoven fabric layer serving as the covering layer of the nonwoven fabric for reinforcing foam molded product of the present invention is not particularly limited as long as it satisfies the requirements of the present invention, but is preferably 0.02 to 0.07 g / cm 3. 0.02-0.06 g / cm 3 is more preferable.
本発明の発泡成形品補強用不織布の基材層となる長繊維不織布層の見掛密度は本発明要件を満たせば特には限定されないが、0.09〜0.20g/cmが好ましく、0.12〜0.18g/cmがより好ましい。 The apparent density of the long-fiber nonwoven fabric layer serving as the base material layer of the nonwoven fabric for reinforcing foam molded products of the present invention is not particularly limited as long as it satisfies the requirements of the present invention, but is preferably 0.09 to 0.20 g / cm 3. .12 to 0.18 g / cm 3 is more preferable.
本発明の発泡成形品補強用不織布を構成する繊維の断面は本発明要件を満たせば特には限定されない。
本発明の発泡成形品補強用不織布の被覆層となる短繊維不織布層は、汎用の短繊維として丸断面を用いるのが好ましいが、異形断面との混繊なども採用できる。嵩高性を向上させる場合、中空断面や異形断面を混繊することができる。
本発明の発泡成形品補強用不織布の被覆層となる短繊維不織布層を構成する繊維の繊維長は特には限定されないが、好ましくは20〜150mmである。繊維長が20mm未満では、梁構造形成での梁機能が発揮できなくなる場合があり、150mmを越えると、混綿開繊時のマイグレーションが不充分になる場合がある。本発明でのより好ましい短繊維の繊維長は40〜110mmである。
The cross section of the fiber constituting the nonwoven fabric for reinforcing a foam molded product of the present invention is not particularly limited as long as it satisfies the requirements of the present invention.
The short fiber nonwoven fabric layer serving as the covering layer of the nonwoven fabric for reinforcing foam molded products of the present invention preferably uses a round cross section as a general-purpose short fiber, but can also be mixed with an irregular cross section. When improving the bulkiness, a hollow cross section or an irregular cross section can be mixed.
Although the fiber length of the fiber which comprises the short fiber nonwoven fabric layer used as the coating layer of the nonwoven fabric for reinforcing foam molded articles of this invention is not specifically limited, Preferably it is 20-150 mm. When the fiber length is less than 20 mm, the beam function in forming the beam structure may not be exhibited. When the fiber length is more than 150 mm, migration during the opening of the mixed cotton may be insufficient. The fiber length of the more preferable short fiber in this invention is 40-110 mm.
本発明の発泡成形品補強用不織布の基材層となる長繊維不織布層を構成する繊維の繊度は本発明要件を満たせば特には限定されないが、遮断機能と補強機能が発現できる1.0〜6dtexが好ましく、1.5〜4dtexがより好ましい。基材層となる長繊維不織布層は、公知のスパンボンド不織布では、生産性から丸断面が好ましいが必要に応じて、扁平断面等の異形断面や中空断面、異繊度混繊なども選択できる。   The fineness of the fibers constituting the long-fiber nonwoven fabric layer serving as the base material layer of the nonwoven fabric for foam molded article reinforcement of the present invention is not particularly limited as long as it satisfies the requirements of the present invention, but the blocking function and the reinforcing function can be expressed from 1.0 to 6 dtex is preferable, and 1.5 to 4 dtex is more preferable. The long fiber nonwoven fabric layer serving as the base material layer is preferably a round cross section from the viewpoint of productivity in the known spunbonded nonwoven fabric, but an irregular cross section such as a flat cross section, a hollow cross section, and a different fineness blend can be selected as necessary.
なお、本発明では、短繊維不織布層及び長繊維不織布層に熱接着繊維成分を含有または混繊させて熱接着不織布構造を形成すると、不織布構造が脆くなり構造破壊を生じて耐久性が劣る場合があり、好ましくない。   In the present invention, when a heat-bonded nonwoven fabric structure is formed by adding or mixing a heat-bonded fiber component to the short-fiber nonwoven fabric layer and the long-fiber nonwoven fabric layer, the nonwoven fabric structure becomes brittle, resulting in structural failure and poor durability. Is not preferable.
本発明の発泡成形品補強用不織布の通気度は特には限定されないが、通気度が50cc/cm/秒未満では、発泡成形時の膨張空気抜けが不均一となり、欠肉、樹脂抜けの発生を生じる場合があり、350cc/cm/秒を越えると発泡剤の漏れによる滲み出しを生じる場合がある。
本発明では、発泡成形時のガス抜け不良や発泡剤の滲み出しを生じない範囲として、好ましくは50〜350cc/cm/秒であり、より好ましくは80〜160cc/cm/秒である。
The air permeability of the nonwoven fabric for reinforcing foam molded products of the present invention is not particularly limited. However, if the air permeability is less than 50 cc / cm 2 / sec, the expansion air escape during foam molding becomes non-uniform, resulting in the occurrence of missing or resin loss. If it exceeds 350 cc / cm 2 / second, bleeding may occur due to leakage of the foaming agent.
In the present invention, the range that does not cause poor gas escape during foam molding or exudation of the foaming agent is preferably 50 to 350 cc / cm 2 / second, more preferably 80 to 160 cc / cm 2 / second.
本発明の要件を満たした発泡成形品補強用不織布は、所定の形状に切断して発泡成形品用補強材としてクッション用金型に突出繊維構造形成面を発泡剤側となるようにセットして発泡剤を注入発泡し、ウレタン発泡フォームからなる発泡成形体が得られる。発泡成形法としては、コールド発泡法、又はホット発泡法で発泡成形される。成形した発泡成形体は良好な形状に仕上り、発泡剤の滲み出しもなく、バネ受け材としては、擦過、屈曲、屈折音を抑制し、保形耐久性、耐摩耗性にも優れた発泡成形品が得られた。
また、所定形状への切断工程及び金型へのセッティングの操作性は、不織布の変形もなく、きわめて良好であった。
The non-woven fabric for foam molded article reinforcement that satisfies the requirements of the present invention is cut into a predetermined shape and set as a foam molding article reinforcing material on the cushion mold so that the protruding fiber structure forming surface is on the foaming agent side. A foaming agent made of urethane foam is obtained by injecting and foaming a foaming agent. As the foam molding method, foam molding is performed by a cold foaming method or a hot foaming method. The molded foam molded body is finished in a good shape, the foaming agent does not bleed out, and as a spring receiving material, it suppresses scratching, bending, and refraction sound, and has excellent shape retention durability and wear resistance. Goods were obtained.
Further, the operability of the cutting process to the predetermined shape and the setting to the mold was very good without deformation of the nonwoven fabric.
本発明の発泡成形品補強用不織布は、取扱性と金型追随性が特に優れており、加工工程でのコスト負荷を極力抑えたコストダウンに寄与することができる。   The nonwoven fabric for reinforcing foamed molded products of the present invention is particularly excellent in handleability and mold followability, and can contribute to cost reduction while minimizing the cost burden in the processing process.
本発明の発泡成形品補強用不織布は、発泡シート用途に限定されるものではなく、発泡成形品の補強材として、車両用の各種内装材や、建築資材、電化製品の表面発泡成形品などの用途にも有用である。   The nonwoven fabric for reinforcing foam molded articles of the present invention is not limited to foam sheet applications, but as a reinforcing material for foam molded articles, various interior materials for vehicles, building materials, surface foam molded articles of electrical appliances, etc. It is also useful for applications.
以下、実施例及び比較例によって本発明をさらに具体的に説明するが、本発明はこれらに何ら限定されるものではない。なお、本発明の実施例および比較例で用いた評価方法は下記の方法でおこなった。   EXAMPLES Hereinafter, although an Example and a comparative example demonstrate this invention further more concretely, this invention is not limited to these at all. In addition, the evaluation method used by the Example and comparative example of this invention was performed with the following method.
(1)繊度[dtex]
試料の最上層及び最下層の各層の任意の場所5点を選び、光学顕微鏡を用いて、単繊維径をn=20で測定して、全平均値(D)を求めた。同場所5点の繊維を取り出し、密度勾配管を用いて、繊維の比重をn=5で測定し、全平均値(ρ)を求めた。
ついで、平均単繊維断面積と平均比重から1万mの重量に換算して繊度をdtexで示す。なお、繊維径測定時中空繊維の判別が難しい場合は下記の(5)SEM写真で繊維断面から求めた。
(1) Fineness [dtex]
Five arbitrary points on each of the uppermost layer and the lowermost layer of the sample were selected, and the single fiber diameter was measured at n = 20 using an optical microscope, and the total average value (D) was obtained. Five fibers at the same place were taken out, and the specific gravity of the fiber was measured at n = 5 using a density gradient tube to obtain the total average value (ρ).
Subsequently, the fineness is expressed by dtex by converting the average single fiber cross-sectional area and the average specific gravity into a weight of 10,000 m. In addition, when it was difficult to discriminate the hollow fiber at the time of measuring the fiber diameter, it was determined from the fiber cross section by the following (5) SEM photograph.
(2)目付[g/m
JIS L 1913『単位面積当たりの質量』に準拠して測定した。
(2) Weight per unit [g / m 2 ]
Measured according to JIS L 1913 “Mass per unit area”.
(3)厚さ[mm]及び低荷重下での嵩変化
JIS L 1913『厚さ』に準拠し、荷重7gf/cmで測定した厚み(t7:mm)及び荷重20gf/cmで測定した厚み(t20:mm)及びその比(t7/t20)を低荷重下での嵩変化として求めた。
(3) conforms to the thickness [mm] and low bulk changes in load under JIS L 1913 "thickness", the thickness was measured at a load 7gf / cm 2 (t7: mm ) and was measured at a load 20 gf / cm 2 The thickness (t20: mm) and the ratio (t7 / t20) were determined as the bulk change under low load.
(4)見掛密度[g/cm
上記(2)での荷重20gf/cmでの測定厚みと(3)で測定した目付から下記式を用いて算出した。
見かけ密度=目付÷(厚さmm×1000)
(4) Apparent density [g / cm 3 ]
It calculated using the following formula from the measured thickness at a load of 20 gf / cm 2 in the above (2) and the basis weight measured in (3).
Apparent density = basis weight ÷ (thickness mm × 1000)
(5)力学特性
JIS L 1913 6.3 『引張強さ及び伸び率』に準拠して、標準雰囲気(22℃)にて、任意の場所5点の試料を切り出し、縦方向と横方向の両方を切断までの伸張荷重曲線を各点n=5で測定し、各値の総平均で算出した。
(5−1)5%伸張時応力(ST5):N/5cm
22℃での5%伸張時応力:N/5cmを求め、5%伸張応力(N/5cm)の値とする。
(5−2)30%伸張時応力(ST30):N/5cm
22℃での30%伸張時応力:N/5cmを求め、30%伸張応力(N/5cm)の値とする。
(5−3)40%伸張時応力(ST40):N/5cm
22℃での40%伸張時応力:N/5cmを求め、40%伸張応力(N/5cm)の値とする。
(5−4)目付当りの強度(DT):N/5cm/(g/m
22℃雰囲気下の伸張変形での最大荷重点の引張強度:N/5cmを不織布の目付当りに換算した値として示す。
(5−5)縦方向の5%伸張時応力と縦方向の30%伸張時応力(ST30m)との差(ΔST5m−ST30m):N/5cm
上記記載の方法で求めた5%伸張時応力と30%伸張時応力の差の絶対値とする。
(5−6)縦方向の30%伸張時応力(ST30m)と40%伸張時応力(ST40m)との差(ΔST30m−ST40m);N/5cm
上記記載の方法で求めた縦方向の30%伸張時応力と40%伸張時応力の差の絶対値とする。
(5−7)目付当りの縦方向と横方向の強度の和(DTm+DTc=DTt):N/5cm/(g/m
上記記載の方法で求めた目付当りの縦方向の強度(DTm)と横方向の強度(DTc)の和として求めた値で示す。
(5) Mechanical properties In accordance with JIS L 1913 6.3 “Tensile Strength and Elongation”, specimens at 5 points were cut out in standard atmosphere (22 ° C.), both in the vertical and horizontal directions. The elongation load curve until cutting was measured at each point n = 5, and the total average of each value was calculated.
(5-1) Stress at 5% elongation (ST5): N / 5 cm
Stress at 5% elongation at 22 ° C .: N / 5 cm is obtained, and the value is 5% elongation stress (N / 5 cm).
(5-2) Stress at 30% elongation (ST30): N / 5 cm
30% elongation stress at 22 ° C .: N / 5 cm is obtained, and the value is 30% elongation stress (N / 5 cm).
(5-3) 40% elongation stress (ST40): N / 5 cm
40% elongation stress at 22 ° C .: N / 5 cm is obtained and set as a value of 40% elongation stress (N / 5 cm).
(5-4) Strength per unit weight (DT): N / 5 cm / (g / m 2 )
The tensile strength at the maximum load point in extension deformation under an atmosphere of 22 ° C .: N / 5 cm is shown as a value converted to the basis weight of the nonwoven fabric.
(5-5) Difference (ΔST5m−ST30m) between 5% longitudinal stress and 30% longitudinal stress (ST30m): N / 5 cm
The absolute value of the difference between the stress at 5% elongation and the stress at 30% elongation obtained by the method described above.
(5-6) Difference (ΔST30m−ST40m) between 30% stretching stress (ST30m) and 40% stretching stress (ST40m) in the longitudinal direction; N / 5cm
The absolute value of the difference between the 30% stretching stress and 40% stretching stress in the longitudinal direction determined by the method described above.
(5-7) Sum of longitudinal and lateral strength per weight (DTm + DTc = DTt): N / 5 cm / (g / m 2 )
The value obtained as the sum of the longitudinal strength (DTm) and the lateral strength (DTc) per basis weight obtained by the method described above.
(6)通気度(cc/cm/sec)
JIS L 1096 8.27.1に準じたフラジール通気度測定機によって行った。
(6) Air permeability (cc / cm 2 / sec)
It was carried out with a Frazier permeability tester according to JIS L 1096 8.27.1.
(7)不織布の判別
被覆層が短繊維不織布層か否かは、構成している繊維を引出して、短繊維形態を確認する。基材層が長繊維不織布層か否かは、交絡している他の繊維不織布層(突出繊維構造部を含む)を剥離して、長繊維で構成されていることを目視で識別する。
(7) Discrimination of non-woven fabric Whether or not the coating layer is a short fiber non-woven fabric layer is obtained by drawing out the constituting fiber and confirming the short fiber form. Whether or not the base material layer is a long-fiber non-woven fabric layer is determined by peeling the other interwoven fiber non-woven fabric layers (including the protruding fiber structure) and visually confirming that it is composed of long fibers.
(8)長繊維不織布層の圧着部面積及び面積率
最下層不織布層を他の繊維不織布層(突出繊維構造部を含む)と剥離して試料とし、任意の20箇所で30mm角に裁断し、SEMにて50倍の写真を撮る。撮影写真をA3サイズに印刷してドット状圧着単位面積を切り抜き、面積(S0)を求める。次いで圧着単位面積内においてドット状圧着部のみを切り抜き個々のドット状圧着部面積(Si:mm)を求め、圧着部面積積算値(ΣSi=Sp)より圧着面積比率(P)を算出する。各ドット状圧着面積及び圧着面積比率P20点の平均値を求めた。
P=Sp/S0 (n=20)
(8) Pressure bonding area and area ratio of the long fiber nonwoven fabric layer The lowermost nonwoven fabric layer is peeled off from other fiber nonwoven fabric layers (including protruding fiber structures) and cut into 30 mm squares at any 20 locations. Take 50x photo with SEM. The photographed photograph is printed in A3 size, the dot-shaped crimping unit area is cut out, and the area (S0) is obtained. Next, only the dot-shaped crimping portion is cut out within the crimping unit area to obtain the individual dot-shaped crimping portion area (Si: mm 2 ), and the crimping area ratio (P) is calculated from the integrated value of the crimping portion area (ΣSi = Sp). The average value of each dot-shaped crimping area and the crimping area ratio P20 was determined.
P = Sp / S0 (n = 20)
(9)突出繊維構造
不織布のニードルパンチ打ち込み面の反対面に突出した繊維の有無を目視判定で行い、必要に応じ、代表される部分の突出繊維の1cm当りの突出繊維長をスケールでn=20にて測定し(mm以下は4捨五入)、平均値で示す。
(9) Protruding fiber structure The presence or absence of fibers protruding on the surface opposite to the needle punch driving surface of the non-woven fabric is determined by visual inspection. If necessary, the protruding fiber length per 1 cm 2 of the protruding fibers of the representative portion is expressed on a scale. = 20 (mm or less is rounded off), and is shown as an average value.
(10)引出し変形評価
JIS L 1913 6.3 『引張強さ及び伸び率』に準拠した幅5cmの不織布試料を用いて、縦方向に対して10N/5cmの伸張応力で伸張回復処理を10回行い、試料を1時間放置した後、縦方向の不織布の伸び変形と目視による形態変化を求めた。
伸び変形5%未満、形態変化なし:○、伸び変形5%以上20%以下、形態変化微小:△、伸び変形20%以上、形態変化あり:×として評価した。
(10) Draw deformation evaluation JIS L 1913 6.3 Using a nonwoven fabric sample with a width of 5 cm in accordance with “Tensile strength and elongation”, stretching recovery treatment was performed 10 times with a tensile stress of 10 N / 5 cm in the longitudinal direction. After the sample was left for 1 hour, the elongation deformation of the nonwoven fabric in the longitudinal direction and the visual form change were obtained.
Elongation deformation was less than 5%, no change in shape: ○, elongation deformation was 5% or more and 20% or less, small change in shape: Δ, elongation deformation was 20% or more, and there was change in shape: x
(11)発泡評価
クッションパッド金型に所定の形状に切断した不織布を発泡成形品用補強材として、形状に馴染ませるようにセットして、セット状態をセット性として官能評価し、次いで、2液ウレタン樹脂にて65℃のコールド発泡を行い、成形品の評価を目視判定で行った。
(11−1)セット性
金型に馴染み易くセット容易:○、馴染み易いがセットし難い:△、馴染み難くセットし難い:×で官能評価した。
(11−2)滲み出し
成型品の補強材面にウレタンの滲み出しがなし:○、滲み出し微小:△、滲み出し明確にあり:×で目視判定した。
(11−3)皺
成型品の補強材面に皺発生なし:○、微小な皺発生:△、皺が発生:×で目視判定した。
(11−4)浮き
成型品の補強材面に浮きが発生なし:○、微小な浮きあり:△、浮きあり:×で目視と触感で判定した。
(11−5)破れ
成型品の補強材面に破れなし:○、破れ直前:△、破れあり:×で目視判定した。
(11−6)剥離
成型品の補強材面と発泡体との境界剥離のし易さを、成型品の補強材端部を1cm剥離して、手で補強材を発泡体から引裂くときに、境界が剥離しない:○、境界剥離に近い剥離を生じる:△、境界で剥離する:×で官能目視判定した。
(11−7)金型追随性
成型品の補強材面が金型形状どうりに成型されている:○、わずかに形状が一致しない:△、形状に一致しない部分がある:×で目視評価した。
(11) Foaming evaluation A non-woven fabric cut into a predetermined shape in a cushion pad mold is set as a reinforcing material for a foamed molded product so as to conform to the shape. Cold foaming at 65 ° C. was performed with urethane resin, and the molded product was evaluated visually.
(11-1) Setability It was easy to adjust to the mold and easy to set: ○, easy to adjust but difficult to set: Δ, difficult to set and difficult to set: ×, sensory evaluation.
(11-2) Exudation No urethane exudation on the reinforcing material surface of the molded product: ○, exudation fine: Δ, exudation clearly present: x was visually judged.
(11-3) Wrinkles were not generated on the reinforcing material surface of the molded product: ○, fine wrinkles were generated: Δ, wrinkles were generated: x was visually determined.
(11-4) Floating No lift occurred on the reinforcing material surface of the molded product: ○, Micro-floating: Δ, Floating: X, and judged by visual and tactile sensation.
(11-5) Tearing No tearing on the reinforcing material surface of the molded product: ○, Immediately before tearing: Δ, There was tearing: x was visually judged.
(11-6) Peeling For ease of boundary peeling between the reinforcing material surface of the molded product and the foam, when the reinforcing material end of the molded product is peeled 1 cm and the reinforcing material is torn from the foam by hand. The boundary does not peel: ○, peeling close to the boundary peeling occurs: Δ, peeling at the boundary: x
(11-7) Mold followability The reinforcing material surface of the molded product is molded according to the shape of the mold: ○, the shape slightly does not match: Δ, there is a part that does not match the shape: × visually evaluated did.
(12)成型品の性能評価
(12−1)制音性
実車にパッドをセットして、時速60kmでの平地走行試験1時間での振動音、擦れ音を聞き、搭載座席に比べ静か:○、搭載座席と同等の静けさ:△、搭載座席と同等以下で煩い:×で官能評価した。
(12−2)耐磨耗性
成型品の補強材面側を発泡体を含めて厚み5mmにスライスした試料を用いて、JIS L 0849に定義される方法により、摩擦試験機II型(学振型)を用いて、補強材面を摩擦面としてセットし、10分間磨耗させて、損傷の程度を目視判定で級別して評価した。損傷なし:5、微小な損傷:4、損傷少しあり:3級、損傷中程度:2級、損傷大:1級とした。
(12−3)保形性
パッドを55cm角10ミリ鉄板上に置き、テンシロン(ボールドウィン社製UCT25T)で、同じ鉄板をロードセルに接合して接触する高さをHcmとすると、半分の高さまで圧縮回復(50%繰返し圧縮)を100回繰返し、補強材面の損傷状態を目視判定して以下の評価をした。○:損傷、剥離なし、△:剥離小、損傷なし、×:剥離あり、損傷あり。
(12) Performance evaluation of molded products (12-1) Sound control performance Set a pad on the actual vehicle, listen to vibration and rubbing sound in a flat-ground running test at 60 km / h for 1 hour, quieter than the seat on which it is mounted: ○ The quietness equivalent to that of the mounted seat: Δ, the same or less the same as that of the mounted seat, and anxious: ×.
(12-2) Abrasion resistance Using a sample obtained by slicing a reinforcing material surface side of a molded product to a thickness of 5 mm including foam, a friction tester type II (Gakushin) The reinforcing material surface was set as a friction surface using a mold, and was worn for 10 minutes, and the degree of damage was classified by visual judgment and evaluated. No damage: 5, Minor damage: 4, Little damage: Grade 3, Damage moderate: Grade 2, Damage large: Grade 1.
(12-3) Shape retention When the pad is placed on a 55cm square 10mm iron plate, and the same iron plate is bonded to the load cell with Tensilon (Baldwin's UCT25T) and the contact height is Hcm, it is compressed to half the height. Recovery (50% repetitive compression) was repeated 100 times, and the damage state of the reinforcing material surface was visually judged and evaluated as follows. ○: Damage, no peeling, Δ: Small peeling, no damage, ×: Peeling, damaged
<実施例1>
繊維Aとして丸断面で2dtexの機械捲縮を有するカット長51mmのポリエチレンテレフタレートからなるポリエステル短繊維と繊維Bとして丸断面で3dtexの機械捲縮を有するカット長51mmのポリエチレンテレフタレートからなるポリエステル短繊維とを40/60質量比で混打綿にて混綿してカードウエッブ化し、クロスレイヤーにて60g/mとなるよう積層し、ついで、予備交絡処理としてペネ数20個/cmの交絡絡合処理を行い、連続して、ペネ数120個/cmにて交絡絡合処理して、目付60g/mの短繊維不織布を得た。
固有粘度0.65のポリエチレンテレフタレート(以下PETと記載する)を用い、紡糸温度285℃、単孔吐出量0.85g/分にて紡糸、振落して、繊度1.7dtexの長繊維からなる目付40g/mのウエッブを得た。ついで、圧着面積率18%の凸格子柄のエンボスローラーを用いて250℃、線圧40kN/mにてエンボス加工を行い、ドット状圧着部面積0.34mm、圧着部の面積比率17%、見掛密度0.16g/mの基材層用ポリエステル長繊維不織布を得た。
ついで、長繊維不織布上面に短繊維不織布を積層して、短繊維不織布面より、ペネ数120個/cmにて針深度10mmにてニードルパンチによる交絡絡合処理を行い、発泡成形品補強用不織布を得た。
<Example 1>
Polyester short fiber made of polyethylene terephthalate with a cut length of 51 mm having a mechanical crimp of 2 dtex in a round cross section as fiber A, and polyester short fiber made of polyethylene terephthalate with a cut length of 51 mm having a mechanical crimp of 3 dtex in a round cross section as fiber B Are mixed with cotton blended at a 40/60 mass ratio to form a card web, and laminated with a cross layer so as to be 60 g / m 2, and then entangled with 20 pene / cm 2 as pre-entanglement treatment The treatment was performed, and the entanglement process was continuously performed at a penetrating number of 120 pieces / cm 2 to obtain a short fiber nonwoven fabric having a basis weight of 60 g / m 2 .
Polyethylene terephthalate (hereinafter referred to as PET) having an intrinsic viscosity of 0.65, spun and shaken at a spinning temperature of 285 ° C. and a single-hole discharge rate of 0.85 g / min, and is composed of long fibers having a fineness of 1.7 dtex A web of 40 g / m 2 was obtained. Next, embossing is performed at 250 ° C. and a linear pressure of 40 kN / m using an embossed roller with a convex lattice pattern with a crimp area ratio of 18%, a dot-like crimp area of 0.34 mm 2 , an area ratio of the crimp area of 17%, A polyester continuous fiber non-woven fabric for a base material layer having an apparent density of 0.16 g / m 2 was obtained.
Next, a short fiber nonwoven fabric is laminated on the upper surface of the long fiber nonwoven fabric, and from the surface of the short fiber nonwoven fabric, entanglement entanglement treatment is performed by a needle punch at a needle depth of 10 mm at a penetrating number of 120 pieces / cm 2 to reinforce the foam molded product. A nonwoven fabric was obtained.
得られた発泡成形品補強用不織布は、目付100g/m、見掛密度0.08g/cm、5%伸張時応力は縦方向17N/5cm、横方向7N/5cm、30%伸張時応力は縦方向30N/5cm、横方向20N/5cm、ΔST5m−ST30mは15N/5cm、40%伸張時応力は縦方向45N/5cm、横方向35N/5cmで、ΔST30m−ST40mは13N/5cm、強度は縦方向174N/5cm(目付当り1.7N/5cm/(g/m))、横方向210N/5cm(目付当り2.1N/5cm(g/m))で強度の和は目付当り3.8N/5cm(g/m)であり、突出繊維構造を長繊維不織布面に形成しており、突出繊維長7mm、突出繊維構造の形成個数は115個/cm、通気性125cc/cm/秒であった。 The obtained nonwoven fabric for reinforcing foam-molded articles has a basis weight of 100 g / m 2 , an apparent density of 0.08 g / cm 3 , and a stress at 5% elongation of 17 N / 5 cm in the longitudinal direction, 7 N / 5 cm in the transverse direction, and stress at 30% elongation. Is 30N / 5cm in the vertical direction, 20N / 5cm in the horizontal direction, 15N / 5cm for ΔST5m-ST30m, the stress at 40% elongation is 45N / 5cm in the vertical direction and 35N / 5cm in the horizontal direction, ΔST30m-ST40m is 13N / 5cm, and the strength is In the longitudinal direction 174 N / 5 cm (1.7 N / 5 cm / (g / m 2 ) per unit weight) and in the horizontal direction 210 N / 5 cm (2.1 N / 5 cm (g / m 2 ) per unit weight), the sum of strengths is 3 per unit weight. 8 N / 5 cm (g / m 2 ), the protruding fiber structure is formed on the surface of the non-woven fabric, the protruding fiber length is 7 mm, the number of protruding fiber structures is 115 / cm 2 , and the air permeability is 125 cc / cm 2 / sec.
得られた発泡成形品補強用不織布を評価した結果、本発明要件を満たす実施例1は、引出し変形、打ち抜き性、金型セット性とも良好で、発泡成形での滲み出し、皺、浮き、破れ、剥離も無く、型添い性も良好であった。性能評価でも、制音性、耐磨耗性、保形性とも良好で、発泡成形用補強材としての優れた性能を持つ発泡成形品補強用不織布であった。   As a result of evaluating the obtained nonwoven fabric for reinforcing foamed articles, Example 1, which satisfies the requirements of the present invention, has good draw deformation, punchability, and mold setting properties, and exudation, wrinkles, floats, and tears in foam molding. There was no peeling, and the moldability was good. Even in the performance evaluation, the nonwoven fabric for reinforcing foam molded articles has good sound damping properties, wear resistance, and shape retention, and has excellent performance as a reinforcing material for foam molding.
<実施例2>
短繊維不織布の目付を80g/mとなるようクロスレイヤーにて80g/mに積層した以外、実施例1と同様にして得られた発泡成形品補強用不織布は、目付120g/m、見掛密度0.09g/cm、5%伸張時応力は縦方向15N/5cm、横方向9N/5cm、30%伸張時応力は縦方向36N/5cm、横方向22N/5cm、ΔST5m−ST30mは11N/5cm、40%伸張時応力は縦方向60N/5cm、横方向38N/5cm、ΔST30m−ST40mは25N/5cmで、強度は縦方向208N/5cm(目付当り1.7N/5cm(g/m))、横方向252N/5cm(目付当り2.1N/5cm(g/m))で強度の和は目付当り3.8N/5cm(g/m)であり、突出繊維構造を長繊維不織布面に形成しており、突出繊維長6mm、突出繊維構造の形成個数は115個/cm、通気性115cc/cm/秒であった。
<Example 2>
Except laminated to 80 g / m 2 basis weight of the short fiber nonwoven fabric at cross-layer so as to be 80 g / m 2, the expansion-molded article reinforcing nonwoven fabric obtained in the same manner as in Example 1, basis weight 120 g / m 2, Apparent density 0.09g / cm 3 , 5% stretching stress is 15N / 5cm in the longitudinal direction, 9N / 5cm in the transverse direction, 30% stretching stress is 36N / 5cm in the longitudinal direction, 22N / 5cm in the lateral direction, ΔST5m-ST30m 11N / 5cm, 40% elongation stress is 60N / 5cm in the vertical direction, 38N / 5cm in the horizontal direction, ΔST30m-ST40m is 25N / 5cm, and the strength is 208N / 5cm in the vertical direction (1.7N / 5cm (g / m per unit weight) 2 )), the transverse direction is 252 N / 5 cm (2.1 N / 5 cm (g / m 2 ) per unit weight), and the sum of strength is 3.8 N / 5 cm (g / m 2 ) per unit basis, and the protruding fiber structure is long. It was formed on the fiber nonwoven fabric surface, the protruding fiber length was 6 mm, the number of protruding fiber structures formed was 115 / cm 2 , and the air permeability was 115 cc / cm 2 / sec.
得られた発泡成形品補強用不織布を評価した結果、本発明要件を満たす実施例2は、引出し変形、打ち抜き性、金型セット性とも良好で、発泡成形での滲み出し、皺、浮き、破れ、剥離も無く、型添い性も良好であった。性能評価でも、制音性、耐磨耗性、保形性とも良好で、発泡成形用補強材としての優れた性能を持つ発泡成形品補強用不織布であった。   As a result of evaluating the obtained nonwoven fabric for reinforcing foamed articles, Example 2, which satisfies the requirements of the present invention, has good draw deformation, punchability, and mold setting properties, and exudation, wrinkles, floats, and tears in foam molding. There was no peeling, and the moldability was good. Even in the performance evaluation, the nonwoven fabric for reinforcing foam molded articles has good sound damping properties, wear resistance, and shape retention, and has excellent performance as a reinforcing material for foam molding.
<実施例3>
短繊維不織布の目付を100g/mとなるようクロスレイヤーにて100g/mに積層した以外、実施例1と同様にして得られた発泡成形品補強用不織布は、目付140g/m、見掛密度0.09g/cm、5%伸張時応力は縦方向20N/5cm、横方向10N/5cm、30%伸張時応力は縦方向40N/5cm、横方向30N/5cm、ΔST5m−ST30mは20N/5cmで、40%伸張時応力は縦方向65N/5cm、横方向50N/5cmで、ΔST30m−ST40mは25N/5cmで、強度は縦方向226N/5cm(目付当り1.6N/5cm(g/m))、横方向324N/5cm(目付当り2.3N/5cm(g/m))で強度の和は目付当り3.9N/5cm(g/m)であり、突出繊維構造を長繊維不織布面に形成しており、突出繊維長6mm、突出繊維構造の形成個数は115個/cm、通気性102cc/cm/秒であった。
<Example 3>
Except laminated to 100 g / m 2 basis weight of the short fiber nonwoven fabric at cross-layer so as to be 100 g / m 2, the expansion-molded article reinforcing nonwoven fabric obtained in the same manner as in Example 1, basis weight 140 g / m 2, Apparent density 0.09g / cm 3 , 5% elongation stress is 20N / 5cm in the longitudinal direction, 10N / 5cm in the transverse direction, 30% elongation is 40N / 5cm in the longitudinal direction, 30N / 5cm in the transverse direction, ΔST5m-ST30m At 20 N / 5 cm, the stress at 40% elongation is 65 N / 5 cm in the longitudinal direction, 50 N / 5 cm in the transverse direction, ΔST30m-ST40 m is 25 N / 5 cm, and the strength is 226 N / 5 cm in the longitudinal direction (1.6 N / 5 cm (g per unit weight) / M 2 )), lateral direction 324 N / 5 cm (2.3 N / 5 cm (g / m 2 ) per unit weight), and the sum of the strengths is 3.9 N / 5 cm (g / m 2 ) per unit basis. The fiber structure was formed on the long fiber nonwoven fabric surface, the protruding fiber length was 6 mm, the number of protruding fiber structures formed was 115 / cm 2 , and the air permeability was 102 cc / cm 2 / sec.
得られた発泡成形品補強用不織布を評価した結果、本発明要件を満たす実施例3は、引出し変形、打ち抜き性、金型セット性とも良好で、発泡成形での滲み出し、皺、浮き、破れ、剥離も無く、型添い性も良好であった。性能評価でも、制音性、耐磨耗性、保形性とも良好で、発泡成形用補強材としての優れた性能を持つ発泡成形品補強用不織布であった。   As a result of evaluating the obtained nonwoven fabric for reinforcing foam molded articles, Example 3, which satisfies the requirements of the present invention, has good draw deformation, punchability, and mold setting properties, and exudation, wrinkles, floats, and tears in foam molding. There was no peeling, and the moldability was good. Even in the performance evaluation, the nonwoven fabric for reinforcing foam molded articles has good sound damping properties, wear resistance, and shape retention, and has excellent performance as a reinforcing material for foam molding.
<比較例1>
2dtex丸断面の機械捲縮を付与した繊維長51mmの短繊維を用いて開繊したウエッブを目付80g/mに積層してニードルパンチにてペネ数100個/cmにて交絡絡合させた目付80g/mの被覆層となる短繊維不織布を作成した。
メルトインデックス60g/10分のポリプロピレン(以下PPと記述する)を用いて、紡糸温度250℃にて丸断面ノズル孔より単孔吐出量0.8g/分で紡糸して、繊度2dtexの長繊維からなる目付40g/mのウエッブを得た。ついで、連続して、圧着面積率18%の楕円文様エンボスローラーを用いて、エンボス温度130℃、線圧20kN/mにてエンボス加工して、2dtexの連続繊維からなる目付40g/m、ドット状圧着部面積0.05mm、圧着部の面積比率16%の基材層となる長繊維不織布を得た。
ついで、長繊維不織布上面に短繊維不織布を積層して、短繊維不織布面より、ペネ100個/cmにて針深度10mmにてニードルパンチによる交絡絡合処理を行い、発泡成形品補強用不織布を得た。
<Comparative Example 1>
A web opened using short fibers having a fiber length of 51 mm with a 2 dtex round cross section is laminated on a basis weight of 80 g / m 2 and entangled with a needle punch at a penetrating number of 100 pieces / cm 2 . A short fiber nonwoven fabric serving as a covering layer having a basis weight of 80 g / m 2 was prepared.
Using polypropylene having a melt index of 60 g / 10 min (hereinafter referred to as PP), spinning at a spinning temperature of 250 ° C. from a round cross-section nozzle hole at a single hole discharge rate of 0.8 g / min, and from a long fiber having a fineness of 2 dtex A web having a basis weight of 40 g / m 2 was obtained. Next, using an oval pattern embossing roller with a crimping area ratio of 18%, the embossing is performed at an embossing temperature of 130 ° C. and a linear pressure of 20 kN / m, and the basis weight is 40 g / m 2 made of continuous fibers of 2 dtex. A long-fiber non-woven fabric serving as a base material layer having an area of a crimped portion of 0.05 mm 2 and an area ratio of the crimped portion of 16% was obtained.
Next, a short fiber nonwoven fabric is laminated on the upper surface of the long fiber nonwoven fabric, and entanglement treatment by needle punching is performed from the surface of the short fiber nonwoven fabric with a needle depth of 10 mm at a penet of 100 pieces / cm 2 , thereby reinforcing a foam molded article reinforcing nonwoven fabric. Got.
得られた発泡成形品補強用不織布は、目付120g/m、見掛密度0.09g/cm、5%伸張時応力は縦方向24N/5cm、横方向6N/5cm、30%伸張時応力は縦方向52N/5cm、横方向22N/5cm、ΔST5m−ST30mは28N/5cm、40%伸張時応力は縦方向78N/5cm、横方向41N/5cmで、ΔST30m−ST40mは26N/5cm、強度は縦方向130N/5cm(目付当り1.1N/5cm(g/m))、横方向140N/5cm(目付当り1.2N/5cm(g/m))で強度の和は目付当り2.3N/5cm(g/m)であり、突出繊維構造を長繊維不織布面に形成しており、突出繊維長8mm、突出繊維構造の形成個数は94個/cm、通気性118cc/cm/秒であった。 The obtained non-woven fabric for reinforcing foam-molded articles has a basis weight of 120 g / m 2 , an apparent density of 0.09 g / cm 3 , and a stress at 5% elongation of 24 N / 5 cm in the longitudinal direction, 6 N / 5 cm in the transverse direction, and stress at 30% elongation. Is 52N / 5cm in the vertical direction, 22N / 5cm in the horizontal direction, 28N / 5cm for ΔST5m-ST30m, the stress at 40% elongation is 78N / 5cm in the vertical direction and 41N / 5cm in the horizontal direction, ΔST30m-ST40m is 26N / 5cm, and the strength is longitudinal 130N / 5 cm (basis weight per 1.1N / 5cm (g / m 2 )), transverse 140 N / 5 cm sum of the intensities at (basis weight per 1.2N / 5cm (g / m 2 )) is per basis weight 2. 3N / 5 cm (g / m 2 ), protruding fiber structure is formed on the surface of the non-woven fabric, protruding fiber length is 8 mm, the number of protruding fiber structures is 94 / cm 2 , and air permeability is 118 cc / cm 2 / sec.
得られた発泡成形品補強用不織布を評価した結果、本発明要件を外れる比較例1は、引出し変形、打ち抜き性、金型セット性とも良好だったが、発泡成形時のΔST5m−ST30mとΔST30m−ST40mが高くなるため発泡成形での金型追随性にやや難点があり、滲み出し、破れ、剥離も無いものの、皺の発生があり、成型品の形状はやや不良であった。性能評価では、制音性は良好だが、皺部から磨耗が生じて耐磨耗性と保形性がやや劣る、発泡成形用補強材としては難点のある発泡成形品補強用不織布であった。   As a result of evaluating the obtained nonwoven fabric for reinforcing foam molded articles, Comparative Example 1 which deviates from the requirements of the present invention was good in drawing deformation, punching property, and mold setting property, but ΔST5m-ST30m and ΔST30m- Since ST40m is high, there is a slight difficulty in following the mold in foam molding, and there is no bleeding, tearing, or peeling, but there are wrinkles and the shape of the molded product is somewhat poor. In the performance evaluation, it was a nonwoven fabric for reinforcing foam molded products, which had good points, but had some disadvantages as a reinforcing material for foam molding.
<比較例2>
固有粘度0.65のポリエチレンテレフタレート(PET)を用い、紡糸温度285℃、単孔吐出量1.0g/分にて溶融紡糸し、繊度2.0dtexの長繊維からなる目付80g/mのウエッブを得た。ついで、カレンダーローラーを用いて250℃で線圧20kN/mで圧着加工を行い、やや弱い全面圧着部を形成したポリエステル長繊維不織布を得て、被覆層とした以外、実施例1と同様にして発泡成形品補強用不織布を得た。
得られた発泡成形品補強用不織布は、目付120g/m、見掛密度0.14g/cm、5%伸張時応力は縦方向56N/5cm、横方向26N/5cm、30%伸張時応力は縦方向87N/5cm、横方向36N/5cm、ΔST5m−ST30mは31N/5cm、40%伸張時応力は縦方向96N/5cm、横方向44N/5cmで、ΔST30m−ST40mは9N/5cm、強度は縦方向325N/5cm(目付当り2.7N/5cm(g/m))、横方向177N/5cm(目付当り1.5N/5cm(g/m))で強度の和は目付当り4.2N/5cm(g/m)であり、突出繊維構造を長繊維不織布面に形成しており、突出繊維長3mm、突出繊維構造の形成個数は41個/cm、通気性48cc/cm/秒であった。
<Comparative example 2>
A polyethylene terephthalate (PET) having an intrinsic viscosity of 0.65, melt-spun at a spinning temperature of 285 ° C. and a single-hole discharge rate of 1.0 g / min, and a web having a basis weight of 80 g / m 2 made of long fibers having a fineness of 2.0 dtex. Got. Next, the same process as in Example 1 was carried out except that a calender roller was used for crimping at 250 ° C. with a linear pressure of 20 kN / m to obtain a polyester continuous fiber nonwoven fabric having a slightly weak full-surface crimped portion, which was used as a coating layer. A nonwoven fabric for reinforcing foam molded articles was obtained.
The obtained non-woven fabric for reinforcing foam-molded articles has a basis weight of 120 g / m 2 , an apparent density of 0.14 g / cm 3 , and a stress at 5% elongation of 56 N / 5 cm in the longitudinal direction, 26 N / 5 cm in the transverse direction, and stress at 30% elongation. Is 87N / 5cm in the vertical direction, 36N / 5cm in the horizontal direction, 31N / 5cm for ΔST5m-ST30m, the stress is 96N / 5cm in the vertical direction and 44N / 5cm in the horizontal direction, ΔST30m-ST40m is 9N / 5cm, and the strength is 9N / 5cm. longitudinal 325N / 5 cm (basis weight per 2.7N / 5cm (g / m 2 )), lateral 177N / 5cm sum of the intensities at (basis weight per 1.5N / 5cm (g / m 2 )) is per basis weight 4. 2N / a 5cm (g / m 2), the projecting fiber structure forms a long-fiber nonwoven fabric surface, the protruding fiber length 3 mm, forming the number of the protruding fiber structure 41 pieces / cm 2, air permeability 48 cc / cm Was / sec.
得られた発泡成形品補強用不織布を評価した結果、本発明要件を外れる比較例2は、引出し変形、打ち抜き性、金型セット性とも良好だったが、5%伸張時応力が高く、ΔST5m−ST30mも高くなるため発泡成形での金型追随性に難点があり、皺の発生が大で、浮きも発生し、破れも少し発生して滲み出しが認められ、成形品の形状は不良であった。性能評価では、制音性も劣り、皺部や浮き部から磨耗が生じて耐磨耗性が劣り、突出繊維構造の形成が悪いためか、発泡層との剥離も発生して保形性が劣る、発泡成形用補強材としては問題のある発泡成形品補強用不織布であった。   As a result of evaluating the obtained non-woven fabric for reinforcing foamed articles, Comparative Example 2 which deviates from the requirement of the present invention was good in drawing deformation, punching property, and mold setting property, but the stress at 5% elongation was high, and ΔST5m− Since ST30m is also high, there is a difficulty in following the mold in foam molding, generation of wrinkles, floating, slight breakage, exudation is observed, and the shape of the molded product is poor. It was. In the performance evaluation, the sound damping property is also inferior, the wear resistance is inferior due to wear from the buttocks and the floating part, and the protruding fiber structure is poorly formed, or peeling from the foam layer occurs and the shape retention is good. It was an inferior nonwoven fabric for reinforcing foam-molded products, which is a problem as a reinforcing material for foam molding.
<比較例3>
実施例2で得た発泡成形品補強用不織布の突出繊維構造面を185℃の熱ローラー面に添わせて毛羽伏せ処理により突出繊維構造をなくしたものを発泡成形品補強用不織布として評価した。なお、不織布特性は突出繊維構造が失われた以外特性に変化はなかった。
<Comparative Example 3>
The nonwoven fabric for reinforcing foam molded articles obtained in Example 2 was evaluated as a nonwoven fabric for reinforcing foam molded articles by adding the protruding fiber structure surface of the nonwoven fabric for reinforcing foam molded articles to a heat roller surface at 185 ° C. and eliminating the protruding fiber structure by fluffing treatment. The nonwoven fabric characteristics did not change except that the protruding fiber structure was lost.
比較例3の発泡成形品補強用不織布は、本発明要件の突出繊維構造が失われているため、引出し変形、打ち抜き性、金型セット性とも良好で、発泡成形での滲み出し、皺、浮き、破れも無く、型添い性も良好であったが、成形品の発泡層と補強層間に若干の剥離を生じ、性能評価では、制音性は良好だが、耐磨耗性、保形性とも剥離による耐久性が劣り、発泡成形用補強材としては問題のある発泡成形品補強用不織布であった。   Since the non-woven fabric for reinforcing foam molded product of Comparative Example 3 has lost the protruding fiber structure that is a requirement of the present invention, the drawing deformation, punching property, and mold setting property are also good. There was no tearing and the moldability was good, but some peeling occurred between the foamed layer and the reinforcing layer of the molded product, and in the performance evaluation, the sound-damping property was good, but the wear resistance and shape retention were both The non-woven fabric for reinforcing foam-molded articles has a problem of durability due to peeling and has a problem as a foam-molding reinforcing material.
<比較例4>
比較例1の短繊維不織布を目付を40g/mとした以外、同一の方法で作成した短繊維不織布を長繊維不織布に変えて基材層として用いた以外、実施例2と同様にして得られた短繊維不織布の積層構造となる発泡成形品補強用不織布は、目付120g/m、見掛密度0.06g/cm、5%伸張時応力は縦方向1.1N/5cm、横方向1.3N/5cm、30%伸張時応力は縦方向9N/5cm、横方向16N/5cm、ΔST5m−ST30mは7.8N/5cm、40%伸張時応力は縦方向13N/5cm、横方向24N/5cm、ΔST30m−ST40mは4N/5cmで、強度は縦方向151N/5cm(目付当り1.26N/5cm(g/m))、横方向182N/5cm(目付当り1.52N/5cm(g/m))で強度の和は目付当り2.78N/5cm(g/m)であり、突出繊維構造を基材層の短繊維不織布面に形成しており、通気性250cc/cm/秒以上であった。
<Comparative example 4>
The short fiber nonwoven fabric of Comparative Example 1 was obtained in the same manner as in Example 2 except that the short fiber nonwoven fabric prepared by the same method was used as a base material layer instead of the long fiber nonwoven fabric except that the basis weight was 40 g / m 2. The non-woven fabric for reinforcing foam-molded products having a laminated structure of the short fiber nonwoven fabric has a basis weight of 120 g / m 2 , an apparent density of 0.06 g / cm 3 , and a 5% elongation stress of 1.1 N / 5 cm in the vertical direction and in the horizontal direction. 1.3N / 5cm, 30% elongation stress is 9N / 5cm in the longitudinal direction, 16N / 5cm in the transverse direction, ΔST5m-ST30m is 7.8N / 5cm, 40% elongation is 13N / 5cm in the longitudinal direction, 24N / in the transverse direction. 5 cm, ΔST30m-ST40m is 4 N / 5 cm, strength is 151 N / 5 cm in the vertical direction (1.26 N / 5 cm (g / m 2 ) per unit weight), 182 N / 5 cm in the horizontal direction (1.52 N / 5 cm per unit weight (g / m ) Sum) in strength is basis weight per 2.78N / 5cm (g / m 2 ), the projecting fiber structure forms a short fiber nonwoven fabric surface of the substrate layer, breathable 250 cc / cm 2 / sec Met.
得られた発泡成形品補強用不織布を評価した結果、基材層に短繊維不織布を用いた本発明要件から外れる比較例4は、引出し変形、打ち抜き性、金型セット性とも不良で、発泡成形での滲み出しは顕著で、皺、破れも少し発生、剥離は無く、型添い性は伸張斑によるのかやや不良であった。性能評価でも、制音性は発泡剤の滲み出しで悪くなり、耐磨耗性、保形性とも形態保持が不良で問題がある発泡成形用補強材であった。   As a result of evaluating the obtained non-woven fabric for foam molded article reinforcement, Comparative Example 4 using short fiber non-woven fabric as the base material layer is out of the requirements of the present invention, and is poor in drawing deformation, punching property and mold setting property. The oozing was remarkable, the wrinkles and tears were slightly generated, there was no peeling, and the moldability was somewhat poor due to stretch spots. Even in the performance evaluation, the sound damping performance deteriorated due to the oozing of the foaming agent, and the foam molding reinforcement material had a problem that the shape retention was poor in both wear resistance and shape retention.
<比較例5>
短繊維不織布の目付を20g/mとし、長繊維不織布の目付を30g/mとした以外、実施例1と同様にして得られた発泡成形品補強用不織布は、目付50g/m、見掛密度0.12g/cm、5%伸張時応力は縦方向8N/5cm、横方向4N/5cm、30%伸張時応力は縦方向17N/5cm、横方向11N/5cm、ΔST5m−ST30mは9N/5cmで、40%伸張時応力は縦方向28N/5cm、横方向22N/5cmで、ΔST30m−ST40mは11N/5cmで、強度は縦方向110N/5cm(目付当り1.8N/5cm(g/m))、横方向138N/5cm(目付当り2.3N/5cm(g/m))で強度の和は目付当り4.1N/5cm(g/m)であり、突出繊維構造を長繊維不織布面に形成しており、突出繊維長6mm、突出繊維構造の形成個数は98個/cm、通気性190cc/cm/秒であった。
<Comparative Example 5>
The nonwoven fabric for reinforcing foam molded articles obtained in the same manner as in Example 1 except that the basis weight of the short fiber nonwoven fabric is 20 g / m 2 and the basis weight of the long fiber nonwoven fabric is 30 g / m 2 is 50 g / m 2 . Apparent density 0.12g / cm 3 , 5% elongation stress is 8N / 5cm in the longitudinal direction, 4N / 5cm in the transverse direction, 30% elongation stress is 17N / 5cm in the longitudinal direction, 11N / 5cm in the transverse direction, ΔST5m-ST30m At 9N / 5cm, the stress at 40% elongation is 28N / 5cm in the longitudinal direction, 22N / 5cm in the transverse direction, ΔST30m-ST40m is 11N / 5cm, and the strength is 110N / 5cm in the longitudinal direction (1.8N / 5cm (g / M 2 )), lateral direction 138 N / 5 cm (2.3 N / 5 cm per unit weight (g / m 2 )), and the sum of the strengths is 4.1 N / 5 cm (g / m 2 ) per unit basis, and the protruding fiber structure The long fiber nonwoven Formed on the fabric surface, the protruding fiber length was 6 mm, the number of protruding fiber structures formed was 98 / cm 2 , and the air permeability was 190 cc / cm 2 / sec.
得られた発泡成形品補強用不織布を評価した結果、本発明要件を満たさない比較例5は、引出し変形、打ち抜き性、金型セット性悪く、取扱性に劣り、発泡成形での滲み出しは微少発生しているが、皺、浮き、破れ、剥離は無く、型添い性も許容される状況であった。性能評価でも、制音性、耐磨耗性、保形性とも不良で、発泡成形用補強材としては不良な発泡成形品補強用不織布であった。   As a result of evaluating the obtained non-woven fabric for reinforcing foamed articles, Comparative Example 5 which does not satisfy the requirements of the present invention is poor in drawing deformation, punching property, mold setting property, inferior handling property, and exudation in foam molding is very small. Although it occurred, there was no wrinkling, floating, tearing or peeling, and the moldability was acceptable. Even in the performance evaluation, the non-woven fabric for reinforcing foam molded products was poor as a foam molding reinforcing material, with poor sound damping, wear resistance and shape retention.
<比較例6>
短繊維不織布の目付を160g/mとなるようクロスレイヤーにて160g/mに積層した以外、実施例1と同様にして得られた発泡成形品補強用不織布は、目付200g/m、見掛密度0.06g/cm、5%伸張時応力は縦方向35N/5cm、横方向20N/5cm、30%伸張時応力は縦方向64N/5cm、横方向50N/5cm、ΔST5m−ST30mは29N/5cmで、40%伸張時応力は縦方向93N/5cm、横方向76N/5cmで、ΔST30m−ST40mは29N/5cmで、強度は縦方向325N/5cm(目付当り1.6N/5cm(g/m))、横方向405N/5cm(目付当り2.0N/5cm(g/m))で強度の和は目付当り3.6N/5cm(g/m)であり、突出繊維構造を長繊維不織布面に形成しており、突出繊維長4mm、突出繊維構造の形成個数は116個/cm、通気性70cc/cm/秒であった。
<Comparative Example 6>
Except laminated to 160 g / m 2 basis weight of the short fiber nonwoven fabric at cross-layer so as to be 160 g / m 2, the expansion-molded article reinforcing nonwoven fabric obtained in the same manner as in Example 1, basis weight 200 g / m 2, Apparent density 0.06g / cm 3 , 5% stretching stress is 35N / 5cm in the longitudinal direction, 20N / 5cm in the transverse direction, 30% stretching stress is 64N / 5cm in the longitudinal direction, 50N / 5cm in the lateral direction, ΔST5m-ST30m At 29N / 5cm, the stress at 40% elongation is 93N / 5cm in the longitudinal direction, 76N / 5cm in the transverse direction, ΔST30m-ST40m is 29N / 5cm, and the strength is 325N / 5cm in the longitudinal direction (1.6N / 5cm (g / m 2)), lateral 405N / 5 cm (basis weight per 2.0N / 5cm (g / m 2 )) by the sum of the intensities is basis weight per 3.6N / 5cm (g / m 2 ), projecting fiber The fiber structure was formed on the surface of the long fiber nonwoven fabric, the protruding fiber length was 4 mm, the number of protruding fiber structures formed was 116 pieces / cm 2 , and the air permeability was 70 cc / cm 2 / sec.
得られた発泡成形品補強用不織布を評価した結果、本発明要件を満たさない比較例6は、引出し変形、打ち抜き性、金型セット性は問題なく取扱性は良好だが、発泡成形での滲み出し、破れ、剥離は無かったが、型添い性が悪く、皺、浮きを発生していた。性能評価では、制音性は良好だが、耐磨耗性がやや劣り、被覆層が磨耗により崩れて保形性が劣る、発泡成形用補強材としては問題の残る発泡成形品補強用不織布であった。   As a result of evaluating the obtained nonwoven fabric for reinforcing foamed articles, Comparative Example 6 which does not satisfy the requirements of the present invention has no problems with draw deformation, punchability, and mold setting properties, but has good handleability, but exudation in foam molding There was no tearing or peeling, but the moldability was poor and wrinkles and floats were generated. In performance evaluation, it is a non-woven fabric for reinforcing foam molded products, which remains problematic as a foam molding reinforcement, although it has good noise suppression but slightly inferior in abrasion resistance, and the covering layer collapses due to wear, resulting in poor shape retention. It was.
<比較例7>
繊維Aとして丸断面で1.4dtexの機械捲縮を有するカット長38mmのポリエチレンテレフタレートからなるポリエステル短繊維と繊維Bとして中空丸断面で15dtexの立体捲縮を有するカット長64mmのポリエチレンテレフタレートからなるポリエステル短繊維とを40/60質量比で混打綿にて混綿してカードウエッブ化し、クロスレイヤーにて60g/mとなるよう積層、ついで、予備交絡処理としてペネ数20個/cmの交絡絡合処理を行い、連続して、ペネ数120個/cmにて交絡絡合処理して目付60g/mの短繊維不織布を用いた以外、実施例1と同様にして得られた発泡成形品補強用不織布は、目付100g/m、見掛密度0.05g/cm、5%伸張時応力は縦方向6N/5cm、横方向4N/5cm、30%伸張時応力は縦方向32N/5cm、横方向26N/5cm、ΔST5m−ST30mは26N/5cmで、40%伸張時応力は縦方向74N/5cm、横方向50N/5cmで、ΔST30m−ST40mは42N/5cmで、強度は縦方向127N/5cm(目付当り1.3N/5cm(g/m))、横方向182N/5cm(目付当り1.8N/5cm(g/m))で強度の和は目付当り3.1N/5cm(g/m)であり、突出繊維構造を長繊維不織布面に形成しており、突出繊維長8mm、突出繊維構造の形成個数は101個/cm、通気性128cc/cm/秒であった。
<Comparative Example 7>
Polyester short fiber made of polyethylene terephthalate with a cut length of 38 mm having a mechanical crimp of 1.4 dtex in a round cross section as the fiber A and polyester made of polyethylene terephthalate with a cut length of 64 mm having a solid round crimp of 15 dtex in a fiber round B Short fibers are blended with blended cotton at a 40/60 mass ratio to form a card web and laminated to a cross layer of 60 g / m 2, and then pre-entangled with 20 pene / cm 2 penetrants Foaming obtained in the same manner as in Example 1 except that the entanglement treatment was performed continuously, and the short fiber nonwoven fabric having a basis weight of 60 g / m 2 was used by entanglement entanglement treatment with a number of pene of 120 pieces / cm 2 . moldings reinforcing nonwoven basis weight 100 g / m 2, an apparent density 0.05g / cm 3, 5% elongation when the stress longitudinal 6N / 5 cm, sideways 4N / 5cm, 30% stretching stress is 32N / 5cm in the longitudinal direction, 26N / 5cm in the lateral direction, ΔST5m-ST30m is 26N / 5cm, and 40% stretching stress is 74N / 5cm in the longitudinal direction, 50N / 5cm in the lateral direction. ΔST30m-ST40m at 42N / 5 cm, strength longitudinal 127N / 5 cm (basis weight per 1.3N / 5cm (g / m 2 )), lateral 182N / 5cm (basis weight per 1.8N / 5cm (g / m 2 )), The sum of the strength is 3.1 N / 5 cm (g / m 2 ) per unit weight, the protruding fiber structure is formed on the long-fiber nonwoven fabric surface, the protruding fiber length is 8 mm, and the number of protruding fiber structures formed is 101 Piece / cm 2 , and air permeability was 128 cc / cm 2 / sec.
得られた発泡成形品補強用不織布を評価した結果、本発明要件を満たさない比較例7は、やや嵩高なため、引出し変形、打ち抜き性にやや問題があり、金型セット性は許容できるので、取扱性は許容範囲だが、発泡成形での浮き、破れ、剥離は無かったが、型添い性がやや悪く、横漏れによる滲み出しや皺を発生していた。性能評価では、制音性、耐磨耗性がやや劣り、被覆層が磨耗により剥離するので保形性にも難点が残る発泡成形品補強用不織布であった。   As a result of evaluating the obtained nonwoven fabric for reinforcing foamed articles, Comparative Example 7 that does not satisfy the requirements of the present invention is somewhat bulky, so there is a slight problem in the drawing deformation and punchability, and the mold setting property is acceptable. Although handling was acceptable, there was no lifting, tearing or peeling in foam molding, but the moldability was somewhat poor, and bleeding and wrinkles due to side leakage occurred. In the performance evaluation, it was a nonwoven fabric for reinforcing foam molded products, in which sound insulation and abrasion resistance were slightly inferior, and the covering layer was peeled off due to abrasion, so that there was a difficulty in shape retention.
<比較例8>
繊維Aとして丸断面で1dtexの機械捲縮を有するカット長38mmのポリエチレンテレフタレートからなるポリエステル短繊維と繊維Bとして丸断面で1.2dtexの機械捲縮を有するカット長51mmのポリエチレンテレフタレートからなるポリエステル短繊維とを40/60質量比で混打綿にて混綿してカードウエッブ化し、クロスレイヤーにて60g/mとなるよう積層、ついで、予備交絡処理としてペネ数20個/cmの交絡絡合処理を行い、連続して、ペネ数120個/cmにて交絡絡合処理して得られた目付60g/mの短繊維不織布を被覆層に用いた以外、実施例1と同様にして得られた発泡成形品補強用不織布は、目付100g/m、見掛密度0.09g/cm、5%伸張時応力は縦方向23N/5cm、横方向11N/5cm、30%伸張時応力は縦方向54N/5cm、横方向23N/5cm、ΔST5m−ST30mは31N/5cmで、40%伸張時応力は縦方向86N/5cm、横方向32N/5cmで、ΔST30m−ST40mは31N/5cmで、強度は縦方向236N/5cm(目付当り2.3N/5cm/(g/m))、横方向302N/5cm(目付当り3.0N/5cm/(g/m))で強度の和は目付当り5.3N/5cm/(g/m)であり、突出繊維構造を長繊維不織布面に形成しており、突出繊維長7mm、突出繊維構造の形成個数は110個/cm、通気性108cc/cm/秒であった。
<Comparative Example 8>
Polyester short fibers made of polyethylene terephthalate with a cut length of 38 mm having a 1 dtex mechanical crimp as a fiber A and polyester short fibers made of polyethylene terephthalate with a cut length of 51 mm having a mechanical cross of 1.2 dtex in a round cross section as fiber B The fiber is mixed with a blended cotton at a mass ratio of 40/60 to form a card web, laminated to a cross layer of 60 g / m 2, and then entangled with 20 pens / cm 2 as a pre-entanglement process. In the same manner as in Example 1 except that a short fiber nonwoven fabric having a basis weight of 60 g / m 2 obtained by performing an entangling process and continuously entangling with a penetrating number of 120 pieces / cm 2 was used for the coating layer. molded foam reinforcing nonwoven was collected using the basis weight 100 g / m 2, an apparent density 0.09g / cm 3, 5% elongation when the stress longitudinal 23N / cm, transverse direction 11 N / 5 cm, 30% elongation stress is 54 N / 5 cm longitudinal direction, 23 N / 5 cm, ΔST5m-ST30m is 31 N / 5 cm, 40% elongation stress is 86 N / 5 cm longitudinal direction, 32 N transverse direction. / 5 cm, ΔST30m-ST40m is 31 N / 5 cm, strength is 236 N / 5 cm in the vertical direction (2.3 N / 5 cm / (g / m 2 ) per unit weight), 302 N / 5 cm in the horizontal direction (3.0 N / 5 cm per unit weight) / (G / m 2 )) and the sum of the strength is 5.3 N / 5 cm / (g / m 2 ) per unit weight, and the protruding fiber structure is formed on the surface of the long fiber nonwoven fabric, the protruding fiber length is 7 mm, the protruding The number of fiber structures formed was 110 / cm 2 , and the air permeability was 108 cc / cm 2 / sec.
得られた発泡成形品補強用不織布を評価した結果、本発明要件を満たさない比較例8は、引出し変形、打ち抜き性、金型セット性は問題なく取扱性は優れている。発泡成形での滲み出し、浮き、破れ、剥離は無かったが、型添い性が悪く、皺も発生した。性能評価では、制音性は良好だが、耐磨耗性がやや劣り、被覆層が磨耗により剥離するので保形性に難点が残る発泡成形品補強用不織布であった。   As a result of evaluating the obtained nonwoven fabric for reinforcing foamed articles, Comparative Example 8, which does not satisfy the requirements of the present invention, is excellent in handleability without any problems in drawing deformation, punching property, and mold setting property. There was no oozing, floating, tearing or peeling in foam molding, but the moldability was poor and wrinkles were also generated. In the performance evaluation, it was a non-woven fabric for reinforcing foam molded articles, which had good sound-damping properties but slightly inferior in abrasion resistance and had a difficulty in retaining its shape because the coating layer peeled off due to abrasion.
<比較例9>
繊維Aとして丸断面で2dtexの機械捲縮を有するカット長51mmのポリエチレンテレフタレートからなるポリエステル短繊維と繊維Bとして丸断面で4.0dtexの機械捲縮を有するカット長51mmのポリエチレンテレフタレートからなるポリエステル短繊維とを92/8質量比で混打綿にて混綿してカードウエッブ化し、クロスレイヤーにて80g/mとなるよう積層、ついで、予備交絡処理としてペネ20個/cmの交絡絡合処理を行い、連続して、ペネ数120個/cmにて交絡絡合処理して得られた目付60g/mの短繊維不織布を被覆層に用いた以外、実施例2と同様にして得られた発泡成形品補強用不織布は、目付120g/m、見掛密度0.09g/cm、5%伸張時応力は縦方向22N/5cm、横方向6N/5cm、30%伸張時応力は縦方向48N/5cm、横方向21N/5cm、ΔST5m−ST30mは26N/5cmで、40%伸張時応力は縦方向74N/5cm、横方向40N/5cmで、ΔST30m−ST40mは26N/5cmで、強度は縦方向129N/5cm(目付当り1.1N/5cm/(g/m))、横方向141N/5cm(目付当り1.2N/5cm/(g/m))で強度の和は目付当り2.3N/5cm/(g/m)であり、突出繊維構造を長繊維不織布面に形成しており、突出繊維長7mm、突出繊維構造の形成個数は100個/cm、通気性120cc/cm/秒であった。
<Comparative Example 9>
A short polyester fiber made of polyethylene terephthalate with a cut length of 51 mm having a mechanical cross section of 2 dtex as a fiber A and a short polyester fiber made of polyethylene terephthalate with a cut length of 51 mm having a mechanical crimp of 4.0 dtex in a round cross section as fiber B The fiber is mixed with a blended cotton at a mass ratio of 92/8 to form a card web, laminated to a cross layer of 80 g / m 2, and then entangled with 20 penes / cm 2 as a pre-entanglement treatment. The same procedure as in Example 2 was conducted, except that a short fiber nonwoven fabric having a basis weight of 60 g / m 2 obtained by continuously entanglement treatment at 120 pene / cm 2 was used for the coating layer. the resulting molded foam reinforcing nonwoven basis weight 120 g / m 2, an apparent density 0.09g / cm 3, 5% elongation when the stress longitudinal 22N / 5c The transverse stress is 6N / 5cm, the stress at 30% elongation is 48N / 5cm in the longitudinal direction, 21N / 5cm in the transverse direction, ΔST5m-ST30m is 26N / 5cm, the stress at 40% elongation is 74N / 5cm in the longitudinal direction, 40N / lateral. 5 cm, ΔST30m-ST40m is 26 N / 5 cm, strength is 129 N / 5 cm in the vertical direction (1.1 N / 5 cm / (g / m 2 ) per unit weight), 141 N / 5 cm in the horizontal direction (1.2 N / 5 cm / per unit weight) (G / m 2 )) and the sum of strengths is 2.3 N / 5 cm / (g / m 2 ) per unit weight, and the protruding fiber structure is formed on the surface of the non-woven fabric, the protruding fiber length is 7 mm, and the protruding fiber is The number of structures formed was 100 / cm 2 and the air permeability was 120 cc / cm 2 / sec.
得られた発泡成形品補強用不織布を評価した結果、本発明要件を外れる比較例9は、引出し変形、打ち抜き性、金型セット性とも良好だったが、発泡成形時のΔST5m−ST30mとΔST30m−ST40mが高くなるため発泡成形での金型追随性にやや難点があり、滲み出し、破れ、剥離も無いものの、皺の発生があり、成型品の形状はやや不良であった。性能評価では、制音性は良好だが、皺部から磨耗が生じて耐磨耗性と保形性がやや劣る、発泡成形用補強材としては難点のある発泡成形品補強用不織布であった。   As a result of evaluating the obtained nonwoven fabric for reinforcing foam molded articles, Comparative Example 9 which deviates from the requirements of the present invention was good in drawing deformation, punchability, and mold setting properties, but ΔST5m-ST30m and ΔST30m- Since ST40m is high, there is a slight difficulty in following the mold in foam molding, and there is no bleeding, tearing, or peeling, but there are wrinkles and the shape of the molded product is somewhat poor. In the performance evaluation, it was a nonwoven fabric for reinforcing foam molded products, which had good points, but had some disadvantages as a reinforcing material for foam molding.
<比較例10>
固有粘度0.65のポリエチレンテレフタレートを用い、紡糸温度285℃、単孔吐出量1.0g/分にて紡糸、振落して、繊度2.0dtexの長繊維からなる目付60g/mのウエッブを得た。ついで、圧着面積率42%の凹織目柄のエンボスローラーを用いて260℃、線圧40kN/mにてエンボス加工を行い、圧着部の面積比率38%で圧着部が独立していない、見掛密度0.16g/mのポリエステル長繊維不織布を得た。
得られた長繊維不織布を基材層に用いた以外、実施例1と同様にして得られた発泡成形品補強用不織布は、目付120g/m、見掛密度0.10g/cm、5%伸張時応力は縦方向43N/5cm、横方向26N/5cm、30%伸張時応力は縦方向146N/5cm、横方向58N/5cm、ΔST5m−ST30mは103N/5cmで、40%伸張時応力は縦方向204N/5cm、横方向76N/5cmで、ΔST30m−ST40mは31N/5cmで、強度は縦方向298N/5cm(目付当り2.5N/5cm/(g/m))、横方向170N/5cm(目付当り1.4N/5cm/(g/m))で強度の和は目付当り3.9N/5cm/(g/m)であり、突出繊維構造を長繊維不織布面に形成しており、突出繊維長7mm、突出繊維構造の形成個数は100個/cm、通気性98cc/cm/秒であった。
<Comparative Example 10>
Using polyethylene terephthalate having an intrinsic viscosity of 0.65, spinning and shaking at a spinning temperature of 285 ° C. and a single hole discharge rate of 1.0 g / min, a web having a basis weight of 60 g / m 2 made of long fibers having a fineness of 2.0 dtex is used. Obtained. Next, embossing is performed at 260 ° C. and a linear pressure of 40 kN / m using an embossed roller with a concave texture pattern with a crimping area ratio of 42%, and the crimping area is 38% and the crimping part is not independent. A polyester continuous fiber non-woven fabric having a hanging density of 0.16 g / m 2 was obtained.
A nonwoven fabric for reinforcing foam molded articles obtained in the same manner as in Example 1 except that the obtained long fiber nonwoven fabric was used for the base material layer had a basis weight of 120 g / m 2 and an apparent density of 0.10 g / cm 3 , 5 The stress at% elongation is 43N / 5cm in the longitudinal direction, 26N / 5cm in the transverse direction, the stress at 30% elongation is 146N / 5cm in the longitudinal direction, 58N / 5cm in the transverse direction, ΔST5m-ST30m is 103N / 5cm, and the stress at 40% elongation is Longitudinal direction 204N / 5cm, transverse direction 76N / 5cm, ΔST30m-ST40m is 31N / 5cm, strength is longitudinal direction 298N / 5cm (2.5N / 5cm / (g / m 2 ) per unit weight), lateral direction 170N / a 5 cm (basis weight per 1.4N / 5cm / (g / m 2)) sum in intensity basis weight per 3.9N / 5cm / (g / m 2), the protruding fiber structure is formed on the long-fiber nonwoven fabric surface And Fiber length 7 mm, forming the number of the protruding fiber structure 100 / cm 2 out was breathable 98cc / cm 2 / sec.
得られた発泡成形品補強用不織布を評価した結果、本発明要件を外れる比較例1は、引出し変形、打ち抜き性、金型セット性とも良好だったが、発泡成形時のST5、ΔST5m−ST30m及びΔST30m−ST40mが高くなるため発泡成形での金型追随性に難点があり、破れ、剥離も無いものの、皺、浮きの発生があり、補強材の外側からの滲み出しを生じ、成形品の形状は不良であった。性能評価では、制音性は許容されるが、皺部から磨耗が生じて耐磨耗性及び保形性にやや難点がある発泡成形品補強用不織布であった。   As a result of evaluating the obtained nonwoven fabric for reinforcing foamed articles, Comparative Example 1 that deviated from the requirements of the present invention was good in drawing deformation, punching property, and mold setting property, but ST5, ΔST5m-ST30m during foam molding and Since ΔST30m-ST40m is high, there is a difficulty in mold followability in foam molding, and there is no tearing or peeling, but wrinkles and floats occur, bleeding from the outside of the reinforcing material occurs, and the shape of the molded product Was bad. In the performance evaluation, the nonwoven fabric was reinforced with foamed molded article, although the sound-damping property was allowed, but abrasion occurred from the heel part and there were some difficulties in wear resistance and shape retention.
本発明の発泡成形品補強用不織布は、柔軟で且つ遮蔽機能が高い基材層と嵩高で制音性に優れる被覆層からなり、突出繊維構造によるアンカー効果で発泡成形部と補強材の一体化が良好で、且つ、初期伸張時の伸びを抑制して取扱性を維持し、成形時の局部的剪断応力負荷時は伸張変形し易くして均一な金型追随性を向上せしめた発泡成形用補強材用途に最適な発泡成形品補強用不織布である。発泡成形時の金型への追従性に優れ、発泡剤の滲み出しもなく、高品位な発泡成形体が得られ、発泡成形体とバネ材間の摩擦によって発生する擦過音防止性に優れ、一体化した補強材の強力が高いので優れた補強効果と耐久性も得られ、製造コストを低く抑えた高機能な発泡成形品を得るための発泡成形品補強用不織布を安価に提供できる。
本発明の発泡成形品補強用不織布は比較的軽量なため、軽量で高品位な発泡成形体を安価に製造でき、その発泡成形体を用いた車両も安価に軽量化でき、車両運用上での省エネルギー化にも寄与できる。
The nonwoven fabric for reinforcing foam molded articles of the present invention comprises a base layer that is flexible and has a high shielding function, and a coating layer that is bulky and excellent in sound-damping properties, and the foam molded part and the reinforcing material are integrated by an anchor effect due to a protruding fiber structure. For foam molding with good moldability, which maintains the handleability by suppressing the elongation at the time of initial stretching, and is easy to stretch and deform when the local shear stress is applied during molding to improve uniform mold followability This is a non-woven fabric for reinforcing foam molded products that is optimal for reinforcing material applications. Excellent conformability to the mold during foam molding, no exudation of foaming agent, high-quality foam molded body is obtained, and excellent resistance to scratching generated by friction between foam molded body and spring material, Since the strength of the integrated reinforcing material is high, an excellent reinforcing effect and durability can be obtained, and a non-woven fabric for reinforcing a foam molded product for obtaining a highly functional foam molded product with a low manufacturing cost can be provided at a low cost.
Since the nonwoven fabric for foam molded article reinforcement of the present invention is relatively lightweight, a lightweight and high-quality foam molded article can be manufactured at low cost, and a vehicle using the foam molded article can also be reduced in weight at low cost. It can also contribute to energy saving.

Claims (3)

  1. 短繊維不織布層と、部分的に緻密圧着部を形成した長繊維不織布層が積層され、短繊維不織布層と長繊維不織布層は部分的に交絡絡合されており、短繊維不織布層を形成する繊維が長繊維不織布層を貫通して突出繊維構造を形成しており、縦方向の5%伸張時応力(ST5m)が10〜30N/5cmであり、横方向の5%伸張時応力(ST5c)が5〜25N/5cmであり、縦方向の5%伸張時応力(ST5m)と縦方向の30%伸張時応力(ST30m)との差(ΔST5m−ST30m)及び、縦方向の30%伸張時応力(ST30m)と縦方向の40%伸張時応力(ST40m)との差(ΔST30m−ST40m)が下記式を満足する発泡成形品補強用不織布。
    ΔST5m−ST30m≦25(N/5cm) ・・・式1
    ΔST30m−ST40m≦25(N/5cm) ・・・式2
    A short fiber nonwoven fabric layer and a long fiber nonwoven fabric layer partially formed with a dense crimping portion are laminated, and the short fiber nonwoven fabric layer and the long fiber nonwoven fabric layer are partially entangled to form a short fiber nonwoven fabric layer. The fiber penetrates the long-fiber nonwoven fabric layer to form a protruding fiber structure, the longitudinal stress (5% stretch) (ST5m) is 10 to 30 N / 5 cm, and the transverse stress 5% stretch (ST5c). Is 5 to 25 N / 5 cm, the difference (ΔST5m−ST30m) between the 5% stretching stress (ST5m) in the longitudinal direction and the 30% stretching stress (ST30m) in the longitudinal direction, and the 30% stretching stress in the longitudinal direction. A non-woven fabric for reinforcing a foam molded product in which a difference (ΔST30m−ST40m) between (ST30m) and a stress in 40% elongation in the vertical direction (ST40m) satisfies the following formula.
    ΔST5m−ST30m ≦ 25 (N / 5 cm) Formula 1
    ΔST30m−ST40m ≦ 25 (N / 5 cm) Equation 2
  2. ポリエステル繊維からなり、目付当りの縦方向の強度(DTm)及び横方向の強度(DTc)が1.6N/5cm以上で、目付当りの縦方向と横方向の強度の和(DTm+DTc=DTt)が3.5N/5cm以上である請求項1に記載の発泡成形品補強用不織布。   Made of polyester fiber, the longitudinal strength per unit weight (DTm) and lateral strength (DTc) is 1.6 N / 5 cm or more, and the sum of the vertical and lateral strength per unit basis weight (DTm + DTc = DTt) The nonwoven fabric for reinforcing foam-molded articles according to claim 1, which is 3.5 N / 5 cm or more.
  3. 短繊維不織布を構成する繊維は、少なくとも2種類の短繊維を含有し、繊度が1.2〜3dtexの繊度の低い繊維(繊維A)と繊度が2〜4dtexの繊度の高い繊維(繊維B)を含有し、繊維Aと繊維Bの繊度差(ΔD)と繊維Aと繊維Bの質量混率(A/B)が下記式を満足する請求項1または2に記載の発泡成形品補強用不織布。
    繊度差(ΔD):0.5≦ΔD≦2(dtex) ・・・式3
    混率(A/B):80/20〜30/70(質量%) ・・・式4
    The fibers constituting the short fiber nonwoven fabric contain at least two types of short fibers, a fiber having a fineness of 1.2 to 3 dtex (fiber A) and a fiber having a fineness of 2 to 4 dtex (fiber B). The nonwoven fabric for reinforcing a foam molded article according to claim 1 or 2, wherein the fineness difference (ΔD) between the fibers A and B and the mass mixture ratio (A / B) between the fibers A and B satisfy the following formula.
    Fineness difference (ΔD): 0.5 ≦ ΔD ≦ 2 (dtex) Formula 3
    Mixing ratio (A / B): 80/20 to 30/70 (mass%) Formula 4
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Cited By (2)

* Cited by examiner, † Cited by third party
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JP2016169562A (en) * 2015-03-13 2016-09-23 七王工業株式会社 Weed prevention sheet and using method thereof
JP2018031079A (en) * 2016-08-22 2018-03-01 東洋紡株式会社 Method for producing reinforcement material for urethane foam molding

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JPH0625391U (en) * 1992-09-09 1994-04-05 千代田株式会社 Non-woven
JP3446349B2 (en) * 1994-11-18 2003-09-16 松下電工株式会社 Laminated nonwoven fabric, electric carpet using the laminated nonwoven fabric, and method for producing the laminated nonwoven fabric
JP2002363849A (en) * 2001-06-01 2002-12-18 Toyobo Co Ltd Laminated nonwoven fabric and needle-punched carpet base fabric
JP2005212204A (en) * 2004-01-28 2005-08-11 Daiwabo Co Ltd Reinforcing material for molded foam

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2016169562A (en) * 2015-03-13 2016-09-23 七王工業株式会社 Weed prevention sheet and using method thereof
JP2018031079A (en) * 2016-08-22 2018-03-01 東洋紡株式会社 Method for producing reinforcement material for urethane foam molding

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