JP2015017339A - Ice accretion resistant and soundproof buffer material and method for producing the same, and vehicle exterior material obtained using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an ice accretion resistant and soundproof buffer material that is rich in sound insulation properties and excellent in icing prevention properties, and is useful for a vehicle exterior material such as a fender liner, an engine undercover or a body undercover of an automobile.SOLUTION: The ice accretion resistant and soundproof buffer material 1 is formed by laminating an air permeable resin surface layer 2 on a fiber base layer 3. The air permeable resin surface layer 2 is constituted of a molten material of a thermoplastic fiber sheet obtained by using only one kind of short fiber comprising a hydrophobic thermoplastic resin or only mixed fibers obtained by mixing two or more kinds of short fibers comprising a hydrophobic thermoplastic resin and having different fiber diameters.

Description

  The present invention relates to an anti-icing / soundproof cushioning material used for, for example, an automobile fender liner, engine undercover, body undercover, and the like.

A kind of soundproof cushioning material such as an automobile fender liner, engine undercover, body undercover, etc. generally comprises a resin layer and a fiber layer laminated on one surface of the resin layer, and is used as, for example, an automobile fender liner. In this case, the resin layer is attached to the inner surface of the tire house with the resin layer facing the tire. In this case, in order to absorb the impact sound when pebbles and sand collide with the fender liner due to the chipping phenomenon while the vehicle is running, the resin layer must be formed with a pore that passes through the fiber layer as the sound absorbing material.
On the other hand, in order to prevent icing on the fender liner in winter, the surface of the resin layer on the tire side needs to be a hydrophobic smooth surface free from fluff.
Conventionally, as a soundproof cushioning material that satisfies both the soundproofing buffering property and the anti-icing property, a base layer made of a nonwoven fabric in which a number of short fibers are bonded to each other, and a resin surface layer covering the surface of the base layer are provided. A soundproof cushioning material is provided (Patent Document 1).

JP 2008-132972 A

In the resin surface layer of the soundproof cushioning material, the resin fibers are formed by mixing the short fibers and the resin fibers forming the resin portion to form a resin surface fiber body, and heating the resin surface layer fiber body. The resin part is melted and embedded with the short fibers. The resin part has innumerable fine holes passing through both surfaces thereof.
However, in the resin surface layer, short fibers are mixed in the resin part, which is a binder, so that short fibers are formed on the surface of the resin layer, which reduces the anti-icing property of the resin layer. It was a cause.
It is an object of the present invention to provide an anti-icing / soundproof cushioning material having excellent soundproofing properties by imparting air permeability to the air permeable resin surface layer without generating a fluff on the air permeable resin surface layer.

As a means for solving the above problems, the present invention comprises a fiber base layer laminated with a breathable resin surface layer, and the breathable resin surface layer is composed of only one kind of short fiber made of hydrophobic thermoplastic resin fibers, Or anti-icing / soundproofing composed of a melt of a thermoplastic fiber sheet using only mixed fibers obtained by mixing two or more types of short fibers that differ only in the fiber diameter of a hydrophobic thermoplastic resin Provide cushioning material.
The melting point of the thermoplastic resin used for the fiber sheet is desirably 140 to 170 ° C.
Further, the thermoplastic fiber sheet is made of a nonwoven fabric in which fibers are bonded to each other by needle punching with a punch density of 200 to 300 / cm ^{2 on} the web of the short fibers or the mixed fibers, The thermoplastic fiber sheet constituting the air permeable resin surface layer is desirably bonded to the fiber base layer by needle punching with a punch density of 50 to 150 / cm ² .
The fiber base layer is preferably made of a fiber containing 30 to 70% by mass of a low-melting thermoplastic resin fiber having a melting point of 110 ° C. or lower and further mixed with 5 to 30% by mass of polypropylene fiber.
Moreover, it is desirable that a spunbonded nonwoven fabric is inserted into the breathable resin surface layer or the fiber base layer in order to reinforce the breathable resin surface layer or the fiber base layer.
The icing / soundproof cushioning material preferably has an air permeability of 30 cc / cm ² · sec or less.
The anti-icing / soundproof cushioning material of the present invention is particularly useful as a vehicle exterior material.
A breathable resin surface layer is laminated on the fiber layer, and the breathable resin surface layer is only one kind of short fiber made of a hydrophobic thermoplastic resin, or only a fiber diameter made of a hydrophobic thermoplastic resin. The method for producing an anti-icing / soundproof cushioning material composed of a melt of a thermoplastic fiber sheet using only mixed fibers obtained by mixing two or more types of short fibers differing in the following steps 1 to 1 It consists of process 3.
Needle punch on a web consisting only of mixed fibers obtained by mixing only one type of short fiber made of a hydrophobic thermoplastic resin, or two or more types of short fibers having different fiber diameters made of a hydrophobic thermoplastic resin. The process 1 which makes a nonwoven fabric which is a thermoplastic resin fiber sheet | seat by processing and couple | bonding fibers mutually.
The nonwoven fabric is polymerized on the surface of the fiber base layer web layer, needle punched to bond the nonwoven fabric and the fiber base layer web layer, and the fibers of the fiber base layer web layer are bound to each other. Step 2 as a base layer.
The polymer of the nonwoven fabric and the fiber base layer is heated at a temperature higher than the melting point of the hydrophobic thermoplastic resin constituting the nonwoven fabric to melt the short fibers or mixed fibers made of the hydrophobic thermoplastic resin. Step 3 of forming a breathable resin surface layer and forming it into a predetermined shape.
The polymer of the nonwoven fabric and the fiber base layer is desirably heated at a temperature 30 to 50 ° C. higher than the melting point of the thermoplastic resin used for the nonwoven fabric.

[Action]
In the anti-icing / soundproof cushioning material of the present invention, only one type of short fiber made of a hydrophobic thermoplastic resin or only the fiber diameter made of a hydrophobic thermoplastic resin is different as the breathable resin surface layer. A melt of a hydrophobic thermoplastic fiber sheet made only of mixed fibers obtained by mixing two or more kinds of short fibers is used. Since the melt of the thermoplastic fiber sheet has voids between the fibers, the melt can have air permeability.
Further, the melt of the thermoplastic fiber sheet is only a single type of short fiber (staple) made of a thermoplastic resin, or only a mixed fiber obtained by mixing two or more types of short fibers (staples) having different fiber diameters only. Is used. Needless to say, it consists of only one type of short fiber (staple), and even when it consists of mixed fibers, the two or more types of short fibers (staples) differ only in fiber diameter and are made of similar thermoplastic resins. Therefore, the entire amount of the short fibers (staples) is melted at a predetermined temperature (melting point of the thermoplastic resin to be used). For this reason, since the surface of the breathable resin surface layer is free from blemishes due to the short fibers (staples), it is difficult for water droplets and ice to adhere to the surface layer, and suitable icing resistance can be exhibited. The normal short fiber (staple) is a fiber having a fiber length of 100 mm or less.
Further, the thermoplastic fiber sheet can melt almost all of the short fibers (staples) at the time of processing and molding by setting the melting point of the thermoplastic resin to be used to 140 to 170 ° C. It can be assumed that there is no fluff due to fibers (staples).
The thermoplastic fiber sheet is needle-punched on the short fiber or mixed fiber web to bond the fibers together to form a nonwoven fabric. At this time, the punch density is 200 to 300 / cm ^2. By making the density high, it is possible to further smooth the surface of the breathable resin surface layer and to improve the anti-icing property (icing resistance) of the breathable resin surface layer while maintaining the breathability. . In addition, since the thermoplastic fiber sheet constituting the breathable resin surface layer is combined with the fiber base layer by needle punching with a punch density of 50 to 150 / cm ² , the fiber base layer Air permeability can be maintained by not using an adhesive or the like for bonding to the surface, and the surface of the air permeable resin surface layer can be further smoothed to prevent icing of the air permeable resin surface layer (anti-icing resistance). Property) can be made suitable.
Further, the fiber base layer covered with the air permeable resin surface layer provides soundproofing to the anti-icing / soundproof cushioning material of the present invention. Usually, a low melting point thermoplastic resin fiber having a melting point of 110 ° C. or lower is used. The strength of the air-permeable resin surface layer and the fiber base layer can be improved by containing 30 to 70% by mass and melting the low-melting point thermoplastic resin fibers at the time of thermoforming to bind the fibers together. Furthermore, heat-resistant shape retention property can be provided to a fiber base layer by mixing 5-30 mass% of polypropylene fibers with the fiber used as a material.
In addition, it is desirable to insert a spunbonded nonwoven fabric into the air permeable resin surface layer or the fiber base layer, and the occurrence of problems such as resin breakage during heat molding can be suppressed.
Moreover, it is desirable that the above-mentioned anti-icing / soundproof cushioning material has an air permeability of 30 cc / cm ² · sec or less, so that soundproofing can be made suitable. The air permeability is a value measured according to JIS L1096 air permeability A method.
The anti-icing / soundproof cushioning material of the present invention is usually composed of the above three steps, Step 1 to Step 3. In step 1, a nonwoven fabric which is a thermoplastic resin fiber sheet to be a breathable resin surface layer is obtained. In step 2, the nonwoven fabric is bonded to the fiber base layer by needle punching.・ Breathability of soundproof cushioning material is secured. Furthermore, in step 3, since all the short fibers (staples) used for the breathable resin surface layer can be reliably melted by heating at a temperature higher than the melting point of the thermoplastic resin, the short fibers (staples) It is possible to prevent the occurrence of scuffing and to make the air permeable resin surface layer have a suitable anti-icing property (icing resistance).
Moreover, if the heating temperature is set to a temperature 30 to 50 ° C. higher than the melting point of the thermoplastic resin used for the short fibers (staples) constituting the nonwoven fabric that becomes the breathable resin surface layer, the short fibers (staples) are completely formed. However, the melt is porous so as not to impair air permeability.

〔effect〕
The anti-icing / sound-proof cushioning material of the present invention is excellent in anti-icing and anti-icing properties, and thus is useful for automotive exterior materials such as automobile fender liners, engine under covers, and body under covers. .

Sectional drawing which shows one Example of an anti-icing and soundproofing shock absorbing material. Sectional drawing which shows one Example of an anti-icing and soundproofing shock absorbing material. Sectional drawing which shows one Example of an anti-icing and soundproofing shock absorbing material.

Embodiments embodying the present invention will be described in detail below.
As shown in FIG. 3, the anti-icing / soundproof cushioning material 1 is configured by laminating a breathable resin surface layer 2 on one surface of a fiber base layer 3. The fiber base layer 3 imparts soundproofing properties to the soundproofing cushioning material 1 and also imparts buffering properties that suppress scratches when hit by stones or the like. The breathable resin surface layer 2 prevents water absorption of the fiber base layer 3 by repelling water or ice when it adheres.
As shown in FIG. 1, in the anti-icing / soundproof cushioning material 1, a spunbonded nonwoven fabric 4 may be inserted into the breathable resin surface layer 2.
As shown in FIG. 2, in the anti-icing / soundproof cushioning material 1, a spunbonded nonwoven fabric 4 may be inserted into the fiber base layer 3.

(Breathable resin surface layer)
The breathable resin surface layer 2 used in the ice-proof / soundproof cushioning material 1 of the present invention prevents water absorption of the fiber base layer 3 as described above, and also provides soundproofing by the fiber base layer 3. Therefore, it has predetermined air permeability.
For the air-permeable resin surface layer 2, a melt of a thermoplastic fiber sheet obtained from short fibers (staples) made of a hydrophobic thermoplastic resin is used. The short fibers (staples) are usually fibers having a length of 100 mm or less.
The above short fibers (staples) are mixed fibers obtained by mixing only one kind of short fibers (staples) or two or more kinds having different fiber diameters in order to ensure the air permeability of the air permeable resin surface layer 2. use. For example, when using a mixed fiber obtained by mixing two or more types that differ only in fiber diameter, the fiber diameter is 4-5 dtex ultrafine fiber, 6-8 dtex medium fine fiber, and 15-20 dtex thick. It is used by mixing three types with diameter fiber. It is desirable that the mixing ratio is such that at least one of the fiber diameters does not fall below 10% by mass in the mixed fiber. In the present invention, for example, two kinds of mixed fibers of the ultrafine fiber and the large diameter fiber, and two kinds of mixed fibers of the medium diameter fiber and the large diameter fiber can be used. In this case, the mixing ratio is preferably in the range of 20:80 to 80:20 mass ratio.
A hydrophobic thing is used for the said thermoplastic resin. As the hydrophobic thermoplastic resin, those having a melting point in the range of 145 to 165 ° C. are desirable, and generally, polyolefins such as polypropylene, ethylene-propylene copolymer, and polyethylene are used, from the viewpoint of strength and rigidity. Polypropylene is desirable as the hydrophobic thermoplastic resin of the present invention.

The above-mentioned one type of short fiber (staple), or a mixed fiber obtained by mixing two or more types of short fibers (staples) that differ only in fiber diameter, only the short fiber (staple) or only the mixed fiber is carded. After being made into a web, the fibers are usually entangled by performing needle punch processing, and the fibers are bonded to each other to form a nonwoven fabric which is a thermoplastic resin fiber sheet. Since the nonwoven fabric which is this thermoplastic resin fiber sheet has a space | gap between fibers and becomes a porous thing, air permeability is provided to the said air permeable resin surface layer 2. FIG. In this case, in order to obtain a surface with high anti-icing property (icing resistance), it is desirable to increase the punch density and set it in the range of 200 to 300 / cm ² .
The nonwoven fabric which is the thermoplastic resin fiber sheet is heated and melted to form the breathable resin surface layer 2, and the heating temperature in that case is usually set to a temperature 30 to 50 ° C. higher than the melting point of the thermoplastic resin. It is desirable to do. When the temperature difference from the melting point of the thermoplastic resin is less than 30 ° C., the short fibers (staples) made of the thermoplastic resin are not sufficiently melted, and the wicking due to the short fibers (staples) is the surface layer 2 of the breathable resin. As a result, the surface having sufficient anti-icing property (icing resistance) may not be obtained. When the temperature difference from the melting point of the thermoplastic resin exceeds 50 ° C., the short fibers (staples) made of the thermoplastic resin are excessively melted, and the molten resin fills the gaps between the fibers. For this reason, there is a possibility that the air permeability of the melt is hindered.
The breathable resin surface layer 2 of the present invention is a melt of the thermoplastic resin fiber sheet (nonwoven fabric), but the mass per unit area of the breathable resin surface layer 2 is usually from the viewpoint of strength, rigidity, etc. Is preferably set to about 50 to 300 g / m ² , and the thickness is preferably set to 1 to 3 mm.

(Fiber base layer)
The fiber base material 3 used for the anti-icing / soundproof cushioning material 1 of the present invention includes, for example, polyester fiber, polyethylene fiber, polypropylene fiber, polyamide fiber, acrylic fiber, urethane fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, Organic synthetic fibers such as acetate fiber, biodegradable fibers made of starch extracted from plants such as corn and sugarcane, vegetable fibers such as pulp, cotton, palm fiber, hemp fiber, bamboo fiber, kenaf fiber, carbon fiber, glass It is a nonwoven fabric or a knitted fabric made of one or more kinds of fibers such as fibers, ceramic fibers, asbestos fibers and the like.
Usually, the fiber material used as the fiber base 3 is a mixture in which normal fibers having a melting point of 180 ° C. or higher and low melting point thermoplastic resin fibers having a melting point of 170 ° C. or lower are mixed at a setting ratio of 30:70 to 70:30. This is a nonwoven fabric in which fibers are entangled by needle punching a fiber web to bond the fibers together. Examples of the low-fusion fiber include polyolefin fibers such as polyethylene having a melting point of 170 ° C. or less, polypropylene, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, polyvinyl chloride fiber, polyurethane fiber, polyester fiber, Examples thereof include thermoplastic fibers such as polyester copolymer fibers, polyamide fibers, and polyamide copolymer fibers.
Further, as the low-melting fiber, for example, a core-sheath fiber having the organic synthetic fiber as a core part and a low-melting thermoplastic resin having a melting point of 100 to 170 ° C. which is a material resin of the low-melting fiber may be used. .
In view of strength / rigidity, soundproofing performance, etc., the fiber base material 3 preferably has a mass per unit area usually set to about 300 to 800 g / m ² and has a thickness of about 3 to 8 mm. It is desirable to set.

[Spunbonded nonwoven fabric]
In order to reinforce the air-permeable resin surface layer 2 or the fiber base layer 3 of the present invention and prevent breakage (hereinafter referred to as resin breakage) that occurs in the air-permeable resin surface layer 2 or the fiber base layer 3 at the time of molding or the like due to uneven density of fibers or the like As shown in FIG. 1, the spunbonded nonwoven fabric 4 is inserted into the breathable resin surface layer 2 or the spunbonded nonwoven fabric 4 is inserted into the fiber base layer 3 as shown in FIG.
In general, the spunbonded nonwoven fabric 4 is obtained by subjecting a filament (long fiber) obtained by extruding a thermoplastic resin from a nozzle to stretching treatment, heat treatment, crimping treatment, etc. Fiber) is a non-woven fabric in which the filaments (long fibers) are bonded together by compressing and heat-treating them that have been appropriately separated and dispersed to form a mat. When forming, the filament (long fiber) flows along the direction of air flow or electrostatic force (longitudinal direction, longitudinal direction), so that the strength such as tensile strength and tear strength is large in the longitudinal direction, and the transverse direction. Small in the width direction.
On the other hand, a non-woven fabric obtained by feeding a web placed on a supply apron to the air permeable resin surface layer 2 or the fiber base layer 3 into a needle punch machine and performing needle punch processing is generally used. Needle punching in a needle punch machine Since it flows along the direction (lateral direction, width direction), the strength is large in the horizontal direction (width direction) and small in the vertical direction (length direction).
Therefore, if the spunbonded nonwoven fabric 4 and the breathable resin surface layer 2 or the fiber base layer 3 are polymerized together in length and width, the fiber flow directions are orthogonal to each other. The fiber base layer 3 and the spunbonded nonwoven fabric 4 have a strength that is high in both the longitudinal and transverse directions, complementing each other in the longitudinal direction (length direction) and the transverse direction (width direction).
In view of strength and rigidity, the spunbonded nonwoven fabric 4 preferably has a mass per unit area of usually 12 to 70 g / m ^2. The breathable resin surface layer 2 or the fiber base layer is preferably used. 3 may be inserted in the upper surface or the lower surface, or in the middle (inside).

[Ice icing / soundproof cushioning material]
The following two methods are conceivable for producing the anti-icing / soundproof cushioning material of the present invention.
[Method 1] (Futoshi two-layer method)
(1). Needle in web layer of only mixed fiber obtained by mixing only one kind of short fiber made of hydrophobic thermoplastic resin, which is the base material of breathable resin surface layer, or two or more kinds of short fibers having different fiber diameters Step 1 of producing a nonwoven fabric which is a thermoplastic resin fiber sheet by punching and bonding fibers together.
(2). The nonwoven fabric is polymerized on the surface of the fiber base layer web layer, needle punched to bond the nonwoven fabric to the fiber base layer web layer, and the fibers of the fiber base layer web layer are bonded to each other. Step 2 as a base layer.
(3) The polymer of the nonwoven fabric and the fiber base layer is heated at a temperature higher than the melting point of the hydrophobic thermoplastic resin fiber of the nonwoven fabric to melt all the short fibers made of the hydrophobic thermoplastic resin. Step 3 of forming a breathable resin surface layer and forming a set shape.
In step 3, for example, when the hydrophobic thermoplastic resin used for the short fibers is polypropylene having a melting point of about 155 ° C., heating is performed at 180 to 190 ° C. for about 3 minutes.
When a spunbonded nonwoven fabric is used, it is usually inserted into the base of the web layer in (1) above or inserted into the base of the fiber base material web layer in (2) above.
[Method 2] (Integrated two-layer method)
(1). A web layer of only mixed fibers obtained by mixing only one kind of short fiber made of the above-mentioned hydrophobic thermoplastic resin or two or more kinds of short fibers having different fiber diameters, and the above-mentioned fiber base layer original web layer Non-woven fabric which is a thermoplastic resin fiber sheet by polymerizing, subjecting the polymer to needle punch processing, and bonding the fibers in the hydrophobic thermoplastic resin fiber mixture web layer, and fibers of the fiber base layer web layer The process 1 which couple | bonds together and makes the fiber base layer, and couple | bonds the said nonwoven fabric and the said fiber base layer.
(2). The polymer of the nonwoven fabric and the fiber base layer is heated at a temperature higher than the melting point of the hydrophobic thermoplastic resin fiber of the nonwoven fabric to melt the hydrophobic thermoplastic resin fiber to form a breathable resin surface layer and a set shape Step 2 of forming.
In step 2, for example, when the short fiber made of the hydrophobic thermoplastic resin is a polypropylene fiber having a melting point of 150 to 160 ° C., heating is performed at 180 to 190 ° C. for about 3 minutes.
When a spunbonded nonwoven fabric is used, it is usually inserted in the base of the web layer or the fiber base layer web layer in (1) above.

Of the above two methods, the method 1 (two-penetration two-layer method) is desirable from the viewpoint of anti-icing property.
In the above method 1 and method 2, it may be stored as a raw material without being formed during heating, and then the original material may be heat-formed into a predetermined shape. For molding, press molding is usually applied.

[Example 1] (Futoshi two-layer method)
A fiber mixture in which the following polypropylene fibers (melting point: 155 ° C.) were mixed at a ratio shown in Table 1 was carded by a carding machine to obtain a web layer used as a resin surface layer.
Medium fine polypropylene fiber: 7.0 dtex
Large diameter polypropylene fiber: 17.0 dtex
A mixed fiber in which a core-sheath composite fiber having a polypropylene fiber (melting point 155 ° C.) and a polyester resin (melting point 253 ° C.) as a core component and a polyester resin having a melting point 110 ° C. as a sheath component is mixed in the ratio shown in Table 1, Carding with a carding machine formed a web layer for use in the fiber base layer.
The web layer used for the resin surface layer is needle-punched with a punch density of 300 / cm ² by a needle punch machine to bond the fibers of the web layer, and also to bond with 20 g / m ^{2 of} a polyester fiber spunbond nonwoven fabric. Thus, a non-woven resin surface layer nonwoven fabric having a unit mass of 220 g / m ² and a thickness of 2 mm was obtained.
The resin base layer nonwoven fabric is polymerized on one surface of the fiber base layer original web layer having a unit mass of 780 g / m ² and needle punched at a punch density of 100 pieces / cm ² to form fibers of the fiber base layer base web layer. The two layers were combined to form a fiber base layer, and the three layers were combined to form a multilayer.
The multi-layered product is heat-treated at 180 ° C. for 3 minutes to completely melt the polypropylene fibers constituting the non-woven fabric of the resin surface layer, and has a breathable resin surface layer 2. A material was formed.

[Example 2] (Futoshi two-layer method)
Anti-icing / soundproofing in the same manner as in Example 1 except that the fiber base layer base web layer of Example 1 has the ratio of each fiber as shown in Table 1 and the unit mass is 480 g / m ^2. A cushioning material was produced.

[Example 3] (Futoshi two-layer method)
Without binding the spunbond nonwoven fabric in the resin surface layer nonwoven fabric of Example 1, the unit mass is 200 g / m ² and the thickness is 2 mm, while the fiber base layer web layer is 300 / cm ² by a needle punch machine. The needle layer is punched according to the punch density to bond the fibers of the web layer together with the polyester fiber spunbond nonwoven fabric 20 g / m ² to obtain a fiber base layer nonwoven fabric having a unit mass of 800 g / m ^2. An anti-icing / soundproof cushioning material having the form shown in FIG. 2 was produced in the same manner as in Example 1 except that the body nonwoven fabric and the fiber base layer nonwoven fabric were combined.

[Example 4] (Futoshi two-layer method)
The unit mass of the resin surface base nonwoven fabric of Example 3 was 250 g / m ² , the thickness was 2 mm, and the same thing as Example 1 was used except that the fiber base layer web layer of Example 2 was used. Ice / soundproof cushioning material was manufactured.

[Example 5] (Futoshi two-layer method)
Example 4 was used in the same manner as in Example 1 except that the resin surface layer base material of Example 4 was used, the fiber base layer base material web layer of Example 2 was used, and the spunbond nonwoven fabric was not used. A soundproof cushioning material having the form shown in FIG. 3 was produced.

[Comparative Example 1] (Integrated two-layer method)
In the fiber base material web layer of Example 5, the ratio of each fiber was set as shown in Table 1 and the unit mass was 250 g / m ^2. A soundproof cushioning material was produced in the same manner.
[Comparative Example 2] (Integrated two-layer method)
In the base fiber web layer of Example 5, in the same manner as in Example 1, except that the ratio of each fiber is as shown in Table 1 and the unit mass is 250 g / m ^2. Manufactured.

〔test〕
(1) Tensile strength: A test piece punched into a dumbbell shape was attached to an Instron type tensile tester, pulled at a speed of 200 mm / min, and a load until the test piece was broken was measured.
(2) Tear strength: A test piece punched into a reverse-hull shape was pulled at a speed of 200 mm / min by a shopper type tester, and the load required to tear the test piece was measured.
(3) Bending strength: A test piece of 150 × 50 mm was stroked with a bending test apparatus at a compression speed of 20 mm / min until the maximum generated load value was obtained. The test was performed on each of the front side and the back side of the sample. The number of N was 3, and the average value was obtained.
(4) Icing shear force: Using a test piece of 100 × 100 mm, a cylindrical jig (inner diameter: 43.85 mm, height: 30 mm, pulling position: 48 mm in the radial direction from the center) in a low temperature chamber of −15 ° C. Inject water at 5 ° C or less into the interior of the 26mm height), allow the test piece to ice, connect the force gauge to the pulling position of the cylindrical jig, pull it up in the vertical direction, and remove the ice from the test piece. The maximum load was measured.
(5) Chipping resistance: A test piece funnel placed at the upper part of the test piece after being mounted on a wear test apparatus after raising two left and right parts of a 150 x 70 x 0.8 mm test piece with a spacer by 20 mm A nut (3 kg for one time) was dropped 60 times from the mouth of the test piece and the number of times until the fiber base layer of the test piece was exposed was measured.
(6) Sound absorption rate: Using a test piece of 1000 × 1000 mm, the sound absorption rate was measured in accordance with the reverberation chamber method sound absorption rate specified in JIS A 1409: 1998.
(7) Ventilation rate: Cylinder-shaped air passage using an air permeability tester (product name: KES-F8-AP1, manufactured by Kato Tech Co., Ltd., steady flow differential pressure measurement method) according to a steady flow differential pressure measurement method. A test piece L was placed in W, and the airflow resistance due to the pressure difference between the start point side and the end point side was measured in a state where the airflow rate V was constant, and the airflow resistance was converted into the air permeability. When the ventilation resistance is R and the air permeability is Q, the measured value is converted according to the relational expression of Q = 12.4 / R.

表１の結果より、実施例１〜５は、全体的に好適な性能を示し、特に着氷せん断力が５Ｎ未満であって耐着氷性に優れ、通気度が３０ｃｃ／ｃｍ^２・ｓｅｃ以下であって防音性に優れたものであることが示された。
一方、比較例１及び比較例２については、着氷せん断力が２０Ｎを超え、耐着氷性が悪く、また通気度が４０ｃｃ／ｃｍ^２・ｓｅｃと３０ｃｃ／ｃｍ^２・ｓｅｃを超えており、防音性に劣るものであることが示された。 〔Test results〕
Table 1 shows the performance of Examples 1 to 5 and Comparative Examples 1 and 2.

From the results shown in Table 1, Examples 1 to 5 show suitable performance as a whole, and in particular, the icing shearing force is less than 5N, the icing resistance is excellent, and the air permeability is 30 cc / cm ² · sec or less. And it was shown that it was excellent in soundproofing.
On the other hand, for Comparative Example 1 and Comparative Example 2, the icing shear force exceeds 20 N, the icing resistance is poor, and the air permeability exceeds 40 cc / cm ² · sec and 30 cc / cm ² · sec, It was shown to be inferior in soundproofing.

  Since the soundproofing cushioning material of the present invention is excellent in soundproofing effect and also in anti-icing property, it is useful for automobile fender liners and can be used industrially.

1 Soundproofing cushioning material 2 Resin surface layer 3 Fiber base layer 4 Spunbonded nonwoven fabric

Claims (9)

A breathable resin surface layer is laminated on the fiber base layer,
A mixed fiber obtained by mixing only one type of short fiber made of a hydrophobic thermoplastic resin or two or more types of short fibers having different fiber diameters, the air permeable resin surface layer being made of a hydrophobic thermoplastic resin. An anti-icing / soundproof cushioning material characterized by comprising a melt of a thermoplastic fiber sheet using only The anti-icing / soundproof cushioning material according to claim 1, wherein the thermoplastic resin used for the thermoplastic fiber sheet has a melting point of 140 to 170 ° C. The thermoplastic fiber sheet is made of a nonwoven fabric in which fibers are bonded to each other by needle punching with a punch density of 200 to 300 / cm ² for the short fiber or the mixed fiber web,
Furthermore, the said thermoplastic fiber sheet which comprises the said air permeable resin surface layer couple | bonds with the said fiber base layer by carrying out a needle punch process by setting a punch density as 50-150 piece / cm < ² >. Icing / soundproof cushioning material. The said fiber base layer contains 30-70 mass% of low melting-point thermoplastic resin fibers whose melting | fusing point is 110 degrees C or less, and also consists of the fiber which mixed the polypropylene fiber 5-30 mass%, and any of Claims 1-3. An anti-icing / soundproof cushioning material according to claim 1. A spunbonded nonwoven fabric is inserted into the breathable resin surface layer or the fiber base layer to reinforce the breathable resin surface layer or the fiber base layer, according to any one of claims 1 to 4. Icing / soundproof cushioning material. 耐着ice soundproofing cushioning material according to any one of claims 1 to 5 air permeability is not more than 30cc / cm 2 · ^sec. An exterior material for a vehicle, comprising the anti-icing / soundproof cushioning material according to any one of claims 1 to 6. Needle punch on a web consisting only of mixed fibers obtained by mixing only one type of short fiber made of a hydrophobic thermoplastic resin, or two or more types of short fibers having different fiber diameters made of a hydrophobic thermoplastic resin. Process 1 for forming a nonwoven fabric which is a thermoplastic resin fiber sheet by processing and bonding fibers together,
The nonwoven fabric is polymerized on the surface of the fiber base layer web layer, needle punched to bond the nonwoven fabric and the fiber base layer web layer, and the fibers of the fiber base layer web layer are bound to each other. Step 2 as a base layer,
The polymer of the nonwoven fabric and the fiber base layer is heated at a temperature higher than the melting point of the hydrophobic thermoplastic resin constituting the nonwoven fabric to melt the short fibers or mixed fibers made of the hydrophobic thermoplastic resin. Step 3 of forming a breathable resin surface layer and forming it into a predetermined shape,
The method for producing an anti-icing / soundproof cushioning material according to any one of claims 1 to 6, comprising the above steps. The method for producing an anti-icing / soundproof cushioning material according to claim 8, wherein the polymer of the nonwoven fabric and the fiber base layer is heated at a temperature 30 to 50 ° C higher than the melting point of the thermoplastic resin used for the nonwoven fabric. .

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