JP2021110065A - Anti-icing nonwoven fabric and manufacturing method thereof - Google Patents

Abstract

To provide an anti-icing nonwoven fabric, which has a sound-absorbing property and an impact noise alleviating property and improved anti-icing property, and a method to manufacture the anti-icing nonwoven fabric at low cost.SOLUTION: An anti-icing nonwoven fabric of the present invention has a surface that consists of thermoplastic fibers such as PET, PP and PE, contains a water repellent agent and is singed. It is preferable that the nonwoven fabric consisting of thermoplastic fibers such as PET, PP and PE has a fiber base layer and a fiber surface layer and that the fiber surface layer contains a water repellent agent and is singed.SELECTED DRAWING: Figure 4

Description

The present invention relates to a non-icing non-woven fabric that can be used for an automobile fender liner or the like and a method for producing the same.

Resin and fiber fender liners are attached to the fenders of automobiles. The resin fender liner is often composed of an injection molded product of an olefin resin such as PP or ABS. The resin liner has a smooth surface and is hydrophobic, so it has excellent icing resistance. It is inferior to the fiber liner in sound absorption and impact sound mitigation such as bounce stones.

Explaining the icing resistance here, if these adhere to the fender liner and grow as icing under conditions such as ice and snow, the icing will run in the form of protruding inside the fender liner and steered. It interferes with sexuality. "Ice resistance" is a spec indicating the magnitude of the icing adhesion force to the liner, and an icing shear force of preferably 10 N or less, more preferably 5 N or less is recommended as a spec.

On the other hand, the fiber fender liner is excellent in sound absorption and shock noise mitigation property, but has a drawback that it is easy for water to permeate and the fiber aggregates are exposed in a mesh shape on the surface, so that icing is easy. As in Patent Document 1 (Patent No. 5283886) and Patent Document 2 (Patent No. 6145341), the fiber base layer and the breathable resin surface layer are combined to achieve both sound absorption / impact sound mitigation and ice resistance. A composite liner has also been proposed. However, there was still room for improvement in terms of the magnitude of the icing shear force and the manufacturing cost.

Japanese Patent No. 5283886 Japanese Patent No. 6145341

Therefore, an object of the present invention is to provide a non-woven fabric having sound absorption and impact sound mitigation properties and improved icing resistance at low cost.

In order to solve the above problems, the non-woven fabric having a non-sticking property of the present invention has a non-woven fabric made of thermoplastic fibers such as PET, PP, and PE, which contains a water repellent and is hair-baked. It is a feature.

Further, in the method for producing a non-icing non-icing non-woven fabric of the present invention, a water repellent agent composed of thermoplastic fibers such as PET, PP and PE is contained in a fiber base layer composed of thermoplastic fibers such as PET, PP and PE. The fiber surface layer is integrated with a needle punch, and the fiber surface layer is hair-baked by a direct flame of a burner or a far-infrared heater.

According to the present invention, it is possible to provide a non-woven fabric having sound absorption and icing resistance at low cost.

It is sectional drawing of the non-woven fabric for icing resistance which concerns on embodiment of this invention. It is the schematic of the car body which shows the mounting position of the fender liner using the non-woven fabric which is resistant to icing. FIG. 3 is a cross-sectional view taken along the line III-III across the fender liner of FIG. It is a flowchart which shows the manufacturing process of the non-woven fabric which is resistant to icing. It is a figure which shows the icing property test result of the Example and the comparative example of the non-woven fabric of the present invention.

FIG. 1 is a cross-sectional view of the non-icing non-woven fabric 10 according to the embodiment of the present invention. The non-icing non-woven fabric 10 has a fiber base layer 11 and a fiber surface layer 12 made of thermoplastic fibers such as PET, PP, and PE. The fiber base layer 11 and the fiber surface layer 12 are formed by entwining polyester fibers (for example, PP fibers, PE fibers or low melting point PET fibers) by needle punching to form a sheet.

The non-woven fabric is not limited to the needle punch non-woven fabric, and the following non-woven fabrics (1) to (5) can also be used.
(1) Spunbonded non-woven fabric that heat-melts the raw material resin and heat-seals the filament extruded from the spinning nozzle (2) When the raw material resin is heat-melted and extruded from the spinning nozzle, it is blown off with high-speed high-temperature air to form fibers. Melt blown non-woven fabric that heat-bonds fibers to each other to form a sheet (3) Spunlace non-woven fabric that entangles fibers in the sheet with a jet water flow (4) Heats and melts the surface of the fibers of the sheet to bond the fibers to each other. Thermal bond non-woven fabric to bond the fibers by mixing low-melting fiber or low-melting resin with the sheet by heating and melting (5) Chemical bond non-woven fabric to bond the fibers of the sheet with a synthetic resin adhesive.

The fiber surface layer 12 is coated and impregnated with a silicon-based water repellent or a fluorine-based water repellent, and is integrated with the fiber base layer 11 by a needle punch. After the fiber surface layer 12 is integrated with the fiber base layer 11 by a needle punch, the surface of the fiber surface layer 12 is hair-baked by an open flame of a burner or a far-infrared heater. The silicon-based water repellent or the fluorine-based water repellent is generally applied and impregnated on the non-woven fabric 10 before the hair burning treatment or heat treatment described later in FIG. 4 (S3).

Further, in FIG. 1, the non-woven fabric 10 which is resistant to ice formation is composed of the fiber base layer 11 and the fiber surface layer 12, but the silicon-based repellent is formed on the surface of the single-layer non-woven fabric formed by needle punching regular PET, PP, PE fibers and the like. A water agent or a fluorine-based water repellent may be applied and impregnated, and the hair may be burnt or heat-treated. In this case, even if the amount of the water repellent used is the same, the material cost is slightly increased because the whole is composed of the fibers appearing on the surface, but there is an advantage that the trouble of forming the fiber base layer 11 and the fiber surface layer 12 into a plurality of layers can be omitted.

On the other hand, when the fiber base layer 11 is divided into two layers as shown in FIG. 1, an inexpensive material cotton can be used for the fiber base layer 11 which does not appear on the surface, so that there is an advantage that the cost can be reduced accordingly. In addition, instead of applying / impregnating a silicon-based water repellent or a fluorine-based water repellent, or in combination with the coating / impregnation, water-repellent PET fibers are applied to regular PET, PP, PE fibers, etc. before needle punching. After mixing a predetermined amount of water-repellent fibers such as, needle punching may be performed.

By the hair baking treatment, the play hair of the fiber surface layer 12 is removed and the surface is smoothed. Further, the fibers of the fiber surface layer 12 are melted by the heat of the hair baking process to form a resin thin film. The original breathability of the fiber surface layer 12 is maintained in this resin thin film.

Smoothing of the fiber surface layer 12 is also possible to some extent by calendar processing or heat press processing. In Comparative Example 3 described later, a hot press roller is used. However, even if the fiber surface layer 12 is smoothed by a calendar process or a hot press process, it is difficult to improve the icing property because some fluff remains.

On the other hand, when the PP and PE fibers of the epidermis are melted by heat treatment as in Comparative Examples 1 and 2, if the amount of melting is too large, the air permeability is too low, and the surface air permeability required for exhibiting sound absorption (for example, about about). It becomes difficult to obtain 10 cc / cm ^{2 · s).} On the contrary, if the melted amount of PP and PE fibers in the epidermis is too small, it is difficult to improve the icing property because the hydrophobic component is reduced, and because of the mold contact when molding into the product shape (for example, fender liner). The surface is scraped and the texture is impaired.

2 and 3 are schematic views showing an example of a mounting position of the fender liner 100 made of the non-woven fabric 10 which is resistant to icing. As shown in FIG. 2, the tire house TH is arranged inside the fender F and above the tire T. The fender liner 100 is heat-molded into a shape corresponding to the tire house TH, and is attached in a state of being separated from the tire house TH by a distance L1.

Various methods of attaching the fender liner 100 to the tire house TH are possible, and there is no particular limitation. For example, the fender liner 100 can be fixed to the tire house TH by providing a holding means (for example, a clip) on the tire house TH side, or a hole can be provided in the fender liner 100 and fixed by fitting into the tire house.

The space S formed by the fender liner 100 and the tire house TH may be a layer made of a sound absorbing body including an air layer, a felt layer, and the like. When a layer made of a sound absorbing body is provided, these layers are integrated with the fender liner 100 to prevent vehicle noise, outside noise (running noise generated during running, etc.) from entering the vehicle. Can function as a structure.

FIG. 4 is a flowchart showing a method for producing the non-icing non-woven fabric 10. As shown in the figure, first, a fiber base layer 11 made of thermoplastic fibers such as PET, PP, and PE is produced by needle punching (S1). The fiber base layer 11 is blended with an appropriate amount of fibers such as low melting point PET fibers, PP fibers, regular PET fibers, etc. so as to have the required rigidity.

Next, the fiber surface layer 12 made of thermoplastic fibers such as PET, PP, and PE is integrated on the fiber base layer 11 by needle punching (S2). An appropriate amount of low melting point PET fiber is blended in the fiber surface layer 12. Next, the non-woven fabric 10 in which the silicon-based water repellent or the fluorine-based water repellent is integrated is coated and impregnated (S3). However, it is also possible to omit the step S3 by mixing a predetermined amount of water-repellent fibers such as water-repellent PET fibers with PET, PP, PE fibers and the like constituting the fiber surface layer 12. Then, the fiber surface layer 12 of the non-woven fabric 10 is hair-baked by an open flame (or a far-infrared heater) of a burner (S4). Finally, the entire non-woven fabric 10 is heat-treated (S5).

By this heat treatment, the low melting point fibers (low melting point PET, PP, PE fibers, etc.) contained in the fiber base layer 11 are melted, and the product rigidity can be increased. The order of S4 and S5 may be changed, and the entire non-woven fabric 10 may be heat-treated first (S5), and finally the hair-baking treatment (S4) may be performed.

The hair burning process is continuously performed along the non-woven fabric transport direction with a far-infrared heater or a burner fixedly arranged on the non-woven fabric production line. As described above, the method for producing the non-icing non-woven fabric 10 is simpler than the conventional method, so that the production cost can be reduced. In addition to the above-mentioned manufacturing method, the fiber base layer 11 and the fiber surface layer 12 may be separately manufactured by needle punching, and then the fiber surface layer 12 may be integrated with the fiber base layer by needle punching, an adhesive, or the like.

FIG. 5 shows Examples and Comparative Examples 1-3 of the non-icing non-woven fabric 10 of FIG. In the embodiment, the fiber base layer (sound absorbing fiber layer) 11 is composed of PP fibers (50% weight) and PET fibers (50% weight). The basis weight of the base layer 11 is 750 g / m ² . Further, the surface layer 12 (skin) is composed of water-repellent PET fibers (40% weight), low melting point PET fibers (30% weight) and regular PET fibers (30% weight). The basis weight of the surface layer 12 is 200 g / m ² , and the total basis weight is 950 g / m ² .

On the other hand, in Comparative Examples 1-3, the same base layer 11 as in Examples was used, but the composition of the surface layer 12 (skin) was changed and the surface treatment (hair burning) was not performed. Others are the same as in the examples. The surface layer 12 of Comparative Example 1 is composed of PE fiber (90% weight) and water-repellent PET fiber (10% weight), and the surface layer 12 of Comparative Example 2 is composed of PP fiber (100% weight). The surface layer 12 of Comparative Example 3 is composed of water-repellent PET fibers (40% by weight), low-melting point PET fibers (30% by weight), and PET fibers (30% by weight).

The results of examining the icing property of Examples and Comparative Examples 1-3 are shown in the rightmost column of FIG. The icing property test was carried out according to the following procedure.
1) Prepare 5 test pieces (nonwoven fabric of Example and Comparative Example 1-3) having a size of 100 × 100 mm for each of Example and Comparative Example 1-3.
2) Stand a metal cylindrical jig (inner diameter: 43.85 mm, height: 30 mm) in the center of the test piece placed horizontally.
3) Fill the inside of the cylindrical jig with water at 5 ° C or lower.
4) Freeze the water in the cylindrical jig in a low temperature chamber at -15 ° C.
5) Connect the force gauge to the cylindrical jig, pull up the cylindrical jig in the vertical direction with the tension / compression universal material tester "Tencilon" (registered trademark), and measure the maximum load when ice is peeled off from the test piece.

As a result of the measurement of a plurality of times (5 times), the icing property of 5N or less on average was obtained only in the examples, and the shearing force of each of the other Comparative Examples 1-3 was more than 5N. Moreover, when the sound absorption test of the non-woven fabric of the example was carried out, the air permeability and the sound absorption property which were equal to or higher than the non-woven fabric used for the conventional fiber fender liner were obtained.

As described above, according to the non-icing non-woven fabric according to the present invention, the surface contains a water repellent and the surface is further subjected to a hair-burning treatment to realize surface smoothing, resulting in water resistance and icing resistance. In addition to improving the properties, the innumerable pores (porous) remaining after the icing treatment provide a predetermined air permeability that satisfies the required level of sound absorption. Therefore, sound absorption equivalent to that of the non-woven fabric used for the conventional fiber fender liner can be obtained.

Although the embodiments of the present invention have been described above, the present invention is not limited to the above embodiments and can be modified in various ways. For example, the non-icing non-woven fabric according to the present invention can be used for other than the fender liner of an automobile, and can also be used for a vehicle undercover such as an engine undercover and a floor undercover.

10: Non-woven fabric that is resistant to ice formation 11: Fiber base layer 12: Fiber surface layer 100: Fender liner F: Fender S: Space T: Tire TH: Tire house

Claims (4)

A non-woven fabric that does not easily adhere to ice, wherein the surface of the non-woven fabric made of thermoplastic fibers such as PET, PP, and PE contains a water repellent and is hair-baked. The present invention is characterized in that the non-woven fabric composed of thermoplastic fibers such as PET, PP, and PE has a fiber base layer and a fiber surface layer, and the fiber surface layer contains a water repellent and is hair-baked. Non-woven fabric that is resistant to ice formation in 1. The non-woven fabric according to claim 1 or 2, wherein the water repellent contains a silicon-based water repellent or a fluorine-based water repellent. A fiber base layer made of thermoplastic fibers such as PET, PP, and PE is integrated with a fiber surface layer made of thermoplastic fibers such as PET, PP, and PE and containing a water repellent by needle punching, and the fibers are integrated. A method for producing a non-woven non-woven fabric that is resistant to ice formation, wherein the surface layer is hair-baked by a direct flame of a burner or a far-infrared heater.

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