JP2018024957A - Web for car interior excellent in lightness, needle-punched nonwoven fabric using the same, method of manufacturing these, and car interior component using these - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a needle-punched nonwoven fabric using a web for car interior excellent in lightness.SOLUTION: The needle-punched nonwoven fabric for car interior is constituted by three-dimensionally entangling and integrating a web by needle punch treatment, the web obtained by fiber-blending and carding the main fibers each other which are a thermoplastic polyester hollow crimped short fiber having a fiber cross section shape of a hollow cross section having a hollowness of 5-40%, and a thermoplastic polyester solid crimped short fiber, where the content of the hollow crimped short fiber is 10-90 mass% to 100 mass% of a total amount of the main fibers, the content of the solid crimped short fiber is 90-10 mass%, the crimping of the main fibers is two-dimensional mechanical crimping, the crimp rate of the mechanical crimping is 5-35 mountains/inch, the crimping degree is 5-40%, the residual crimping degree is 3-35%, and the basis weight of the nonwoven fabric is 180-350 g/m.SELECTED DRAWING: None

Description

  The present invention relates to an automobile interior web excellent in lightness, a needle punched nonwoven fabric using the same, a method for producing them, and an automobile interior part obtained by using them. Specifically, thermoplastic polyester hollow crimped short fiber and thermoplastic polyester solid crimped short fiber as the main fiber, blending the main fibers together, obtaining a uniform web by carding, obtained by needle punching, The present invention relates to a needle punched nonwoven fabric for automobile interiors that is less likely to cause “scaling” and is excellent not only in light weight but also in bulkiness, design and mechanical strength.

  Thermoplastic polyesters, especially polyethylene terephthalate (PET) are widely used as textile products for automobile interiors because of their excellent balance of mechanical properties, heat resistance, moldability, chemical resistance, and the like, and low cost. In practice, needle punched nonwoven fabrics are widely used in which original fibers having various colors obtained by kneading a colorant at the spinning stage are mixed and oriented by carding and entangled by needle punching. Recently, with the widespread use of hybrid vehicles, plug-in hybrid vehicles, and electric vehicles, and the rise of fuel cell vehicles, weight reduction for improving the fuel efficiency of next-generation vehicles has become an urgent issue.

  A non-woven fabric that forms a fabric shape with an aggregate of fibers is formed by a combination of a fleece-like cotton aggregate, technically called a web, and a bonding step that physically and chemically bonds and entangles the same.

  The main method for forming fleece is a dry method in which short fibers are carded using a carding machine and are arranged in a certain direction or randomly in an air flow called air lay. A short net is dispersed in water to form a net-like net. There are a wet method in which a fleece is formed by pulling up into a shape, and a spunbond method in which a melted raw material resin is directly eluted and spun from the tip of a nozzle to form a fleece with continuous long fibers.

  As a method of bonding the fibers, a chemical pond method in which an adhesive resin of an emulsion type is attached to a fleece by a method such as impregnation or spraying, and heated and dried to bond the intersections of the fibers, or a low melting point heat fusion fiber is used. The mixed fleece is hot-pressed between hot rolls, or a thermal pond method in which hot air is applied to bond the fibers together. The fleece is repeatedly pierced with a needle that moves up and down at high speed, and the fibers are entangled by protrusions called barbs carved into the needle. There is a needle punch method. The needle punch method is characterized by high bulkiness and no separation between fibers, and this method alone is used for commercialization or in combination with another bonding method.

  As a method for reducing the weight of the fiber, there are a method using a flame retardant fiber in which the step of applying a flame retardant backing is reduced (for example, Patent Document 1) and a method for reducing the basis weight. However, the method using the flame retardant fiber has a problem that the flame retardant is likely to be clogged in the nozzle hole for producing the hollow fiber. It has been pointed out that it has reached the limit in order to significantly reduce the appearance quality and mechanical strength of parts. Here, “skee” means “a phenomenon in which the fiber density of the nonwoven fabric is low, so that a part of the base of the nonwoven fabric can be seen”. It becomes prominent at the top part.

  In order to improve bulkiness and lightness, hollow fibers and highly crimped fibers are widely used particularly in the bedding and clothing fields. For example, in Patent Document 2, in a fiber structure having polyester-based synthetic fibers and binder fibers as main constituent members, a fiber structure in which hollow fibers are blended and compressed and fixed by binder fibers is used as a cushion material, a heat insulating material, It is disclosed that it is useful as a sound absorbing material. Patent Document 3 is made of polytrimethylene terephthalate polyester, has a three-dimensional crimp (latent crimp) with a crimp number of 9 to 30 peaks / inch, and a crimp rate of 20 to 50%, and A hollow crimped polyester fiber having a crimped elastic modulus of 80% or more is disclosed. Furthermore, Patent Document 4 discloses a lightweight felt material in which a nonwoven fabric sheet is interposed and integrated between two hard cotton layers made of ultrafine fibers and hollow fibers imparting bulkiness. Furthermore, Patent Document 5 discloses a granular cotton containing elastic composite fibers that exhibit three-dimensional crimps (latent crimps) as a constituent component.

  On the other hand, for a needle punched nonwoven fabric widely used as an interior material for automobiles, for example, Patent Document 6 is used for in-mold molding of a molded product having a top portion where ridgelines meet, and is a thermoplastic synthetic material. It has been disclosed that when a non-woven fabric for a molded product obtained by subjecting a fiber sheet to needle punching can be used, leaching of the resin to the surface and scaling can be prevented. Moreover, in patent document 7, when the high intensity | strength needle punch nonwoven fabric which consists of a polyethylene terephthalate fiber which consists of a biomass origin component is used, it is disclosed that the tear at the time of shaping | molding and a scaling can be prevented. Furthermore, Patent Document 8 discloses that polyethylene terephthalate fibers imparted with hollow and non-hollow (solid) mechanical crimps (two-dimensional crimps) are used as polyester solid cotton for cushion materials.

Table 2010/001972 JP-A-8-302551 JP 2001-254239 A JP2015-37842A JP2015-155586A JP 2004-270089 A JP 2013-11028 A JP-A-6-220759

  The present invention is a mixture of hollow crimped short fibers and solid crimped short fibers, a web excellent in card properties and yield, and by subsequent needle punching treatment, it is excellent in bulkiness, design properties, mechanical strength and elongation, In addition, the present invention provides a needle punched nonwoven fabric for automobile interior that is free from leaching and scaling and has low weight and excellent weight, a method for producing the same, and an automobile interior part using them.

  Patent Document 2 discloses fiber structures suitable for applications such as bedding such as mattresses, various cushioning materials such as furniture and automobile interior parts, heat insulating materials such as backrests such as sofas and chairs, and sound absorbing materials. In addition, Patent Document 3 discloses that a fiber product such as a nonwoven fabric, stuffed cotton, and spun yarn knitted fabric that has good card-passability and excellent bulkiness and sag resistance can be obtained. However, in both cases, there is no description regarding the carding property of the mixed cotton of the hollow crimped short fiber and the solid crimped short fiber and the weight reduction of the fiber product. Further, Patent Document 4 discloses that sound absorption and flame retardancy are high, flexible, and suitable for automobiles and vehicle interior materials, industrial materials, clothing, and the like. However, Patent Document 5 is used as an optimum batting material for bedding and clothing, but there is no description regarding lightness and automobile use.

  Patent Documents 6 and 7 disclose that the nonwoven fabric can be provided with a basis weight general portion and a basis weight increasing portion, and by using polyethylene terephthalate fibers composed of biomass-derived components, leaching and scaling can be prevented on the resin surface. In Patent Document 8, a polyester elastomer-based binder fiber having a melting point of 100 ° C. or higher is used to make a mechanically crimped polyethylene terephthalate fiber to be spot-bonded, thereby eliminating a lack of softness of the texture, ease of settling, and the like. Although disclosed, nothing is described about blending of hollow crimped fibers and solid crimped fibers, and weight reduction of automobiles.

  Textile products for automobile interiors are strongly desired to have designs and colors and shapes that match the current trends, and cost performance that does not increase the price even in response to environmental changes. Compared to bedding, etc. Therefore, strict product standards and stable quality are desired. For this reason, usually, a single fiber is not used, but a plurality of crimped short fibers having different colors, physical properties, costs, and the like are generally mixed to satisfy the required characteristics. For this reason, the card property at the time of blending of crimped short fibers is an important factor for commercialization.

  In order to solve the problem of weight reduction, which is an urgent issue for next-generation automobiles, the present inventors have a bulky (large specific volume) and light weight, so that they can be used in bedding and bedding like futon cotton. The thermoplastic polyester hollow short fiber having a widely used three-dimensional crimp (also called a latent crimp or a three-dimensional crimp) was applied to automobile applications. Therefore, a needle punched nonwoven fabric for automobile interior is obtained by blending and carding hollow short fibers imparted with such latent crimps and solid staple fibers imparted with mechanical crimps used for automobile interiors. Tried to reduce the weight. However, it was found that the card could not be used due to deterioration of card properties during web production, yield reduction due to cotton falling, and generation of scales during nonwoven fabric production. An attempt was made to produce a hollow short fiber for automobile interior having a high crimping performance, but the hollow shape was crushed by a strong mechanical crimp, and a hollow short fiber having a high hollow ratio could not be obtained. Optimization of nozzle hole shape, spinning temperature, discharge rate during spinning, cooling speed and winding speed (or take-up speed), stretching conditions, crimping conditions, etc. Succeeding in obtaining hollow short fibers that satisfy the above requirements, this short fiber is greatly related to the problems of carding and yield during web production, and the problem of non-woven fabric obtained by needle punching. I found it.

  The present inventors have sought to reduce the weight of automobile interior fiber products, and as a result of earnestly studying the production method of hollow crimped short fibers and the blend of hollow crimped short fibers and solid crimped short fibers, the card at the time of carding It has been found that the property and yield and the cause of “scaling” of the nonwoven fabric have a great influence on the crimped shape of the short fibers used and the crimping performance, thereby completing the present invention. That is, the present invention provides the following (1) to (13).

  (1) A thermoplastic polyester hollow crimped short fiber and a thermoplastic polyester solid crimped short fiber having a hollow cross section having a hollow cross section of 5 to 40% hollow ratio as a main fiber, and a total amount of the main fiber of 100% by mass The hollow crimped short fibers are 10 to 90% by mass, the solid crimped short fibers are 90 to 10% by mass, the main fibers are mixed and carded, and the main fibers are crimped twice. Needle punched nonwoven fabric for automobile interiors, which is a three-dimensional mechanical crimp, wherein the number of crimps by the mechanical crimp is 5 to 35 ridges / inch, the crimp rate is 5 to 40%, and the residual crimp rate is 3 to 35%. Used for web.

  (2) The inter-fiber friction coefficient of single yarn of hollow crimped short fiber is 0.35 to 0.50, and the inter-fiber friction coefficient of single yarn of solid crimped short fiber is 0.25 to 0.40. (1) A web used for the needle punched nonwoven fabric for automobile interior.

  (3) The hollow crimped short fiber is 20 to 80% by mass, the solid crimped short fiber is 80 to 20% by mass, the hollowness is 10 to 30% with respect to the total amount of the main fibers of 100% by mass, the wrinkle The automobile interior according to any one of the above (1) and (2), wherein the number of crimps is 10 to 25 crests / inch, the crimp rate is 10 to 30%, and the residual crimp rate is 7 to 25%. Web used for needle punched nonwoven fabric.

(4) A thermoplastic polyester hollow crimped short fiber and a thermoplastic polyester solid crimped short fiber having a hollow cross section having a hollow cross section of 5 to 40% hollow ratio as main fibers, and blending and carding the main fibers together. The web is a non-woven fabric that is three-dimensionally entangled and integrated by needle punching, and the hollow crimped short fibers are 10% by mass to 90% by mass with respect to the total amount of the main fibers of 100% by mass. The actual crimped short fibers are 90% by mass to 10% by mass, the crimps of the main fibers are two-dimensional mechanical crimps, and the number of crimps by the mechanical crimps is 5 to 35 threads / inch. A needle punched nonwoven fabric for automobile interiors having a rate of 5 to 40%, a residual crimp rate of 3 to 35%, and a basis weight of the nonwoven fabric of 180 to 350 g / m ² .

  (5) The inter-fiber friction coefficient of single yarn of hollow crimped short fiber is 0.35 to 0.50, and the inter-fiber friction coefficient of single yarn of solid crimped short fiber is 0.25 to 0.40. (4) The needle punch nonwoven fabric for automobile interior according to (4).

  (6) The needle punched nonwoven fabric for automobile interior according to any one of (4) to (5), wherein the main fiber has a cut length of 5 to 200 mm and a fiber thickness of 1.0 to 20 dtex.

  (7) The hollow crimped short fiber is 20 to 80% by mass, the solid crimped short fiber is 80 to 20% by mass, the hollow ratio is 10 to 30%, and the crimp number is 10 to 25 mountain / inch, (4) to (4) above in which the crimp rate is 10 to 30%, the residual crimp rate is 7 to 25%, the main fiber has a cut length of 10 to 80 mm and a fiber thickness of 2.0 to 10 dtex. 6. The needle punch nonwoven fabric for automobile interior according to any one of 6).

  (8) The needle punch nonwoven fabric for automobile interior according to the above (4) to (7), wherein the main fiber is an original fiber.

  (9) The needle punched nonwoven fabric for automobile interior according to the above (4) to (8), wherein the thermoplastic polyester resin used for the hollow and / or solid crimped short fibers is a recycled PET (polyethylene terephthalate) resin.

  (10) A thermoplastic polyester hollow crimped short fiber and a thermoplastic polyester solid crimped short fiber having a hollow cross section with a hollow cross-section of 5 to 40% hollow ratio as a main fiber, and a total amount of the main fiber of 100% by mass The hollow crimped short fiber is 10 to 90% by mass, the solid crimped short fiber is 90 to 10% by mass, the main fibers are mixed together, obtained by carding, and the main fibers are crimped. A hollow crimped short fiber, which is a two-dimensional mechanical crimp, has a number of crimps of 5 to 35 peaks / inch, a crimp rate of 5 to 40% and a residual crimp rate of 3 to 35%. Used for a needle punched nonwoven fabric for automobile interiors in which the single fiber yarn has a coefficient of friction between fibers of 0.35 to 0.50, and the single fiber of solid crimped short fiber has a coefficient of friction between fibers of 0.25 to 0.40. Web manufacturing method.

(11) A thermoplastic polyester hollow crimped short fiber and a thermoplastic polyester solid crimped short fiber having a hollow cross section with a hollow cross section of 5 to 40% hollow ratio as a main fiber, blending the main fibers together, and by carding A method for producing a nonwoven fabric obtained by forming a web and then needle-punching and integrating three-dimensionally entangled, wherein the hollow crimped short fibers are 10 to 90 mass% with respect to 100 mass% of the total amount of the main fibers. %, The solid crimped short fiber is 90 to 10% by mass, and the crimp of the main fiber is a two-dimensional mechanical crimp, and the number of crimps by the mechanical crimp is 5 to 35 threads / inch, The crimp rate is 5 to 40%, the residual crimp rate is 3 to 35%, the inter-fiber friction coefficient of the single yarn of the hollow crimped short fiber is 0.35 to 0.50, and the solid crimped short fiber The inter-fiber friction coefficient of a single yarn is A .25～0.40 method automotive interior needle punched nonwoven fabric basis weight is 180~350g / ^{m 2.}

  (12) The web according to any one of (1) to (3) above, the nonwoven fabric according to any one of (4) to (9) above, and the method for producing the web according to (10) above and the above (11) An automotive interior part obtained by the method for producing a nonwoven fabric described in (11).

  According to the present invention, as a main fiber, a thermoplastic polyester hollow short fiber imparted with mechanical crimp and a thermoplastic polyester solid short fiber imparted with mechanical crimp are used as a blended cotton for general use. Compared with hollow short fibers with latent crimps, the web has excellent cardability and yield, and the needle punching process ensures excellent bulkiness, design, mechanical strength and elongation, and A needle punch nonwoven fabric for automobile interiors that is free from leaching and scaling, has a low weight, and is excellent in lightness can be provided, and can be used as an automotive interior part to contribute to the weight reduction of next-generation automobiles.

It is the sample for determination used for the evaluation of the skating property of a nonwoven fabric. It is drawing which represented the shape of the mechanical crimped short fiber typically. It is drawing which represented the shape of the latent crimped short fiber typically.

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In the description of the drawings, the same elements are denoted by the same reference numerals, and redundant description is omitted. In addition, the dimensional ratios in the drawings are exaggerated for convenience of explanation, and may be different from the actual ratios.

The present invention comprises a thermoplastic polyester hollow crimped short fiber and a thermoplastic polyester solid crimped short fiber having a hollow cross section having a hollow cross section of 5 to 40% in hollow ratio, and a crimp number of 5 to 35 threads / inch. Mechanical crimps with a crimp rate of 5 to 40% and residual crimp rate of 3 to 35%, and a single fiber of hollow crimped short fiber has an inter-fiber friction coefficient of 0.35 to 0.50. A main web in which the inter-fiber friction coefficient of a single staple fiber is 0.25 to 0.40, the main fibers are mixed with each other, and there is no mixing unevenness or carding and yield reduction by carding. Is then obtained by three-dimensional entanglement and integration by needle punching, wherein the hollow crimped short fibers are 10 to 90% by mass with respect to the total amount of the main fibers of 100% by mass, 90-1 actual crimped short fibers Is the mass%, basis weight is to provide a car interior needle punched nonwoven fabric contribute to weight reduction in 180~350g / ^{m 2.} In the present specification, unless otherwise noted, the numerical range indicated by “to” includes an upper limit and a lower limit. For example, “10-30%” means “10% or more and 30% or less”.

<Main fiber>
The thermoplastic polyester hollow crimped short fiber and the thermoplastic polyester solid crimped short fiber used as the main fiber in the present invention are obtained by kneading and melt spinning a thermoplastic polyester resin together with additives such as a colorant and a flame retardant, drawing and crimping. It is obtained by a known production method for automobile interior fiber comprising drying, heat setting and cutting processes. In this case, in order to impart lubricity to the fiber, a fiber oil agent can be used as an additive in the spinning, drawing, and crimping steps. There is no restriction | limiting in particular as a thermoplastic polyester resin used by this invention, Any polyester resin can be used regardless of the structural component, if it is thermoplastic. The reason for limiting to the thermoplastic polyester resin is that if it is thermoplastic, the waste polyester can be reused, for example, recycled PET (polyethylene terephthalate resin, etc.). It is the process of cutting the long fiber which came out of the heat setting process into a fixed length by a cutting machine.

(Thermoplastic polyester resin)
Polyester is a polycondensate of polycarboxylic acid (dicarboxylic acid) and polyalcohol (diol). The polyvalent carboxylic acid (dicarboxylic acid) component constituting such a thermoplastic polyester resin is not particularly limited. For example, terephthalic acid, isophthalic acid, 2,6-naphthalenedicarboxylic acid, 1,5 -Naphthalenedicarboxylic acid, 4,4'-diphenyldicarboxylic acid, bis- (4-carboxyphenyl) sulfone, bis (4-carboxyphenyl) ether, 1,2-bis (4-carboxyphenyl) ethane, 5-sodium sulfo Examples include isophthalic acid, diphenyl-p, p′-dicarboxylic acid, p-phenylenediacetic acid, and trans-hexahydroterephthalic acid and their alkyl esters, aryl esters, and ethylene glycol esters.

  On the other hand, the polyalcohol (diol, glycol) component constituting the thermoplastic polyester resin is not particularly limited. For example, ethylene glycol, butylene glycol, 1,2-propylene glycol, 1,4 -Butanediol, trimethylene glycol, 1,6-hexanediol, 1,4-cyclohexanediol, neopentyl glycol, 1,4-cyclohexanedimethanol, bisphenol A, bisphenol S and its ethylene glycol and polyethylene glycol adducts , Diethylene glycol, polyethylene glycol and the like.

  Furthermore, a condensation-type polyester resin of hydroxycarboxylic acid such as polylactic acid or a known flame-retardant polyester obtained by copolymerizing a flame retardant component can be used. Depending on the combination of the carboxylic acid component and the glycol component, the resulting polymer (thermoplastic polyester resin or binder fiber) can have a wide range of melting points of 150 to 300 ° C, and the low melting point polymer can be combined with the high melting point polymer. It can be used as a fiber. Among these, as the thermoplastic polyester resin of the present invention, polyethylene terephthalate (melting point 258 ° C.), polybutylene terephthalate (melting point 243 ° C.) and polyethylene naphthalate (265 ° C.) which are used in large quantities and can be obtained at low cost are preferable. Moreover, examples of the low melting point polymer include copolymer polyesters composed of polyethylene terephthalate segments having a melting point of 180 ° C. or less, and polylactic acid resins. As the binder fiber, a widely used polypropylene fiber can be used in addition to the thermoplastic polyester fiber. A thermoplastic polyester resin may be used independently and may be used combining plurality. In general, a solid fiber is used as the binder fiber, and 5 to 20 parts by mass is used with respect to 100 parts by mass of the main fiber, but this is not included in the main fiber of the present invention. Moreover, a binder fiber is an arbitrary component used suitably as needed.

  The number average molecular weight of the thermoplastic polyester resin is not particularly limited, but is preferably 1,000 to 100,000, and more preferably 5,000 to 50,000. If it is 1,000 or more, yarn formation is possible, and if it is 100,000 or less, an increase in viscosity can be suppressed, so that melt spinning is easy. In addition, said number average molecular weight can be measured by a gel permeation chromatography (GPC), for example. Usually, the above-mentioned number average molecular weight can be substituted by an intrinsic viscosity which is easy to measure, and the intrinsic viscosity is 0.05 to 2.53, preferably 0.19 to 1.40. Intrinsic viscosity can be calculated | required by the method based on JISK7390 (2003).

  Moreover, in this invention, what was discarded after use as this thermoplastic polyester resin, and the end material at the time of manufacturing an industrial product can also be utilized. That is, the thermoplastic polyester resin of the present invention can include recycled (recycled) polyester resins (among them, recycled polyethylene terephthalate, recycled polybutylene terephthalate and recycled polyethylene naphthalate resin, and recycled polyethylene terephthalate resin is preferred). In the present invention, the discarded polyester resin includes a wide range of polyester resins other than products, such as used polyester resins, pre-use but non-standard products, and not used as products. Examples of such waste polyester resin include synthetic resin manufacturers, film manufacturers, PET bottle manufacturing industries, polyester resins that are less than standard grades from polyester polymerization manufacturers, and polyester resins obtained by the General Waste Containers and Packaging Recycling Law. it can. This makes it possible to material-recycle waste materials that should be discarded or subject to incineration, contributing to environmental conservation and economically advantageous.

(Additive)
As the colorant used in the present invention, known ones such as organic pigments and inorganic pigments can be used. For example, organic pigments made of azo, anthraquinone, quinacridone, cyanine green and cyanine blue, dioxazine, phthalocyanine, α-phthalocyanine and β-phthalocyanine, perinone, berylene, and polyazo A titanium oxide based on titanium yellow, ultramarine, iron oxide, petal, zinc white, anatase titanium and rutile titanium oxide, and a carbon based inorganic pigment composed of carbon black, graphite, spirit black, channel black and furnace black. But are not limited to these. Usually, a desired color can be imparted to the fiber by selecting a plurality of appropriate pigments from these colorants and mixing and using appropriate amounts. Moreover, the light resistance (color deterioration prevention effect) of a fiber can be provided by making it into an original fiber by mix | blending and spinning a coloring agent directly to a raw material as an auxiliary material.

  In addition to the colorant, other additives can be further added as long as the spinnability and fiber characteristics are not impaired. Other additives include red phosphorus, ammonium polyphosphate, melamine polyphosphate, polyphosphate ester, organic phosphate metal salt, flame retardant such as phosphazene, flame retardant aid such as antimony oxide and biscumyl, aluminum oxide, hydroxide Flame retardants such as magnesium, sodium carbonate, calcium carbonate and talc, plasticizers such as phthalate esters, phosphate esters and aliphatic carboxylic acids, stabilizers such as inorganic salts and metal soaps, antioxidants such as alkylphenols and alkylenebisphenols There are known additives such as UV absorbers, such as an agent, salicylic acid ester, benzotriazole, and hydroxybenzophenone.

  Regarding the use amount of these additives, a thermoplastic polyester resin composition (which is a raw material of the thermoplastic polyester hollow crimped short fiber and the thermoplastic polyester solid crimped short fiber used as the main fiber) (hereinafter also referred to as raw material resin) The content of the colorant is 0.01 to 5% by mass, preferably 0.1 to 2% by mass, and the content of the flame retardant is 0.1 to 12% by mass, preferably 1. ˜5 mass%. If the colorant is 0.01% by mass or more, the fiber product is excellent in that it can be colored relatively easily in various colors, and if it is 5% by mass or less, it is a cause of deterioration of light resistance such as discoloration. It is excellent in that it does not become. Further, if the content of the flame retardant is 0.1% by mass or more, it is excellent in that sufficient flame retardancy can be imparted, and if it is 12% by mass or less, it is excellent in that spinning can be easily performed. Yes. About the usage-amount of another additive, it can be included in the range which does not impair spinnability and a fiber characteristic.

(Spinning, drawing, crimping, drying / heat setting and cutting processes)
The main fiber of the present invention is produced by continuously or discontinuously performing a series of processes such as kneading of raw material resin, melt spinning, drawing, crimping and cutting into short fibers, and after crimping or cutting Is followed by a drying and heat setting step. These steps can be performed by a generally used method.

  For example, a raw resin melt-kneaded by a single-screw or twin-screw extruder is extruded from a nozzle, water supply is applied or a spinning oil is supplied if necessary, and an undrawn yarn is obtained by winding a yarn. The cross-sectional shape in that case is arbitrary, and any of round cross-section fiber, irregular cross-section fiber, hollow fiber, etc. may be sufficient. The irregular cross section (shape) as used herein refers to a solid fiber cross section having a cross section other than a round cross section. About the irregular-shaped cross section of a solid fiber and the hollow cross section of a hollow fiber, the thing of various shapes can be used according to a use application. In the case of hollow cross-section fibers, the hollow ratio of the hollow cross section is 5 to 40%, preferably 10 to 30%. If the hollowness is less than 5%, it is difficult to achieve the desired weight reduction of the fiber, and if it exceeds 40%, the hole tends to be crushed and easily broken, and the weight reduction, sound absorption, This is not preferable because it causes a decrease in the strength of the fiber. There are 1C, 2C, 3C, 4C, 5C, etc. corresponding to the number of air intakes of the outside air, and the hole shape of the nozzle used for manufacturing the hollow fiber is not crushed by crimping and maintains the hollow ratio of the present invention. In order to do so, 1C, 2C, 3C and 4C are preferred. Here, the ring-shaped hole shape uses a nozzle for producing a core-sheath conjugate fiber, uses a nozzle whose resin is the sheath and air is the core, 1C uses a normal nozzle, and the hole shape is C-shaped. The air intake is fixed to a part of the ring-shaped hole. 2C has two air intakes in the ring shape (two C-shaped ones face each other to form a ring), 3C has three, 4C has four and 5C has five air intakes It is. The number of holes is obtained by multiplying the number of holes per nozzle by the number of nozzles, and the productivity in spinning, that is, the length and amount of fibers per fixed time, are determined by the discharge amount, the number of holes, and the winding speed. The number of holes in the nozzle is not particularly limited because it depends on the scale of the production facility, but is preferably 200 to 2000 from the viewpoint of productivity, quality abnormality (stick generation) due to yarn breakage and fusion. In the case of a hollow fiber, it is preferably 200 to 1500 because of quality abnormality due to yarn breakage and fusion.

  The melt spinning process is not limited to a wet process and a dry process, and a known method can be used. However, a dry process is preferable. From the viewpoint of productivity, yarn breakage prevention, and quality abnormality due to fusion, a take-up speed (winding speed) of 300 From the viewpoint of quality abnormality due to clogging of nozzle holes, yarn breakage spinning and fusion, it is preferable to perform melt spinning at a spinning temperature of 200 to 300 ° C., depending on the yarn formation state. The conditions are changed as appropriate and the optimum conditions are used. For hollow fibers, the same conditions are applied, but there are several conditions such as the types of raw materials used, such as resins and additives, product specifications, external manufacturing environment such as external temperature and humidity, and characteristics of manufacturing equipment. Since it is determined by multiplication, it is more preferable to grasp the optimum conditions by performing preliminary experiments or the like in advance and perform melt spinning, and stricter management conditions are required than the production of solid fibers. Further, in the case of hollow fibers, cooling at the nozzle outlet is particularly important, and it is necessary to control so as to obtain an optimal hollow shape. More preferably, the atmospheric temperature at the nozzle outlet may be determined within a range of 20 to 50 ° C. by conducting a preliminary experiment or the like in advance in the context of other conditions.

  The unstretched yarn may be stretched in a continuous process as it is, or may be stretched after being taken into a can or wound on a bobbin and then aged. The stretching process may be a single stage or a multistage of two or more stages. From the viewpoint of ensuring the optimum strength and elongation of the fiber, the draw ratio is preferably about 1.0 to 6.0. If the draw ratio is 1.0 or more, a sufficient strength can be maintained, and if it is 6.0 or less, it is excellent in that a sufficient elongation can be maintained. In the case of hollow fibers, from the viewpoint of securing the optimum strength, elongation, and hollow ratio of the fibers, the draw ratio is 2.0 to 5.0, and if it is 2.0 or more, sufficient fiber strength is maintained. If it is 5.0 or less, it is preferable in that an optimum hollow ratio can be maintained. In the stretching process, there is no problem even if a contact or non-contact type heat source is used. Moreover, in order to perform extending | stretching smoothly, a fiber oil agent can be provided in the range which does not have a bad influence on a fiber raw material.

  In the crimping process, a known mechanical crimping method that is flat, so-called two-dimensional crimping can be used. By setting appropriate conditions, a stable shape can be maintained for a long period of time, and carding characteristics of mixed cotton. Becomes better. For example, in the method using an indentation crimper, an appropriate number of crimps, crimp rate, and residual crimp rate can be imparted to the fiber by adjusting the nip pressure and stuffing pressure, or applying steam. The crimp is preferably strong, and the nip pressure is set to 0.05 to 0.85 MPa, particularly 0.10 to 0.55 MPa, and the stuffing pressure is set to 0.05 to 0.85 MPa, particularly 0.10 to 0.45 MPa. It is preferable that a more stable crimp can be applied. The number of crimps, the crimp rate, and the residual crimp rate are determined by delicate adjustment of both, and if the nip pressure and the stuffing pressure are each 0.05 MPa or more, the number of crimps, the crimp rate, and the residual crimp rate are remarkably high. The decrease can be effectively prevented, and when it is 0.85 MPa or less, the number of crimps, the crimp rate, and the residual crimp rate can be prevented from increasing. As a result, it is excellent in that the variation of the product can be effectively prevented and the quality can be further stabilized. Regarding the number of crimps, the crimp rate, and the residual crimp rate, it is preferable to perform the same crimping conditions for both solid fibers and hollow fibers in order to improve carding and needle punching. .

  The number of crimps of the main fiber obtained by the drying / heat setting process described later is 5 to 35 threads / inch, preferably 10 to 25 threads / inch. Can be obtained. If the number of crimps is less than 5 ridges / inch, the fiber entanglement may be insufficient, and the web may be lost during the lamination process after passing through the card. On the other hand, if the number of crimps exceeds 35 ridges / inch, neps are likely to occur, which causes a reduction in surface quality.

  If the crimp rate of the main fiber obtained by the drying / heat setting process described later is 5 to 40%, preferably 10 to 30%, and the residual crimp rate is 3 to 35%, preferably 7 to 25%, A non-woven fabric having both card process passability and surface quality can be obtained. If any one of the crimp ratio is less than 5% and the residual crimp ratio is less than 3%, the fiber entanglement is insufficient, and the web may be loosened in the lamination process after passing through the card. is there. In addition, if any one of the crimp ratio exceeds 40% and the residual crimp ratio exceeds 35%, the cohesive force between the short fibers becomes too strong, and nep is likely to be generated, which causes the deterioration of the surface quality. It becomes.

  Usually, mechanical crimping (also referred to as two-dimensional crimping or demonstrable crimping) is used for manufacturing automobile interior textiles. In the spinning process, using an anisotropic cooling or a spinning method (conjugate spinning) that uses two types of thermoplastic resins having different thermal shrinkage rates, three-dimensional crimping (also called three-dimensional crimping, also called latent crimping), A light web of large specific volume suitable for bedding like duvet cotton is obtained. The hollow short fiber used in the present invention is a highly crimped fiber obtained by mechanical crimping.

  About the friction coefficient of the main fiber obtained by the drying / heat setting process described later, a non-woven fabric obtained by opening a short fiber on a smooth metal plate, forming a web, and then needle punching is laid on the above, Place a rectangular metal block covered with non-woven fabric. This metal lump is pulled by using a universal testing machine with a twist on the string, and the static friction coefficient is calculated from the maximum load (maximum static friction force) when the metal lump moves in the horizontal direction. Obtained as the average of times. Under the same conditions, the method of obtaining the average static friction coefficient of a plurality of non-woven fabrics at the same time and obtaining the relative numerical value was adopted, which adopted a method with high accuracy and reduced man-hours. However, in order to make this value as a standard value, using the short fibers used for the production of the nonwoven fabric, in accordance with JISL1015: 2010 (8.13), the single-fiber inter-fiber static friction coefficient (10 to 20 times) The average value of measurement) was determined, and the correlation between the average static friction coefficient of the nonwoven fabric and the inter-fiber friction coefficient of the single yarn was determined and corrected to obtain the inter-fiber static friction coefficient. The inter-fiber friction coefficient of the single yarn of the hollow crimped short fiber thus obtained is 0.35-0.50, and the inter-fiber friction coefficient of the single yarn of the solid crimped short fiber is 0.25-0. 40. If the inter-fiber friction coefficient of the single yarn of the hollow crimped short fiber is 0.35 or more and the inter-fiber friction coefficient of the single yarn of the solid crimped short fiber is 0.25 or more, the single yarn fibers may pass through each other. In addition, the entanglement is excellent and the carding property is improved, and it can greatly contribute to the improvement of the elongation of the nonwoven fabric and the prevention of the occurrence of the skein. Below, when the inter-fiber friction coefficient of a single crimped short staple fiber is 0.40 or less, slipping is improved (improved), effectively preventing the occurrence of wrinkles and floats, and greatly increasing productivity. It is preferable at the point which can improve (improve). However, since the coefficient of friction changes depending on the temperature and humidity at the time of manufacturing the main fiber, and the type and amount of the oil agent, care must be taken in the measurement. In other words, as a means for adjusting (controlling) the friction coefficient, it is possible to adjust (control) depending on the temperature and humidity at the time of manufacturing the main fiber, and also the type and amount of the oil agent.

  The thickness of the main fiber obtained by the drying / heat setting process described later is the discharge rate during spinning (g / min), the take-up speed (winding speed) (m / min), the number of nozzle holes, and the draw ratio. And can be expressed by decitex, which is the number of grams per 10,000 m of fiber length. The thickness of the fiber is preferably 1.0 to 20 dtex, more preferably 2.0 to 10 dtex. If the thickness is 1.0 dtex or more, yarn breakage can be prevented during spinning, while if it is 20 dtex or less, the rigidity of the main fiber can be prevented from becoming excessively strong and the processability of the fiber is improved ( Can be improved).

  Moreover, the cut length (fiber length) of the main fiber obtained by the drying / heat setting process described later is preferably 5 to 200 mm, more preferably 10 to 80 mm. If the cut length (fiber length) of the main fiber is 5 mm or more, the entanglement between the fibers is sufficiently developed, and it is excellent in that continuous fiber can be easily discharged by operations such as carding. If the cut length (fiber length) of the fiber is 200 mm or less, it is possible to effectively suppress the fiber entanglement from becoming too strong, and it is excellent in that the carding can be performed uniformly.

  Next, the drying / heat setting step uses a heating furnace to remove moisture adhering during stretching, and then increases the fiber strength by aging at a temperature not lower than the melting point and not higher than the glass transition temperature of the resin. it can. The heat-set long fibers are finally made into short fibers by a cutting process using a cutting machine, and then packed and packed. The cut length has been described above. The cutting step may be after the drying / heat setting step or after the stretching / crimping step.

  Textile oil agents include fatty acid ester type, polyether type synthetic lubricants, PEG (polyethylene glycol) type, ester type, amide type nonionic surfactants, sulfonate type, phosphate type, carboxylate type anions, etc. The surfactants, amphoteric surfactants, nonionic surfactants, and the like that are usually used as textile oil agents for automobiles can be used. The amount of the oil agent attached to the fiber may be used within a range that does not impair the effects of the present invention, and may be used within a range where the characteristics and functions as the fiber oil agent can be effectively expressed. Preferably it is 0.01 to 1.0% with respect to the fiber obtained, More preferably, it is 0.05 to 0.5%. If the adhesion amount of the oil agent to a fiber is the said range, it is preferable at the point which is excellent in card property and punching property.

<Web and needle punched nonwoven fabric>
The web and the needle punched nonwoven fabric can be produced by a known method.

Web production (mixed cotton and card process)
For example, the polyester hollow crimped short fibers and the thermoplastic polyester solid crimped short fibers (main fibers), which are the main fibers described above, are mixed in a predetermined ratio (mixing process) and carded with a card machine (card process). The web is prepared by arranging short fibers in a certain direction. That is, the web used for the needle punched nonwoven fabric for automobile interior of the present invention is formed by blending and carding the main fibers.

Manufacture of needle punched nonwoven fabric (needle punching process)
Next, the web is laminated using a cross wrapper and is adjusted to a predetermined basis weight. Thereafter, the web is punched with a needle punching machine (needle punching process), and short fibers are entangled (specifically, entangled and integrated three-dimensionally) to obtain a nonwoven fabric. That is, the needle punched nonwoven fabric for automobile interior of the present invention is obtained by three-dimensionally interlacing and integrating a (uniform) web obtained by blending and carding the main fibers with each other by needle punching. When the web contains binder fibers, it can be heat-treated at a temperature not lower than the melting point of the binder fibers (polymer) and not higher than the melting point of the main fiber to obtain a final product having a stable shape.

  The ratio of the crimped staple fibers to be mixed is 10% by mass to 90% by mass, preferably 20% by mass to 80% by mass, with respect to the total amount of the main fibers of 100% by mass. The crimped short fiber is 90% by mass to 10% by mass, more preferably 80% by mass to 20% by mass. If the hollow crimped short fiber is less than 10% by mass (the solid crimped short fiber exceeds 90% by mass), the weight of the nonwoven fabric is not reduced, and exceeds 90% by mass (the solid crimped short fiber is 10% by mass). Is less than that), which leads to a significant decrease in the scalability of the nonwoven fabric. In addition, if the hollow crimped short fiber and the solid crimped short fiber are within this range, it becomes possible to adjust to various colors requested by the customer by blending cotton, and by reducing the number of original fibers and mass production Cost can be reduced.

The amount of web to be laminated is, scale prevention nonwoven, weight reduction, from the viewpoint of strength and the like, preferably 3 to 10 sheets, nonwoven basis weight is preferably ^{180~350g / m 2, 200~350g / m} 2 Gayori 200 to 300 g / m ² is more preferable. When the basis weight of the nonwoven fabric is less than 180 g / m ² , the nonwoven fabric has a large basis weight unevenness, causes skein generation, and deteriorates the surface quality. If the basis weight exceeds 350 g / m ² , the nonwoven fabric is used even if the hollow fiber is used. This is not preferable because it does not lead to weight reduction. As a method for producing the web and needle punched nonwoven fabric of the present invention, known methods can be used.

  The effects of the web and the nonwoven fabric of the present invention are mainly governed by the composition of the main fiber used and the structure and characteristics of the main fiber. However, since the structure and characteristics of the main fiber are slightly changed depending on the manufacturing process of the web and nonwoven fabric, it cannot be specified only by the structure and characteristics of the web and nonwoven fabric.

<Automobile interior parts>
The automobile interior part according to the present invention is obtained by the above-described web, nonwoven fabric, web production method and nonwoven fabric production method of the present invention. According to the present invention, as a main fiber, a thermoplastic polyester hollow short fiber imparted with mechanical crimp and a thermoplastic polyester solid short fiber imparted with mechanical crimp are used as a blended cotton for general use. Compared with hollow short fibers with latent crimps, the web has excellent cardability and yield, and the needle punching process ensures excellent bulkiness, design, mechanical strength and elongation, and A needle punch nonwoven fabric for automobile interiors that is free from leaching and scaling, has a low weight, and is excellent in lightness can be provided, and can be used as an automotive interior part to contribute to the weight reduction of next-generation automobiles.

  Hereinafter, the present invention will be specifically described with reference examples, comparative reference examples, examples and comparative examples of the present invention. In addition, the measuring method of each characteristic value is as follows.

A. Method for measuring short fibers (1) Single yarn fineness (decitex)
It is a unit representing the thickness of a fiber thread and is the number of grams per 10,000 m. From the discharge amount (g / min) during spinning, the winding speed (take-up speed) (m / min), the number of holes in the nozzle, and the draw ratio, the following formula was used. In the case of hollow fibers, the calculation was performed in consideration of the hollow ratio.

(2) Single yarn fineness (decitex) and hollow ratio determined from microscope observation The cross-sectional area (μm ² ) and hollow area (μm ² ) of the single yarn were measured with a microscope, and the PET resin density was 1.38 g / cm. ^From the average of 10 points as ³ , the single yarn fineness was determined by the following formula, and the hollow ratio was determined from the ratio of the hollow area in the cross-sectional area of the single yarn.

(3) Outer diameter Using a micrometer, the outer diameter (μm) of the single yarn was measured and determined from the average of 10 points.

(4) Cut length (fiber length)
The short fiber sample obtained in the cutting process is sampled from two places, and the length of the short fiber when measured in a natural state (see FIGS. 2 and 3) is measured. A total of 10 samples at each sampling place are measured. It calculated | required as an average value (mm) of an individual measured value.

(5) Strength / Elongation Using a strong elongation meter (Orientic STA-1150, 2N), the strength and elongation were measured according to JIS L1013 (8.5.1). A single yarn is taken from the short fiber and attached to the knob of the testing machine with the sample loosely stretched. The distance between grips was 20 mm, the initial load (5.88 mN × decitex × 0.1), the elongation at that time was C (mm), and the tensile speed was 20 mm / min. The tensile strength and elongation when the strength A (cN) at the time of cutting and B (mm) as the elongation at the time of cutting were determined by the following equations. In addition, the decitex used for (3) Formula uses what was calculated | required by (1) Formula.

(6) Crimp Test The crimp rate, residual crimp rate, and crimp elastic modulus were measured according to JISL1015 (8.12) using short fiber bundles as test pieces instead of single yarns. A short fiber having a width of about 4 mm and a weight of about 0.1 g is sampled and accurately weighed using a precision balance to obtain a test piece, which is pulled at a speed of 10 mm / min using a universal testing machine (SHIMADZU Autograph, load cell 50N). Obtained by the following equation.

  Here, A is the length (mm) when an initial load (approx. 0.001 mN / dtex) is applied to the end of its own weight level, and B is the length when a load of 4.41 mN x decitex number is applied. The length (mm), C, is the length (mm) when the initial load is applied after leaving for 1 minute, excluding the load.

  The number of crimps was measured according to JIS L1015 (8.12) using a short fiber bundle as a test piece instead of a single yarn. A short fiber having a width of about 4 mm and a weight of about 0.1 g is sampled and accurately weighed using a precision balance to obtain a test piece. The number of peaks (n) where the elongation was achieved to some extent was counted and determined according to the following equation.

  Here, A is the length (mm) when an initial load (approx. 0.001 mN / decitex load is applied to the end of its own weight level).

(7) Dry heat shrinkage rate Conforms to JISL1015 (8.12, b), pull out 10 single yarns from short fibers one by one, attach a clip on one side, fix one side with thick paper with tape, and place the cardboard on the wall And measure the single yarn length (Amm) with calipers. After drying at 170 ° C. for 10 minutes, the yarn length (Bmm) was measured again, and the average value of 10 was obtained by the following formula.

(8) Oil content The short fibers are loosened with a hand card to form cotton, and dried at 170 ° C. for 10 minutes. 2.000-2.020 g of cotton is accurately weighed (A), packed in a test tube, immersed in 10 ml of methanol for 45 seconds, and the methanol solution is squeezed into a previously weighed cup (B). The methanol liquid was evaporated on a hot plate, the weight (C) of the cup was weighed, and an average of 5 points was obtained from the following formula.

(9) Coefficient of static friction between fibers A non-woven fabric obtained by opening a short fiber on a smooth metal plate, forming a web and needle punching is laid, and a rectangular metal block covered with the non-woven fabric is placed thereon. From this maximum load (maximum static frictional force) when the metal lump is moved horizontally by pulling this metal lump with a pulley on a stringed thread, changing the direction at right angles with a universal tester, and using the following formula The static friction coefficient is obtained, and the same operation is repeated 5 times to calculate the average static friction coefficient.

  Under the same conditions, the average static coefficient of friction of a plurality of nonwoven fabrics is obtained at the same time, and a relative numerical value for the nonwoven fabric is obtained. On the other hand, using the short fibers used to produce the nonwoven fabric, in accordance with JISL1015: 2010 (8.13), the inter-fiber static friction coefficient of single yarn (average value of 10 to 20 measurements) is obtained, The correlation between the average static friction coefficient of the nonwoven fabric and the inter-fiber friction coefficient of the single yarn was determined and corrected to obtain the inter-fiber static friction coefficient. The measurement of the inter-fiber friction coefficient of a single yarn requires advanced technology, so it can be easily obtained by correlation with the non-woven fabric friction coefficient. Can be requested.

B. Measurement method of web (1) Blending condition Solid short fibers and hollow short fibers are opened using a card machine, and if a person skilled in the art can determine the blending condition, the quality of the blending condition can be sufficiently judged only by visual observation. Therefore, it is confirmed visually (specifically, visually by comparison with a good / bad sample prepared based on experience), and the good cases are shown in Tables 3, 4, 7, and 9 as ◯. In addition, when this example is re-examined, instead of the sample, for example, the web obtained in Example 1 is used as a good sample, and the web obtained in Comparative Example 1 is used as a bad sample. Thus, the quality of other examples and comparative examples can be determined. In addition, by adding the webs obtained in other examples and comparative examples to the samples in the case of good and unsatisfactory samples, it is possible to obtain a more accurate sample (large sample). It can also be used to determine the quality of web blending performed under conditions other than the examples.

(2) Card characteristics When coming out of the card machine, those skilled in the art can determine how the cylinder is wound, the occurrence of scum and neps, and how the web is connected. Since the five-stage evaluation of occurrence and web connection can be sufficiently judged by visual observation, the five-stage evaluation was performed visually (specifically, by comparison with a five-stage sample prepared based on experience). . The five-level evaluation is shown in the following Tables 3, 4, 7, and 9 as 5: very good, 4: slightly good, 3: good, 2: bad, 1: very bad. In addition, when this example is re-examined, instead of the sample, for example, the web obtained in Example 11 is used as a sample of evaluation 5 (very good). Similarly, the web obtained in Example 10 was used as a sample for evaluation 4 (slightly good), the web obtained in Example 3 was used as a sample for evaluation 3 (good), and the web obtained in Comparative Example 1 was evaluated as 2 The web obtained in Comparative Example 9 is used as a sample for evaluation 1 (very bad). By carrying out like this, evaluation (judgment) can be performed in five stages of webs of other examples and comparative examples. In addition, by adding the webs obtained in the other examples and comparative examples to the five-stage sample, it is possible to obtain a more accurate sample (large sample), which is performed under conditions other than the examples and comparative examples. It can also be used for the determination of the five-stage evaluation of the card property of the web.

(3) Web yield The amount of short fibers charged into the card machine and the yield of the finished web were measured to determine the amount of cotton falling and the web yield (%).

(4) Specific volume / compression rate / recovery rate The specific volume, compression rate, and recovery rate were measured according to JISL 1097 (5.2, 5.3 method). The web is folded at a floor area of 20 cm × 20 cm to prepare a web test piece adjusted to about 40 g, and the weight (W) is accurately measured. An acrylic plate (20 cm × 20 cm, 267.2 g) is placed on the obtained test piece, a 2 kg weight A is placed for 30 seconds, the weight A is then removed, and the mixture is allowed to stand for 30 seconds. This operation is repeated three times. After leaving the weight A for 30 seconds, the heights of the four corners are measured to obtain an average value (h ₀ ) of the bulkiness, and the specific volume is calculated according to the following formula. This test was performed on three test pieces, and the average web specific volume was determined.

A 4 kg weight B is placed on the test piece for which the bulkiness is measured for 30 seconds, the heights of the four corners are measured, and the average value (h ₁ ) is obtained. Next, the weight B is removed, and after standing for 3 minutes, the heights of the four corners are measured, the average value (h ₂ ) is obtained, and the compression rate and the recovery rate are calculated according to the following equations. This test was performed on three test pieces and indicated as an average value.

C. Nonwoven fabric measurement method (1) Actual weight (weight)
The end of the nonwoven fabric was cut into 40 cm × 40 cm in length and width, and the actual weight was obtained from the area and weight.

(2) Nonwoven fabric thickness (bulky)
Cut the non-woven fabric so that it is about 5 cm x 5 cm in length and width, and use it as a test piece. Apply a pressure of 0.5 kPa according to JISL1913 (6.1.1.A method) and measure the thickness after 10 seconds. The thickness (mm) of the nonwoven fabric was determined as an average value of 10 points.

(3) Specific volume of non-woven fabric The specific volume of the non-woven fabric was determined from the actual weight (g / m ² ) and thickness (mm) by the following formula.

(4) Scaling Surround the perimeter with a cardboard box, place a red light projector on the bottom, cover the top with a translucent acrylic plate, place a 40cm x 40cm non-woven fabric on it, see through the red light, Evaluated. In the case where the part without the scale is red and the part with the scale is shown in FIG. 1 in which the redness is taken depending on the degree of the scale and the higher degree of the scale is thinner (lighter yellow) in black and white. , X portion (the portion surrounded by a solid line in the vicinity of the x mark in the figure; the portion with a relatively high degree of scaling and the portion displayed in white) is partly present, In the figure, the part surrounded by a solid line in the vicinity of the △ mark; if the degree of skein is relatively low and slightly white, the skate property △, ○ part (enclosed by the solid line in the figure) A portion marked with a circle; if there is no squeeze or there is almost no squeeze, and only a portion that is relatively black (or gray), it was evaluated as skeletability. In addition, the part with the scale is cut into a size of 1 cm in length and width, and the part with the least transmittance of the skelability ○ is set to 0% transmittance, and the average transmittance within 1 cm in length and width is obtained by image analysis processing. This was a quantitative guide. Scalability ○: Transmittance 0% to 30%, Scalability Δ: Transmittance 31% to 60%, Scalability X: 61% to 100%.

(5) Strength and elongation of nonwoven fabric Strength and elongation were measured using a universal testing machine (SHIMADZU Autograph) in accordance with JISL1913 (6.1.2A, 6.3 method). The non-woven fabric is cut to have a width of 40 mm and a length of about 200 mm in the longitudinal direction (needle punching direction) and in the lateral direction (perpendicular to the needle punching direction), respectively, and five test pieces are produced. Attach the test piece to the tester so that the initial load (the extent that the test piece is pulled by hand) is 150 ± 1 mm. A load was applied at a tensile speed of 100 mm / min until the test piece was cut, and the strength (N / mm ² ) and elongation (%) at the maximum load were measured, and an average value of 5 sheets was used.

Reference Examples 1 to 5 and Comparative Reference Example 1 (Production of solid and hollow short fibers)
Polyethylene terephthalate (PET) resin (Mitsubishi Chemical Corporation, trade name “NOVAPEX”) is kneaded with an extruder, then melt spun at 230 to 285 ° C. under the spinning setting conditions shown in Table 1, and stretched in Table 1 in a hot water bath Stretching at a magnification, then using an indentation crimper to adjust nip pressure and stuffing pressure to give mechanical crimp or latent crimp, cut with a rotary cutter (cutting machine) after drying and heat setting, as shown in Table 2 Short fibers were obtained.

  Reference Example 1 is an original solid short fiber imparted with a mechanical crimp for an automobile interior material, Reference Example 2 is a hollow short fiber imparted with a mechanical crimp for an automobile interior material, and Reference Example 3 is It is an original hollow short fiber imparted with a mechanical crimp for automobile interior materials, and Reference Example 5 is a recycled PET resin having an intrinsic viscosity of 0.65 obtained from a waste PET bottle and a waste PET film, instead of a PET resin. It is the original hollow short fiber which gave the mechanical crimp for the used automobile interior materials, Comparative Reference Example 1 is the hollow short fiber which gave the latent crimp for the futon cotton, Reference Example 4 and Reference Example 5 It is an original solid short fiber to which mechanical crimping using the same recycled PET resin is applied. As the colorant, carbon black having a content of 1% by mass was used. As oil agents, Reference Examples 1 to 5 and Comparative Reference Example 1 use fiber oil agents for automobile interior materials (a mixture of PEG-type and ester-type nonionic surfactants and phosphate-type and carboxylate-type anionic surfactants). It was. In addition, since the oil agent used by this reference example etc. will not affect the performance evaluation content of the following webs and nonwoven fabrics if it is a fiber oil agent for automobile interior materials that is usually used, other automobile interiors You may substitute with the textile oil agent for materials.

  Moreover, the short fiber which gave the mechanical crimp obtained by the reference examples 1 thru | or 5 showed the crimp shape of the two-dimensional zigzag like FIG. 2, and provided the latent crimp obtained by the comparative reference example 1. FIG. The short fiber showed the shape of a three-dimensional solid crimp as shown in FIG.

Examples 1 to 12 and Comparative Examples 1 to 24 (production of web)
Preliminary opening (mixed cotton) by measuring the required amount of the solid short staple fibers obtained by Reference Example 1 and the hollow short fibers obtained by Reference Example 2 so as to achieve the nonwoven fabric target weight and mixing ratio shown in Table 3 Then, the input amount shown in Table 3 was determined, applied to a card machine, and opened (carded) three times while changing the direction to produce a web. In this case, the yield is obtained by measuring the amount of fallen cotton, and the blending condition and cardability are observed, and the specific volume, compression rate and recovery rate are obtained, and Table 3 is shown as Comparative Examples 1 to 8 and Examples 1 to 12. Indicated.

  On the other hand, in place of Reference Example 2, the hollow short fibers provided with latent crimps for the futon cotton obtained in Comparative Reference Example 1 were used, and the same procedure as in Comparative Examples 1 to 8 and Examples 1 to 12 was performed. Webs were prepared, and the results are shown in Table 4 as Comparative Examples 9 to 24.

  From the results of Tables 3 and 4, when hollow short fibers imparted with mechanical crimps were added to solid staples imparted with mechanical crimps, specific volume and compression ratio decreased, but latent crimps were imparted. It was found that when hollow short fibers were added, the compression rate did not change much, but the specific volume increased conversely. It can be seen that the hollow short fibers provided with latent crimps are excellent as futon cotton because of their high specific volume. In both cases, the card property was improved as the input amount (nonwoven fabric target weight) was increased. On the other hand, when hollow short fibers with mechanical crimps are used, there is little cotton loss, high yield, good cardability and recovery rate, and reuse of cotton loss is required for automotive applications with strict product standards. It is difficult to find suitable for automotive applications.

Examples 13 to 21, Comparative Examples 25 to 48 and Comparative Reference Examples 2 to 4 (production of non-woven fabric)
Using the needle room (model NL-380), the webs obtained according to Tables 3 and 4 were moved 380 mm, stroke 75 mm, number of strokes: 190 strokes / minute, web pitch width 4 mm, number of needles 750, needle pitch. : Punching is performed under the conditions of 12.5 mm in width, 30 rows in pitch, 10.0 mm in length, and 25 rows in pitch to produce a nonwoven fabric, and the non-woven fabric's scaleability, bulkiness (thickness), specific volume, strength, and elongation The results are shown in Tables 5 and 6 as Comparative Examples 25 to 48, Comparative Reference Examples 2 to 4 and Examples 13 to 21. In the present invention, as described above, by realizing a novel hollow short fiber (a hollow crimped short fiber subjected to mechanical crimping) that simultaneously satisfies a high crimping performance and a hollowness ratio that are not conventional, Of the examples using only the hollow crimped short fibers subjected to the mechanical crimping, the examples in which the actual basis weight (weight per unit area) satisfies the requirements of the present invention are the conventional examples (comparative examples). Therefore, Comparative Reference Examples 2 to 6 (see Tables 5, 8, and 10) are used.

  From the results shown in Tables 5 and 6, when hollow short fibers with mechanical crimps are added to solid short fibers with mechanical crimps, the specific volume and the longitudinal and transverse strength increase, and the extent of this is determined by the latent crimps. It turns out that it is larger than the case where the hollow short fiber which provided | wore was added. On the other hand, the degree of elongation is significantly higher in the case of hollow short fibers with mechanical crimps compared to short fibers with latent crimps, and by adding each hollow short fiber, mechanical crimps are imparted. In the case of the short hollow fibers, no significant change is observed, but in the case of the short fibers to which the latent crimps are imparted, it can be seen that the number is significantly reduced. In addition, the skelability and specific volume vary greatly depending on the basis weight, and the skelability improves as the basis weight increases, but the specific volume decreases, and the weight reduction and skelability contradict each other. It can be seen that it is superior to Comparative Examples 25 to 51. When nonwoven fabric is used as an automobile interior material, it is often molded while pulling the nonwoven fabric, especially when in-mold molding of a molded product having vertices where the ridgelines meet so that local scaling is noticeable. Therefore, it is understood that a nonwoven fabric having a high degree of elongation with little change even when stretched is desired, and the present invention is particularly excellent. That is, in Examples 13 to 21, it can be seen that a nonwoven fabric meeting such a demand can be obtained.

Examples 22 to 27 and Comparative Example 49 and Comparative Reference Example 5 (in the case of using an original hollow crimped fiber)
In Example 4 to 6 and Comparative Examples 3 and 4, instead of using the hollow short fiber imparted with mechanical crimp of Reference Example 2, the original hollow short fiber colored with carbon black imparted with mechanical crimp of Reference Example 3 was used. And webs and nonwoven fabrics were produced according to Examples 4 to 6 and Comparative Examples 3 and 4, respectively, and the results were designated as Examples 22 to 27, Comparative Example 49 and Comparative Reference Example 5 as Table 7 and This is shown in FIG.

  From the results of Tables 7 and 8, it was found that by replacing the colorless hollow short fibers with the original hollow short fibers, the skelability was remarkably improved without lowering other physical properties, and it was possible to contribute to weight reduction.

Examples 28 to 33 and Comparative Examples 50 to 52 and Comparative Reference Example 6 (when using recycled PET resin)
A web produced by using the original solid short fibers imparted with mechanical crimps obtained by using the recycled PET resin of Reference Example 4 instead of Reference Example 1 is used as Comparative Example 51, and the nonwoven fabric is used as Comparative Example 52. In Examples 22 to 27 and Comparative Example 49 and Comparative Reference Example 5, instead of Reference Example 3, the recycled PET resin of Reference Example 5 was used, and in Examples 22 and 27, Comparative Example 49 and Comparative Reference Example 5, Accordingly, webs and nonwoven fabrics were respectively produced, and the results are shown in Tables 9 and 10 as Examples 28 to 33 and Comparative Examples 50 to 52 and Comparative Reference Example 6.

  By comparing Tables 7 and 8 with Tables 9 and 10, it was found that almost the same results were obtained even when the PET resin was replaced with a recycled PET resin.

  Needle punch nonwoven fabric obtained by the present invention includes hood covers, transmission tunnels, oil filters, transmission filters, turbo compressors and other engine parts, car mats, floor linings, air bag covers, seat cushions, doors, side panels, ceiling materials, It can be used for interiors such as sunroofs, trunks such as rear shelves, spare tire covers, and automobile interior parts such as exterior covers for wheel exterior textiles, underbody, and exhaust systems, and can contribute to weight reduction of next-generation vehicles.

Claims (12)

  A thermoplastic polyester hollow crimped short fiber having a hollow cross section with a hollow cross section of 5 to 40% in hollow ratio and a thermoplastic polyester solid crimped short fiber as a main fiber, the hollow fiber is used in a total amount of 100% by mass of the main fiber. The crimped short fiber is 10 to 90% by mass, the solid crimped short fiber is 90 to 10% by mass, the main fibers are mixed and carded, and the main fibers are crimped in two dimensions. Used as a needle punched nonwoven fabric for automobile interiors, wherein the number of crimps is 5 to 35 crests / inch, the crimp rate is 5 to 40%, and the residual crimp rate is 3 to 35%. Web.   The inter-fiber static friction coefficient of the single yarn of the hollow crimped short fiber is 0.35 to 0.50, and the inter-fiber static friction coefficient of the single yarn of the solid crimped short fiber is 0.25 to 0.40. The web used for the needle punch nonwoven fabric for motor vehicle interiors of Claim 1.   The total amount of the main fibers is 100% by mass, the hollow crimped short fibers are 20 to 80% by mass, the solid crimped short fibers are 80 to 20% by mass, the hollow ratio is 10 to 30%, and the number of crimps 3 to 25 / inch, the crimp rate is 10 to 30%, and the residual crimp rate is 7 to 25%. Web. A web comprising a thermoplastic polyester hollow crimped short fiber and a thermoplastic polyester solid crimped short fiber having a hollow cross section with a hollow cross section of 5 to 40% in hollow ratio as a main fiber, and a mixture of the main fibers and carding. A non-woven fabric that is three-dimensionally entangled and integrated by needle punching, wherein the hollow crimped short fibers are 10 to 90% by mass and the solid crimped short fibers are 100% by mass of the total amount of the main fibers. 90 to 10% by mass, and the crimp of the main fiber is a two-dimensional mechanical crimp, and the number of crimps of the mechanical crimp is 5 to 35 mountain / inch, and the crimp rate is 5 to 40%. A needle punched nonwoven fabric for automobile interiors having a residual crimp rate of 3 to 35% and a basis weight of the nonwoven fabric of 180 to 350 g / m ² .   The inter-fiber friction coefficient of a single yarn of a hollow crimped short fiber is 0.35 to 0.50, and the inter-fiber friction coefficient of a single yarn of a solid crimped short fiber is 0.25 to 0.40. Needle punch nonwoven fabric for automobile interior.   The needle punched nonwoven fabric for automobile interior according to any one of claims 4 to 5, wherein the main fiber has a cut length of 5 to 200 mm and a fiber thickness of 1.0 to 20 dtex.   The hollow crimped short fiber is 20 to 80% by mass, the solid crimped short fiber is 80 to 20% by mass, the hollow rate is 10 to 30%, the number of crimps is 10 to 25 ridges / inch, and the crimp rate is 10 to 30%, the residual crimp rate is 7 to 25%, the cut length of the main fiber is 10 to 80 mm, and the fiber thickness is 2.0 to 10 dtex. The needle punch nonwoven fabric for automobile interior according to the item.   The needle punch nonwoven fabric for automobile interior according to any one of claims 4 to 7, wherein the main fiber is an original fiber.   The needle punched nonwoven fabric for automobile interior according to any one of claims 4 to 8, wherein the thermoplastic polyester used for the hollow and / or solid crimped short fibers is a recycled polyethylene terephthalate resin.   A thermoplastic polyester hollow crimped short fiber having a hollow cross section with a hollow cross section of 5 to 40% in hollow ratio and a thermoplastic polyester solid crimped short fiber as a main fiber, the hollow fiber is used in a total amount of 100% by mass of the main fiber. The crimped short fiber is 10 to 90% by mass, the solid crimped short fiber is 90 to 10% by mass, the main fibers are mixed with each other, obtained by carding, and the main fibers are crimped in two dimensions. Mechanical crimps, wherein the number of crimps is 5 to 35 crests / inch, the crimp rate is 5 to 40%, and the residual crimp rate is 3 to 35%. A web used for a needle punched nonwoven fabric for automobile interiors, wherein the inter-fiber friction coefficient of the yarn is 0.35 to 0.50, and the solid inter-fiber friction coefficient of the solid crimped short fiber is 0.25 to 0.40. Manufacturing method. A thermoplastic polyester hollow crimped short fiber and a thermoplastic polyester solid crimped short fiber having a hollow cross section with a hollow cross section of 5 to 40% of hollow ratio are used as main fibers, the main fibers are mixed together, and a web is formed by carding. Next, a method for producing a nonwoven fabric three-dimensionally entangled and obtained by needle punching, wherein the hollow crimped short fibers are 10 to 90% by mass relative to 100% by mass of the main fibers, The solid crimped short fiber is 90 to 10% by mass, the crimp of the main fiber is a two-dimensional mechanical crimp, and the number of crimps of the mechanical crimp is 5 to 35 threads / inch. The rate of 5-40% and the residual crimp rate of 3-35%, the inter-fiber friction coefficient of the single yarn of the hollow crimped short fiber is 0.35-0.50, and the single yarn of the solid crimped short fiber The inter-fiber friction coefficient is 0.25- .40 a and method for automotive interior needle punched nonwoven fabric basis weight is 180~350g / ^{m 2.}   It obtains by the web of any one of Claims 1-3, the nonwoven fabric of any one of Claims 4-9, the manufacturing method of the web of Claim 10, and the manufacturing method of the nonwoven fabric of Claim 11. Automotive interior parts.