JP2016052772A - Nonwoven fabric for reinforcing foam molded article - Google Patents
Nonwoven fabric for reinforcing foam molded article Download PDFInfo
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- JP2016052772A JP2016052772A JP2014221455A JP2014221455A JP2016052772A JP 2016052772 A JP2016052772 A JP 2016052772A JP 2014221455 A JP2014221455 A JP 2014221455A JP 2014221455 A JP2014221455 A JP 2014221455A JP 2016052772 A JP2016052772 A JP 2016052772A
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- nonwoven fabric
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- foam molded
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- 239000004745 nonwoven fabric Substances 0.000 title claims abstract description 91
- 230000003014 reinforcing effect Effects 0.000 title claims abstract description 58
- 239000006260 foam Substances 0.000 title claims abstract description 22
- 229920005989 resin Polymers 0.000 claims abstract description 42
- 239000011347 resin Substances 0.000 claims abstract description 42
- 230000035699 permeability Effects 0.000 claims abstract description 10
- 238000010030 laminating Methods 0.000 claims description 6
- 239000002184 metal Substances 0.000 abstract description 12
- 229910052751 metal Inorganic materials 0.000 abstract description 12
- 239000004744 fabric Substances 0.000 abstract description 3
- 238000000034 method Methods 0.000 description 29
- 239000010410 layer Substances 0.000 description 28
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 16
- 238000005187 foaming Methods 0.000 description 9
- 239000005038 ethylene vinyl acetate Substances 0.000 description 8
- 239000000835 fiber Substances 0.000 description 8
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 8
- 230000000052 comparative effect Effects 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- -1 polybutylene terephthalate Polymers 0.000 description 6
- 239000000463 material Substances 0.000 description 5
- 238000010097 foam moulding Methods 0.000 description 4
- 229920000728 polyester Polymers 0.000 description 4
- 239000000523 sample Substances 0.000 description 4
- 229920000098 polyolefin Polymers 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 239000004925 Acrylic resin Substances 0.000 description 2
- 229920000178 Acrylic resin Polymers 0.000 description 2
- 230000002159 abnormal effect Effects 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- UORVGPXVDQYIDP-UHFFFAOYSA-N borane Chemical compound B UORVGPXVDQYIDP-UHFFFAOYSA-N 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 229920001707 polybutylene terephthalate Polymers 0.000 description 2
- 229920000139 polyethylene terephthalate Polymers 0.000 description 2
- 239000005020 polyethylene terephthalate Substances 0.000 description 2
- 229920002215 polytrimethylene terephthalate Polymers 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- 238000010998 test method Methods 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000000740 bleeding effect Effects 0.000 description 1
- 229910000085 borane Inorganic materials 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 238000009820 dry lamination Methods 0.000 description 1
- 229920006244 ethylene-ethyl acrylate Polymers 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229920000554 ionomer Polymers 0.000 description 1
- 230000005389 magnetism Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 239000011112 polyethylene naphthalate Substances 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000007650 screen-printing Methods 0.000 description 1
- 238000009958 sewing Methods 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000009864 tensile test Methods 0.000 description 1
- KKEYFWRCBNTPAC-UHFFFAOYSA-L terephthalate(2-) Chemical compound [O-]C(=O)C1=CC=C(C([O-])=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-L 0.000 description 1
- 230000000930 thermomechanical effect Effects 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
Landscapes
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Molding Of Porous Articles (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Nonwoven Fabrics (AREA)
- Laminated Bodies (AREA)
Abstract
Description
本発明は、発泡成形品補強用不織布に関する。より詳しくは、発泡時の金型セット性に優れた発泡成形品補強用に最適な不織布に関する。 The present invention relates to a nonwoven fabric for reinforcing foam molded products. More specifically, the present invention relates to a non-woven fabric optimal for reinforcing a foamed molded article having excellent mold setting properties during foaming.
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いる。一般的に、発泡ウレタン成形体としてはの成形時に補強用不織布が一体化されたものが用いられている。かかる補強用不織布は、発泡ウレタン成形体と自動車シートの金属スプリングの間に位置して、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。この補強用不織布を使用し、クッション材を生産するには、まず生産するクッション形状に合わせ補強用不織布を打ち抜きまたはカットし、縫製する。さらには金型にセットするための穴を開ける。その後、金型に取り付けた突起やピン等のセット治具に前記穴を突き刺して金型にセットした後、ウレタンを発泡させ、発泡ウレタン成形体を生産する。 In recent years, urethane foam molded bodies have been widely used as cushion materials for seats and the like. In general, a foamed urethane molded body in which a reinforcing nonwoven fabric is integrated at the time of molding is used. The reinforcing nonwoven fabric is located between the urethane foam molded body and the metal spring of the automobile seat, and evenly disperses the cushioning action of the metal spring and protects the urethane foam molded body from the friction received from the metal spring. Is responsible for. In order to produce a cushion material using this reinforcing nonwoven fabric, first, the reinforcing nonwoven fabric is punched or cut in accordance with the shape of the cushion to be produced, and then sewn. Furthermore, a hole for setting in a mold is made. Thereafter, the hole is pierced into a setting jig such as a projection or a pin attached to the mold and set in the mold, and then urethane is foamed to produce a urethane foam molded body.
近年、自動車シートにはいろいろなセンサーや機能を付与するため、形状が複雑となり、補強用不織布の縫製等の負担が大きくなり、工数やコストアップとなっている。上記の通り、金型への補強用不織布のセットも負荷となっており、さまざまな工夫がなされている。例えば、補強用不織布にホッチキスやメタル等を取り付け、金型に取り付けた磁石等の磁力を活用する方法や、補強用不織布または金型に接着剤などを塗布する方法である。 In recent years, since various sensors and functions are given to automobile seats, the shape becomes complicated, and the burden of sewing a reinforcing nonwoven fabric increases, resulting in an increase in man-hours and costs. As described above, the reinforcement nonwoven fabric set on the mold is also a load, and various ideas have been made. For example, a stapler or metal is attached to the reinforcing nonwoven fabric and a magnetic force such as a magnet attached to the mold is utilized, or an adhesive is applied to the reinforcing nonwoven fabric or mold.
ホッチキスやメタル等を取り付ける方法では、あらかじめ金型に磁石等の磁力を取り付ける必要があり、設計が変わるたびに、磁石等の取り付け場所を変更するなど手間とコストが高くなる問題がある。接着剤を活用する方法は金型を汚す問題がある。 In the method of attaching a stapler, metal, or the like, it is necessary to attach a magnetic force such as a magnet to the mold in advance, and there is a problem that labor and cost increase, such as changing the attachment location of the magnet or the like every time the design changes. The method of using an adhesive has a problem of soiling the mold.
特許文献１には、発泡金型内部に装着ピンをあらかじめ備えることで補強用不織布をセットする方法が提案されている。しかし、この方法では、発泡形状が変わる都度製作する金型に装着ピンを設置する必要があるだけでなく、発泡後の取り外し時に補強用不織布へダメージを与える可能性がある。 Patent Document 1 proposes a method of setting a reinforcing nonwoven fabric by providing a mounting pin in advance in a foaming mold. However, according to this method, it is not only necessary to install a mounting pin in the mold to be produced every time the foam shape changes, but there is a possibility that the reinforcing nonwoven fabric may be damaged when removed after foaming.
特許文献２には、あらかじめ補強用不織布に使用するバインダー中に鉄粉または砂鉄を混入して補強用不織布に磁性を付与する方法が提案されている。しかし、この方法では金属スプリングとの接触による鉄粉または砂鉄の脱落で車内を汚す恐れや異音の可能性がある。さらに、補強用不織布への金属混入、例えば補強用不織布製造工程で使用するニードルパンチの針混入などの検知がし難い問題がある。 Patent Document 2 proposes a method of imparting magnetism to a reinforcing nonwoven fabric by previously mixing iron powder or sand iron in a binder used for the reinforcing nonwoven fabric. However, with this method, there is a possibility that the interior of the vehicle may be soiled due to dropping off of iron powder or sand iron due to contact with a metal spring, and there is a possibility of abnormal noise. Furthermore, there is a problem that it is difficult to detect the metal contamination in the reinforcing nonwoven fabric, for example, the needle punch used in the reinforcing nonwoven fabric manufacturing process.
特許文献３には、補強用不織布に金属製のワイヤを取り付け、発泡成形型に設けられた永久磁石に吸着させることで、型内に装着する方法が提案されている。しかし、この方法も補強用不織布へのワイヤ取り付けの工程が増えるだけでなく、発泡成形型に永久磁石を設ける必要がある。 Patent Document 3 proposes a method in which a metal wire is attached to a reinforcing nonwoven fabric and attached to a permanent magnet provided in a foaming mold so as to be mounted in the mold. However, this method not only increases the number of steps for attaching the wire to the reinforcing nonwoven fabric, but also requires a permanent magnet to be provided in the foam mold.
従来は、金型に改良を加えず、従来の金型を使用し、汚すこともなく簡単に補強用不織布をセットする方法は提案はなされていなかった。本発明は従来技術を背景になされたもので、補強用不織布の金型セット性をより向上させて、効率良くクッション材を発泡成形させることが可能な補強用不織布を提供することを課題とする。 Conventionally, there has been no proposal for a method for setting a reinforcing nonwoven fabric without using a conventional mold and making it dirty without simply improving the mold. The present invention has been made against the background of the prior art, and it is an object of the present invention to provide a reinforcing nonwoven fabric capable of efficiently foam-molding a cushion material by further improving the mold setting property of the reinforcing nonwoven fabric. .
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、ウレタンを発泡させウレタン発泡成形体を生産するため、金型は通常６０℃以上の温度に昇温されており、この温度で補強用不織布と金型が接着する樹脂を補強用不織布にあらかじめ塗布しておくことにより、簡単にセットできることを見出し、本発明に到達した。 As a result of diligent research to solve the above-mentioned problems, the present inventors have usually raised the temperature of the mold to a temperature of 60 ° C. or higher in order to produce urethane foam molded products by foaming urethane. It has been found that the resin can be easily set by previously applying a resin to which the nonwoven fabric for bonding and the mold adhere to the reinforcing nonwoven fabric.
すなわち、本発明は、以下の通りである。
（１）補強用不織布層と樹脂層を積層させてなる発泡成形品補強用不織布であって、樹脂の軟化点Ａが３０℃以上６０℃以下、不織布の通気度が３０ｃｃ／ｃｍ２／秒以上である発泡成形品補強用不織布。
（２）樹脂層が線状に間隔を開けて積層されている（１）に記載の発泡成形品補強用不織布。
（３）樹脂層がドット状に積層されている（１）に記載の発泡成形品補強用不織布。
That is, the present invention is as follows.
(1) A non-woven fabric for reinforcing foam molded articles obtained by laminating a reinforcing non-woven fabric layer and a resin layer, wherein the softening point A of the resin is 30 ° C. or higher and 60 ° C. or lower, and the air permeability of the non-woven fabric is 30 cc / cm 2 / sec or higher. A non-woven fabric for reinforcing foam molded products.
(2) The nonwoven fabric for reinforcing foam-molded products according to (1), wherein the resin layers are laminated in a linear manner at intervals.
(3) The nonwoven fabric for reinforcing foam molded products according to (1), wherein the resin layers are laminated in a dot shape.
本発明の発泡成形品補強用不織布は、補強用不織布層と樹脂層を積層し、樹脂層に発泡時の金型の温度で軟化する樹脂を選定する。さらに発泡成形品補強用不織布の通気度を一定以上に保つことにより、発泡時に発生するガスを抜くことができ、見栄えの良いクッション材を得ることができる。
その結果、従来の金型を使用し、縫製のみ施された発泡成形品補強用不織布を効率良く金型にセットでき、作業性を向上できる。
この発泡成形品補強用不織布は、発泡成型後の金型への汚れもなく、発泡成形品補強用不織布の成型性にも影響を与えないため、従来と全く同じ方法で使用することができるという利点がある。
The non-woven fabric for reinforcing foamed articles of the present invention is formed by laminating a reinforcing non-woven fabric layer and a resin layer, and selecting a resin that softens the resin layer at the temperature of the mold during foaming. Furthermore, by keeping the air permeability of the nonwoven fabric for reinforcing foamed articles at a certain level or higher, the gas generated during foaming can be removed, and a good-looking cushioning material can be obtained.
As a result, it is possible to efficiently set a non-woven fabric for reinforcing a foam molded article that is only sewn using a conventional mold, and to improve workability.
This non-woven fabric for reinforcing foam molded articles has no dirt on the mold after foam molding and does not affect the moldability of the non-woven fabric for reinforcing foam molded products, so it can be used in exactly the same way as before. There are advantages.
本発明の発泡成形品補強用不織布の補強用不織布層には、従来知られている不織布全てを適用することができるが、不織布の引き裂き強力が２０Ｎ以上、発泡後の強力（発泡後の不織布層を切り出し、ＪＩＳ Ｌ １９１３（２０１０）に準拠して強力を測定する）が１０Ｎ／ｃｍ以上、ウレタンの染み出しを少なくさせる密度が高い部位を持つ不織布が好ましい。 For the reinforcing nonwoven fabric layer of the nonwoven fabric for reinforcing foamed articles of the present invention, all conventionally known nonwoven fabrics can be applied. Is measured at 10 N / cm or more, and a non-woven fabric having a high density part that reduces urethane exudation is preferable.
補強用不織布層に使用する不織布を構成する樹脂としては、ポリエステル、ポリオレフィンやポリアミドが好ましく、汎用熱可塑性樹脂で安価なポリエステルやポリオレフィンが特に好ましい。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およびそれらの共重合ポリエステルなどが例示できる。また、ポリオレフィンではポリエチレンやポリプロピレンなどが例示できる。 As the resin constituting the nonwoven fabric used for the reinforcing nonwoven fabric layer, polyester, polyolefin and polyamide are preferable, and inexpensive polyester and polyolefin which are general-purpose thermoplastic resins are particularly preferable. Examples of the polyester include polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polybutylene naphthalate (PBN), polyethylene naphthalate (PEN), polycyclohexanedimethyl terephthalate (PCHT), and polytrimethylene terephthalate (PTT). Examples thereof include homopolyesters and copolymerized polyesters thereof. Examples of polyolefin include polyethylene and polypropylene.
補強用不織布層に使用する不織布の製造方法は、長繊維不織布としてはスパンボンド法、メルトブロー法などに、短繊維不織布としてはニードルパンチ法、スパンレース法などによる機械交絡によるものや、ケミカルボンド法、サーマルボンド法などが例示できる。さらにこれらを複合したものも使用することができる。
スパンボンド法により得られる不織布を使用する補強用不織布層としては、目付が３０〜２００ｇ／ｍ２で、空隙率が９０〜９４％のかさ高な不織布と目付が２０〜１００ｇ／ｍ２で、空隙率８７〜９１％の緻密な不織布を積層し、ニードルパンチ法で積層一体化させたものや、一層であるが厚み方向に密度差を付け、ウレタン補強層とウレタン発泡時の染み出し防止層を兼ね備えたニードルパンチスパンボンド不織布を使用したもの、さらには捲縮数が２〜４０個／２５ｍｍ、繊維径が１〜３０μｍである捲縮長繊維不織布で構成され、目付が５０〜２００ｇ／ｍ２、厚さが０．５〜２．０ｍｍのスパンボンド不織布を使用したものが好ましい。
また、短繊維不織布とスパンボンド不織布との複合不織布層であれば、繊維径が１〜２３デシテックスの繊維で形成され、目付が２０〜１００ｇ／ｍ２であるスパンボンド不織布に短繊維のカードウェッブを片面もしくは両面に積層し、ニードルパンチ法で一体化させた複合不織布層が好ましい。
The manufacturing method of the nonwoven fabric used for the reinforcing nonwoven fabric layer is a long fiber nonwoven fabric by a spunbond method, a melt blow method, etc., and a short fiber nonwoven fabric by a mechanical entanglement by a needle punch method, a spunlace method, etc. And a thermal bond method. Furthermore, what combined these can also be used.
As a reinforcing nonwoven fabric layer using a nonwoven fabric obtained by the spunbond method, the basis weight is 30 to 200 g / m 2 , the porosity is 90 to 94% bulky nonwoven fabric and the basis weight is 20 to 100 g / m 2 , A dense non-woven fabric with a porosity of 87 to 91% is laminated and laminated and integrated by the needle punch method, or a single layer has a density difference in the thickness direction, and a urethane reinforcing layer and a bleeding prevention layer at the time of urethane foaming Using a needle punched spunbonded nonwoven fabric, and further comprising a crimped continuous fiber nonwoven fabric having a crimp number of 2 to 40 pieces / 25 mm and a fiber diameter of 1 to 30 μm, and a basis weight of 50 to 200 g / m 2 , What uses the spun bond nonwoven fabric whose thickness is 0.5-2.0 mm is preferable.
Moreover, if it is a composite nonwoven fabric layer of a short fiber nonwoven fabric and a spunbond nonwoven fabric, it is formed of fibers having a fiber diameter of 1 to 23 dtex, and a short fiber card web is formed on a spunbond nonwoven fabric having a basis weight of 20 to 100 g / m 2. A composite nonwoven fabric layer in which is laminated on one side or both sides and integrated by the needle punch method is preferable.
樹脂層には、軟化点Ａが３０℃以上６０℃以下、好ましくは３０℃以上５５℃未満、より好ましくは３５℃以上５０℃未満の樹脂を用いることで金型セット性が良好となる。軟化点Ａが３０℃未満であると通常保管状態で粘着性が上がり、重ねて保管した場合、取り扱い性が悪くなり、場合によっては完全に接着してしまう場合がある。軟化点Ａが６０℃より高くなると、金型温度での接着性が不十分となり、セット性が悪くなり、作業中に剥がれるなどの問題が発生する。上記範囲の軟化点Ａを得るためには、ビカット軟化温度が３０℃以上６０℃以下である樹脂を使用することで得ることができる。 A mold setting property is improved by using a resin having a softening point A of 30 ° C. or more and 60 ° C. or less, preferably 30 ° C. or more and less than 55 ° C., more preferably 35 ° C. or more and less than 50 ° C. for the resin layer. When the softening point A is less than 30 ° C., the tackiness is increased in a normal storage state, and when stored repeatedly, the handleability is deteriorated, and in some cases, it may be completely adhered. When the softening point A is higher than 60 ° C., the adhesiveness at the mold temperature becomes insufficient, the setability is deteriorated, and problems such as peeling during the operation occur. In order to obtain the softening point A in the above range, it can be obtained by using a resin having a Vicat softening temperature of 30 ° C. or more and 60 ° C. or less.
軟化点Ａが上記の範囲であれば、樹脂の種類は特に限定されないが、エチレン−酢酸ビニルコポリマー、エチレン−エチルアクリレートコポリマー、アイオノマー樹脂、ウレタン樹脂、またはこれらの誘導体が好適に使用できる。 If the softening point A is in the above range, the type of the resin is not particularly limited, but an ethylene-vinyl acetate copolymer, an ethylene-ethyl acrylate copolymer, an ionomer resin, a urethane resin, or a derivative thereof can be preferably used.
補強用不織布と樹脂層を積層した発泡成形品補強用不織布の通気度は３０ｃｃ／ｃｍ２／秒以上、好ましくは４０ｃｃ／ｃｍ２／秒以上３００ｃｃ／ｃｍ２／秒以下、よりに好ましくは５０ｃｃ／ｃｍ２／秒以上２５０ｃｃ／ｃｍ２／秒以下である。通気度が３０ｃｃ／ｃｍ２／秒未満となるとウレタン発泡時に発生するガスが抜け難くなり、発泡ウレタン成形体に欠点が発生する。また、３００ｃｃ／ｃｍ２／秒より高くなると発泡成形品補強用不織布からウレタンが染み出し、金属スプリングとの接触による異音の問題が発生する。 The air permeability of the non-woven fabric for reinforcing foam-molded articles obtained by laminating the reinforcing non-woven fabric and the resin layer is 30 cc / cm 2 / sec or more, preferably 40 cc / cm 2 / sec or more and 300 cc / cm 2 / sec or less, more preferably 50 cc / cm 2 / sec or more and 250 cc / cm 2 / sec or less. When the air permeability is less than 30 cc / cm 2 / sec, it is difficult for the gas generated during urethane foaming to escape and a defect occurs in the foamed urethane molded product. On the other hand, if it is higher than 300 cc / cm 2 / sec, urethane oozes out from the nonwoven fabric for reinforcing foamed molded products, which causes a problem of abnormal noise due to contact with the metal spring.
樹脂層を積層し、最適な通気度を得るための方法としては、樹脂押し出しラミネート法、タンデム押し出しラミネート法、ドライラミネート法、カーテンスプレー法などの公知の方法を用いることができる。さらに、プリント法等によるドット加工などを用いることができる。これらの方法を用い、積層する樹脂層の面積率は、補強用不織布の面積に対し好ましくは１０％以上９０％以下、より好ましくは２０％以上８０％以下、さらに好ましくは３０％以上７０％以下である。積層する樹脂層面積率が１０％未満となると、金型へのセット性が不十分となり、９０％以上となると通気度の確保が難しくなる。 As a method for laminating the resin layers and obtaining the optimum air permeability, known methods such as a resin extrusion lamination method, a tandem extrusion lamination method, a dry lamination method, and a curtain spray method can be used. Furthermore, dot processing by a printing method or the like can be used. Using these methods, the area ratio of the resin layer to be laminated is preferably 10% or more and 90% or less, more preferably 20% or more and 80% or less, and further preferably 30% or more and 70% or less with respect to the area of the reinforcing nonwoven fabric. It is. When the resin layer area ratio to be laminated is less than 10%, the setting property to the mold becomes insufficient, and when it is 90% or more, it is difficult to ensure air permeability.
金型セット性への付与と通気度をより最適にするための樹脂層としては、樹脂を線状に間隔を開けて積層する方法あるいはドット状に積層することが好ましい。線状に積層する場合、樹脂の幅は好ましくは０．３〜１０ｍｍであり、樹脂間の間隔は好ましくは１〜１０ｍｍである。ドット状に積層する場合は、ドット形状に特に指定はなく、丸型や菱型等を用いることができる。サイズも特に指定はないが、円換算での直径で好ましくは１ｍｍ以上１０ｍｍ以下である。配置については格子状や千鳥配列等を用いることができる。 As a resin layer for imparting to the mold setting property and optimizing the air permeability, it is preferable to laminate the resin in a linear manner or in a dot manner. When laminating linearly, the width of the resin is preferably 0.3 to 10 mm, and the interval between the resins is preferably 1 to 10 mm. In the case of stacking in a dot shape, the dot shape is not particularly specified, and a round shape or a diamond shape can be used. The size is not particularly specified, but the diameter in terms of a circle is preferably 1 mm or more and 10 mm or less. For the arrangement, a lattice shape, a staggered arrangement, or the like can be used.
本発明の発泡成形品補強用不織布は、クッション用途に限定されるものではなく、金型を用い、成型する発泡成形品の補強用不織布として、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 non-woven fabric for reinforcing foam molded products of the present invention is not limited to cushion applications, but as a non-woven fabric for reinforcing foam molded products to be molded using a mold, various interior materials for vehicles, building materials, and electrical appliances. It is also useful for applications such as surface foam moldings.
以下、実施例およ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）ビカット軟化温度（℃）
ＪＩＳ Ｋ ７２０６（１９９９）「プラスチック−熱可塑性プラスチック−ビカット軟化温度（ＶＳＴ）試験方法」に準拠して測定した。
(1) Vicat softening temperature (℃)
Measured in accordance with JIS K 7206 (1999) “Plastic—Thermoplastic—Vicat Softening Temperature (VST) Test Method”.
（２）軟化点Ａ（℃）
補強用不織布から樹脂層をサンプリングし、ＴＡ ｉｎｓｔｒｕｍｅｎｔｓ社製「Ｑ４００」を用い、ＴＭＡ（熱機械分析）により求めた。プローブは針入プローブ、荷重０．１Ｎ、温度条件−３０℃→１００℃、昇温速度５℃／ｍｉｎ、雰囲気Ｎ２下で行った。図１に例示した通り、２つの接線の交点を軟化点Ａとした。
(2) Softening point A (° C)
The resin layer was sampled from the reinforcing nonwoven fabric and obtained by TMA (thermomechanical analysis) using “Q400” manufactured by TA instruments. The probe was a probe probe, a load of 0.1 N, a temperature condition of −30 ° C. → 100 ° C., a heating rate of 5 ° C./min, and an atmosphere N 2 . As illustrated in FIG. 1, the intersection of the two tangents was defined as a softening point A.
（３）通気度（ｃｃ／ｃｍ２／秒）
ＪＩＳ Ｌ １０９６（２０１０）「織物及び編物の生地試験方法」８．２６．１ Ａ法（フラジール形法）」に準拠して測定した。
(3) Air permeability (cc / cm 2 / sec)
Measured in accordance with JIS L 1096 (2010) “Fabric and knitted fabric test method” 8.26.1 A method (Fragile method) ”.
（４）樹脂層の面積率（％）
ＳＥＭにて樹脂層側から撮影し、単位当りの樹脂層の面積を求め、百分率で示した。
(4) Resin layer area ratio (%)
Images were taken from the resin layer side with an SEM, and the area of the resin layer per unit was determined and expressed as a percentage.
（５）金型への接着性（Ｎ／φ２２ｍｍ）
試験片を幅２５ｍｍ、長さ１００ｍｍにカットし、１端を金属板（ＳＳ４００フラットバー幅３０ｍｍ、長さ１００ｍｍ）の１端に５１．６ｋＰａ Ｋｙｏｗａ製「ゲージメイト」を使用し、２ｋｇｆ／φ２２ｍｍ端子の荷重で３０℃±３℃および７０℃±３℃で１０秒間圧縮する。その後、島津製引張試験機のチャック上部に金属板を、チャック下部に試験片の反対の１端をチャック間距離が１０ｍｍとなるようセットする。引張速度１００ｍｍ／分で引っ張り試験を行い、最大強度を求める。
(5) Adhesiveness to mold (N / φ22mm)
The test piece was cut to a width of 25 mm and a length of 100 mm, and one end of a metal plate (SS400 flat bar width 30 mm, length 100 mm) was used with a “gauge mate” made by 51.6 kPa Kyowa, 2 kgf / φ22 mm terminal Compress for 10 seconds at 30 ° C. ± 3 ° C. and 70 ° C. ± 3 ° C. Thereafter, the metal plate is set on the upper part of the chuck of the Shimadzu tensile tester, and the opposite end of the test piece is set on the lower part of the chuck so that the distance between the chucks is 10 mm. A tensile test is performed at a pulling speed of 100 mm / min to obtain the maximum strength.
（６）室温３０℃での補強用不織布の取り扱い性
２０ｃｍ×２０ｃｍにカットした試験片を１０枚重ね、１０ｋｇ／４００ｃｍ２となるよう荷重を掛け、室温３０℃の部屋で２４時間放置する。その後、重りを除き、１枚１枚取り出すときの状況を以下の通り評価した。
○：各層で接着がなく取り出すことができた。
×：各層で接着が起こり、取り出すことが難しかった。
(6) Handling of reinforcing non-woven fabric at room temperature of 30 ° C. Ten test pieces cut to 20 cm × 20 cm are stacked and a load of 10 kg / 400 cm 2 is applied and left in a room at room temperature of 30 ° C. for 24 hours. Then, the situation when taking out one by one except for the weight was evaluated as follows.
○: It was possible to take out without adhesion in each layer.
X: Adhesion occurred in each layer, and it was difficult to take out.
（７）発泡成形加工性
○：発泡ウレタン成形体の表面にガスの後がなく、きれいに発泡されていた。
×：発泡ウレタン成形体んｐ表面にガスの後があり、痘痕状などの欠点があった。
(7) Foam molding processability ○: The surface of the foamed urethane molded body had no gas behind and was foamed cleanly.
X: There was a gas on the surface of the foamed urethane molded product p, and there were defects such as scratches.
＜実施例１＞
東洋紡株式会社製不織布ボランス「ＣＲＥ３０８０」の白色面側に幅１ｍｍのヤスハラケミカル株式会社製ヒロダイン７５０４（エチレン酢酸ビニルコポリマー、ビカット軟化温度４２℃）をＴ−ダイから押し出し、上記不織布の長手方向と平行に２ｍｍの間隔で線状に積層した。樹脂は２０ｇ／ｃｍ２であった。
<Example 1>
A 1 mm wide Hirodine 7504 (ethylene vinyl acetate copolymer, Vicat softening temperature 42 ° C.) having a width of 1 mm was extruded from a T-die on the white side of a nonwoven fabric bolance “CRE 3080” manufactured by Toyobo Co., Ltd., parallel to the longitudinal direction of the nonwoven fabric. They were laminated in a line at intervals of 2 mm. The resin was 20 g / cm 2 .
＜実施例２＞
三井化学株式会社製不織布タフネル「ＥＳＥ４４４」の片面に幅１ｍｍのヤスハラケミカル株式会社製ヒロダイン７５０４（エチレン酢酸ビニルコポリマー、ビカット軟化温度４２℃）をＴ−ダイから押し出し、上記不織布の長手方向と平行に２ｍｍの間隔で線状に積層した。樹脂は３０ｇ／ｃｍ２であった。
<Example 2>
Extruded Hirodine 7504 (ethylene vinyl acetate copolymer, Vicat softening temperature 42 ° C.) made by Yashara Chemical Co., Ltd. having a width of 1 mm on one side of a non-woven fabric tufnel “ESE444” manufactured by Mitsui Chemicals, Inc., 2 mm parallel to the longitudinal direction of the nonwoven fabric. Were laminated in a line at intervals of The resin was 30 g / cm 2 .
＜実施例３＞
三井化学株式会社製不織布タフネル「ＥＳＥ４４４」の片面に幅２ｍｍのヤスハラケミカル株式会社製ヒロダイン７５０４（エチレン酢酸ビニルコポリマー、ビカット軟化温度４２℃）をＴ−ダイから押し出し、上記不織布の長手方向と平行に２ｍｍの間隔で線状に積層した。樹脂は３０ｇ／ｃｍ２であった。
<Example 3>
Hirodine 7504 (ethylene vinyl acetate copolymer, Vicat softening temperature 42 ° C.) made by Yashara Chemical Co., Ltd. having a width of 2 mm is extruded from one side of a non-woven fabric tufnel “ESE444” manufactured by Mitsui Chemicals Co., Ltd. from a T-die and 2 mm parallel to the longitudinal direction of the nonwoven fabric. Were laminated in a line at intervals of The resin was 30 g / cm 2 .
＜実施例４＞
東洋紡株式会社製不織布ボランス「ＣＲＥ３０８０」白色面側に幅１ｍｍのヤスハラケミカル株式会社製ヒロダイン７５０４（エチレン酢酸ビニルコポリマー、ビカット軟化温度４２℃）をスクリーン印刷にてドット状に積層した。樹脂は２０ｇ／ｃｍ２であった。
<Example 4>
A 1 mm width Hirodine 7504 (ethylene vinyl acetate copolymer, Vicat softening temperature 42 ° C.) having a width of 1 mm was laminated in a dot shape by screen printing on a white surface side of a nonwoven fabric Borance “CRE 3080” manufactured by Toyobo Co., Ltd. The resin was 20 g / cm 2 .
＜比較例１＞
東洋紡株式会社製不織布ボランス「ＣＲＥ３０８０」白色面側に幅１ｍｍのヤスハラケミカル株式会社製ヒロダイン７５３６（エチレン酢酸ビニルコポリマー、ビカット軟化温度８３℃）をＴ−ダイから押し出し、上記不織布の長手方向と平行に２ｍｍの間隔で線状に積層した。樹脂は２０ｇ／ｃｍ２であった。
<Comparative Example 1>
Toyobo Co., Ltd. Nonwoven Borance “CRE3080” Hirodine 7536 (ethylene vinyl acetate copolymer, Vicat softening temperature 83 ° C.) 1 mm wide on the white surface side is extruded from a T-die and 2 mm parallel to the longitudinal direction of the nonwoven fabric. Were laminated in a line at intervals of The resin was 20 g / cm 2 .
＜比較例２＞
東洋紡株式会社製不織布ボランス「ＣＲＥ３０８０」白色面側に幅１ｍｍのサイデン化学株式会社製アクリル系樹脂 ＡＴＲ−１を上記不織布に２０ｇ／ｍ２となるよう塗布した。上記アクリル系樹脂は常温（２０℃）でも粘性が高く、樹脂層のサンプルを取ることができず、軟化点Ａは測定できなかった。
<Comparative Example 2>
Acrylic resin ATR-1 made by Seiden Chemical Co., Ltd. having a width of 1 mm was applied to the nonwoven fabric at 20 g / m 2 on the white surface side of the nonwoven fabric Borans “CRE3080” manufactured by Toyobo Co., Ltd. The acrylic resin had a high viscosity even at room temperature (20 ° C.), a sample of the resin layer could not be taken, and the softening point A could not be measured.
＜比較例３＞
東洋紡株式会社製不織布ボランス「ＣＲＥ３０８０」白色面側に幅２ｍｍのヤスハラケミカル株式会社製ヒロダイン７５２８（エチレン酢酸ビニルコポリマー、ビカット軟化温度４０℃）をＴ−ダイから押し出し、上記不織布の長手方向と平行に０．１ｍｍの間隔で線状に積層した。樹脂は５０ｇ／ｃｍ２であった。
<Comparative Example 3>
Toyobo Co., Ltd. non-woven borane “CRE 3080” Hirodine 7528 (ethylene vinyl acetate copolymer, Vicat softening temperature 40 ° C.) having a width of 2 mm on the white surface side is extruded from a T-die and 0 in parallel with the longitudinal direction of the non-woven fabric. .Laminated linearly at intervals of 1 mm. The resin was 50 g / cm 2 .
＜比較例４＞
東洋紡株式会社製不織布ボランス「ＣＲＥ３０８０」白色面側に幅１ｍｍのヤスハラケミカル株式会社製ヒロダイン７５２８（エチレン酢酸ビニルコポリマー、ビカット軟化温度４０℃）をＴ−ダイから押し出し、上記不織布の長手方向と平行に９ｍｍの間隔で線状に積層した。樹脂は５ｇ／ｃｍ２であった。
<Comparative example 4>
Toyobo Co., Ltd. Nonwoven Borance “CRE3080” Hirodine 7528 (ethylene vinyl acetate copolymer, Vicat softening temperature 40 ° C.) 1 mm wide on the white surface side is extruded from a T-die and 9 mm parallel to the longitudinal direction of the nonwoven fabric. Were laminated in a line at intervals of The resin was 5 g / cm 2 .
実施例１〜４および比較例１〜４で得られた補強用不織布の測定した各物性を表１にまとめた。 Table 1 shows the measured physical properties of the reinforcing nonwoven fabrics obtained in Examples 1 to 4 and Comparative Examples 1 to 4.
本発明の発泡成形品補強用不織布は、金型に改良を加えず、従来の金型を使用し、金型を汚すこともなく簡単に補強用不織布を金型にセットできるため、縫製から発泡成形までの工程を簡略化でき生産性を大幅に改善することができ産業界への寄与大である。 The non-woven fabric for reinforcing foam-molded products of the present invention does not improve the mold, uses a conventional mold, and can easily set the reinforcing non-woven fabric in the mold without contaminating the mold. The process up to molding can be simplified and productivity can be greatly improved, contributing greatly to the industry.
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| PCT/JP2015/074595 WO2016035732A1 (en) | 2014-09-01 | 2015-08-31 | Non-woven fabric for reinforcing expansion-molded articles |
| US15/507,613 US20170282490A1 (en) | 2014-09-01 | 2015-08-31 | Nonwovens for reinforcing foam-molded article |
| EP15837473.6A EP3189966B1 (en) | 2014-09-01 | 2015-08-31 | Nonwovens for reinforcing foam-molded article |
| CN201580043104.3A CN106573456B (en) | 2014-09-01 | 2015-08-31 | Expansion-molded article enhancing non-woven fabrics |
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| JPH04141405A (en) * | 1990-10-03 | 1992-05-14 | Mitsui Petrochem Ind Ltd | Reinforcing material for foam molded form |
| JP2015048544A (en) * | 2013-08-30 | 2015-03-16 | トヨタ紡織株式会社 | Reinforcement cloth-like material for urethane foam molding and method of producing urethane foam molding using the same |
| JP6365875B2 (en) * | 2014-09-01 | 2018-08-01 | 東洋紡株式会社 | Nonwoven fabric for reinforcing foam molded products |
| JP6372269B2 (en) * | 2014-09-12 | 2018-08-15 | 東洋紡株式会社 | Nonwoven fabric for reinforcing foam molded products |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2019527640A (en) * | 2016-07-26 | 2019-10-03 | テスカ フランス | Method for manufacturing an automobile seat cushion |
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