JP2016516917A - 構造用部品のための高い強度重量比を有する成形可能な不織布およびその作成方法 - Google Patents
構造用部品のための高い強度重量比を有する成形可能な不織布およびその作成方法 Download PDFInfo
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- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
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- B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-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
- D04H1/42—Non-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
- D04H1/425—Cellulose series
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- D04H—MAKING 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-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
- D04H1/42—Non-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
- D04H1/4282—Addition polymers
- D04H1/4291—Olefin series
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-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
- D04H1/44—Non-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
- D04H1/46—Non-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
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-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
- D04H1/44—Non-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
- D04H1/46—Non-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
- D04H1/48—Non-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 in combination with at least one other method of consolidation
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- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-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
- D04H1/54—Non-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 by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/542—Adhesive fibres
- D04H1/544—Olefin series
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/10—Fibres of continuous length
- B32B2305/20—Fibres of continuous length in the form of a non-woven mat
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/718—Weight, e.g. weight per square meter
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/003—Interior finishings
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
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Abstract
Description
本願は、2013年3月15日に出願された米国仮出願連続番号第61/794,630号の利益を主張する。当該仮出願はその全体がここに引用により援用される。
1.技術分野
この発明は一般に、不織布材料およびそれらの作成方法に関し、より特定的には、少なくとも部分的に天然繊維から作成され、高い強度重量比を有する構造用不織布に関する。
特に自動車業界用の今日の構造用および半構造用部品は、射出成形、熱成形、または吹込成形のいずれかにより、プラスチックなどの石油系材料を用いて作られる。また、製品は木または金属から作られるが、これらの最終製品は高い強度重量比を有する。業界、特に自動車、航空機および航空宇宙業界は、重量の減少および強度の増加を目指しており、このため、強度重量比が高い構造用材料を探している。これは主に、より軽量の車両を作る必要性によって駆り立てられており、それは次に、燃費および性能効率の向上をもたらす。さらに、業界は、寿命の終わりに環境に対して悪影響を与えないような、環境にやさしい構造用材料を探している。
この発明の別の局面によれば、スクリム層は、1対の不織布ウェブ間に挟まれ、各不織布ウェブ内へと少なくとも部分的に拡散されている。
この発明の別の局面によれば、不織布材料は、車両ドアボルスター(vehicle door bolster)または他の構造用部品を形成するために成形される。
この発明のこれらのならびに他の局面、特徴、および利点は、以下の現在好ましい実施形態および最良の形態の詳細な説明、添付された請求項、および添付図面に関連して検討されると、より容易に理解されるようになるであろう。
図面をより詳細に参照すると、図1は、この発明の一局面に従って作成された不織布材料12(図2)から作成された車両ドアボルスター10を示す。ドアボルスター10は、ドアハンドルを含む外側の装飾されたドアパネルが取付けられる、内側の車両ドアパネルである。したがって、ドアボルスター10は、ドアを繰返し開閉することから受ける力、および車両ドアパネルが受ける他のルーティング力に耐えることができなければならない。そのようなドアボルスターに対して突きつけられた極端な要望を想定して、製造業者らは通常、ドアボルスターが満たさなければならない特定の仕様を有する。たとえば、そのような1つの要件は、ドアボルスター材料が1600gsmを有していなければならないということである。この要件は、ドアボルスターが、典型的な車両ドア用途に耐えるために、(マシン方向(machine direction)の)曲げ強度が55.5N、(マシン方向を横断する(across machine direction:AMD))曲げ強度が70.5N、(マシン方向の)曲げ靭性が98.6%、(マシン方向を横断する)曲げ靭性が97.5%、(マシン方向の)曲げ剛性が6.02N/m、および(マシン方向を横断する)曲げ剛性が8.84N/mという要件を満たすには、この密度が必要である、という考えから生じている。この発明に従って作成された不織布材料12は、ドアボルスター10の構成へと圧縮成形されて、約1200gsmしか有していないもののこれらの要件を満たすことまたは上回ることが可能であり、それは最終的には重量を減少させるものの、前述の構造要件を達成し、上回る。
Claims (11)
- 不織布材料であって、
天然セルロース繊維と、無水マレイン酸グラフト化ポリプロピレンと混合されたポリプロピレンを含有する変性ポリプロピレン繊維とから形成された、少なくとも1つの不織布ウェブと、
スクリム層とを含み、前記スクリム層は、前記少なくとも1つの不織布ウェブの外面に結合され、前記少なくとも1つの不織布ウェブ内へと少なくとも部分的に拡散されて、前記少なくとも1つの不織布ウェブおよび前記スクリム層双方の材料を含有する混和領域を形成し、
前記少なくとも1つの不織布ウェブは、約300〜1200gsmの総密度を有する、不織布材料。 - 前記スクリム層は、前記少なくとも1つの不織布材料の外面を形成する、請求項1に記載の不織布材料。
- 前記不織布材料は、マシン方向を横断する曲げ強度が約76Nである、請求項2に記載の不織布材料。
- 前記スクリム層は、1対の前記少なくとも1つの不織布ウェブ間に挟まれ、各々の前記不織布ウェブ内へと少なくとも部分的に拡散されて、前記スクリム層の両側に1対の混和領域を形成し、前記混和領域は、前記不織布ウェブおよび前記スクリム層のそれぞれからの材料を含有する、請求項1に記載の不織布材料。
- 前記不織布材料は、マシン方向を横断する曲げ強度が約80Nである、請求項4に記載の不織布材料。
- 前記1対の不織布ウェブの各不織布ウェブは、約600gsmの密度を有する、請求項4に記載の不織布材料。
- 前記不織布材料は、車両ドアボルスターを形成するために成形される、請求項1に記載の不織布材料。
- 不織布材料を作成する方法であって、
天然セルロース繊維と、無水マレイン酸グラフト化ポリプロピレン繊維を含有するポリプロピレンとの混合物を混合するステップと、
混合された混合物から少なくとも1つの不織布ウェブを形成するステップと、
少なくとも1つの不織布ウェブを結合するステップと、
結合された少なくとも1つのウェブの表面にスクリム層を積層し、スクリム材料を少なくとも部分的に溶融して、少なくとも1つの不織布ウェブの表面内へと拡散させて、前記少なくとも1つの不織布ウェブおよびスクリム層双方の材料を含有する混和領域を形成し、約300〜1200gsmの密度を有する完成した不織布材料を提供するステップとを含む、方法。 - 1対のウェブを形成して結合し、スクリム層を、結合された1対のウェブ間に挟まれる関係で積層して、不織布ウェブおよびスクリム層の材料を含有する1対の混和領域を形成するステップをさらに含む、請求項8に記載の方法。
- 車両ドアボルスターを形成するために不織布材料を成形するステップをさらに含む、請求項8に記載の方法。
- 天然セルロース繊維が約50%、無水マレイン酸グラフト化ポリプロピレン繊維を含有するポリプロピレンが約50%という比率を有する混合物を形成するステップをさらに含む、請求項8に記載の方法。
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Application Number | Priority Date | Filing Date | Title |
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US201361794630P | 2013-03-15 | 2013-03-15 | |
US61/794,630 | 2013-03-15 | ||
PCT/US2014/030225 WO2014145457A1 (en) | 2013-03-15 | 2014-03-17 | Moldable nonwoven having high strength to weight ratio for structural components and method of construction thereof |
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JP2016516917A true JP2016516917A (ja) | 2016-06-09 |
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US (1) | US20140272343A1 (ja) |
EP (1) | EP2971312B1 (ja) |
JP (1) | JP2016516917A (ja) |
KR (1) | KR102165529B1 (ja) |
CN (1) | CN105143541B (ja) |
BR (1) | BR112015023096A8 (ja) |
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WO2016044826A1 (en) * | 2014-09-19 | 2016-03-24 | Federal-Mogul Powertrain, Inc. | Moldable natural fiber nonwoven wire harness trough and method of construction thereof |
BR112017011038A2 (pt) * | 2014-11-26 | 2018-02-14 | Federal-Mogul Powertrain Llc | manga acústica de não tecido e método de construção da mesma |
KR20200034584A (ko) * | 2018-09-21 | 2020-03-31 | 주식회사 동진쎄미켐 | 신규한 캡핑층용 화합물 및 이를 포함하는 유기 발광 소자 |
US11958273B2 (en) * | 2019-09-06 | 2024-04-16 | Auria Solutions Uk I Ltd. | Decorative nonwoven laminates |
CN115821483A (zh) * | 2022-11-07 | 2023-03-21 | 江阴市华思诚无纺布有限公司 | 一种汽车用非织造布内饰材料及其制备方法 |
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DE19506083A1 (de) * | 1995-02-22 | 1995-07-13 | Thueringisches Inst Textil | Hybridvliese mit haftungsverbessernden Eigenschaften für faserverstärkte Kunststoffe |
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US7618907B2 (en) * | 2002-08-02 | 2009-11-17 | Owens Corning Intellectual Capital, Llc | Low porosity facings for acoustic applications |
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- 2014-03-17 WO PCT/US2014/030225 patent/WO2014145457A1/en active Application Filing
- 2014-03-17 CN CN201480022561.XA patent/CN105143541B/zh not_active Expired - Fee Related
- 2014-03-17 EP EP14721147.8A patent/EP2971312B1/en active Active
- 2014-03-17 US US14/216,444 patent/US20140272343A1/en not_active Abandoned
- 2014-03-17 KR KR1020157028475A patent/KR102165529B1/ko active IP Right Grant
- 2014-03-17 JP JP2016503354A patent/JP2016516917A/ja active Pending
- 2014-03-17 BR BR112015023096A patent/BR112015023096A8/pt not_active Application Discontinuation
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JPH06259081A (ja) * | 1993-01-21 | 1994-09-16 | Minnesota Mining & Mfg Co <3M> | 不織布防音ウェブおよびそれにより防音する方法 |
DE20300098U1 (de) * | 2003-01-07 | 2003-03-27 | Quadrant Plastic Composites Ag | Naturfaser-Mischvlies |
JP2009234129A (ja) * | 2008-03-27 | 2009-10-15 | Toyota Boshoku Corp | 植物性繊維複合材の製造方法 |
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BR112015023096A2 (pt) | 2017-07-18 |
KR20150131170A (ko) | 2015-11-24 |
US20140272343A1 (en) | 2014-09-18 |
BR112015023096A8 (pt) | 2019-12-03 |
WO2014145457A1 (en) | 2014-09-18 |
EP2971312A1 (en) | 2016-01-20 |
CN105143541A (zh) | 2015-12-09 |
EP2971312B1 (en) | 2017-07-19 |
CN105143541B (zh) | 2018-02-16 |
KR102165529B1 (ko) | 2020-10-14 |
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