JP2021181671A - Substrate for molding - Google Patents

Abstract

To provide a substrate for molding a vehicle exterior material allowing attached snow and ice to easily fall off.SOLUTION: A substrate for molding 100 comprises a fiber substrate layer 10 including core-sheath type composite fibers with a sheath part made of polypropylene-based resin and a core part made of polyester-based resin. In the substrate for molding 100, the mass percentage of the core-sheath type composite fibers in the fibers constituting the fiber substrate layer 10 is more than 70 mass%.SELECTED DRAWING: Figure 1

Description

The present invention relates to a base material for molding.

An underbody shield material (a type of exterior material) is used at the bottom of the vehicle for the purpose of reducing unevenness on the underside of the vehicle to suppress air resistance during driving, protecting the vehicle from flying stones on the tires, and reducing road noise. Hereinafter, the underbody shield material may be abbreviated as UBS), and a wheel house liner material to be attached to the wheel house of the vehicle body is provided.

As a constituent member of an exterior material such as a UBS or a wheel house liner material, as described in Japanese Patent Application No. 2019-208366 (Patent Document 1), the sheath portion is a polypropylene resin and the core portion is a core portion. Has been studying a molding base material having a fiber base material layer containing a core-sheath type composite fiber which is a polyester resin. In addition, the applicant of the present application tends to be able to provide an exterior material having excellent heat resistance as the mass percentage of the core-sheath type composite fiber in the fibers constituting the fiber base material layer is higher in Patent Document 1. The finding that the mass percentage is preferably 50% by mass or more is described.

Japanese Patent Application No. 2019-208366

However, with exterior materials such as UBS and wheel house liner materials prepared using a molding base material that satisfies the above configuration, snow and ice that bounce off the road surface adhere to the surface of the exterior material and are difficult to peel off. there were. After that, the snow or ice still attached to the exterior material may freeze, and / or the snow or ice still attached to the exterior material may be frozen by water or rainwater on the road surface. Then, when snow or ice frozen on the exterior material is peeled off due to strong vibration generated during running, cracks or internal peeling occur on the surface of the exterior material, which causes the exterior material to be destroyed. was there.

The exterior material destroyed in this way has a problem that the expected effects such as the effect of suppressing air resistance during running, the effect of protecting the vehicle body, and the effect of reducing road noise cannot be satisfactorily exhibited. ..

In order to prevent the above-mentioned problems from occurring, there has been a demand for a molding base material capable of realizing an exterior material such as an exterior material for a vehicle in which attached snow and ice are easily peeled off.

The present invention is "(claim 1) a molding base material provided with a fiber base material layer, and the fiber base material layer has a core-sheath type in which the sheath portion is a polypropylene-based resin and the core portion is a polyester-based resin. A base material for molding, which contains a composite fiber and has a core-sheath type composite fiber having a mass percentage of more than 70% by mass in the fibers constituting the fiber base material layer.
(Claim 2) The fiber base material layer has a portion (a) including one main surface, a portion (b) including the other main surface, and the portion (a) and the portion (b). The molding substrate according to claim 1, which has a sandwiched portion (c), and the density of the portion (a) is higher than the density of the portion (c). "
Is.

As a result of continued examination by the applicant of the present application, it is generated in a molding base material having a fiber base material layer containing a core-sheath type composite fiber in which the sheath portion is a polypropylene resin and the core portion is a polyester resin. It has been found that the problem that the attached snow and ice are difficult to peel off can be solved by adjusting the mass percentage of the core-sheath type composite fiber in the fibers constituting the fiber base material layer.
Specifically, by using a molding base material having a fiber base material layer having a mass percentage of more than 70% by mass, it is possible to realize an exterior material such as a vehicle exterior material in which attached snow and ice are easily peeled off. Provided a base material for molding.

Further, as a result of continued examination by the applicant of the present application, the density of the portion including at least one main surface of the fiber base material layer provided in the molding base material is high, so that the attached snow and ice are easily peeled off. We have found that it is possible to provide a base material for molding that can realize an exterior material such as an exterior material for use.

The reason why such an effect is exhibited is that solids (snow and ice) and liquids (water and rainwater on the road surface) do not easily pass through the dense part, so that attached snow and ice and water on the road surface It is difficult for ice and rainwater to pass through the portion and enter the inside of the fiber base material layer. As a result, it is considered that it is possible to provide a base material for molding capable of realizing an exterior material in which the attached snow or ice only adheres to the surface of the exterior material and the attached snow or ice is more easily peeled off.

Further, by using a molding base material satisfying the configuration according to the present invention, it is possible to realize an exterior material having excellent sound absorption performance and sound insulation performance and exhibiting high rigidity even in a high temperature atmosphere. It is possible to provide a molding base material having the following effects.

It is a schematic cross-sectional view showing the base material for molding which concerns on this invention. It is a schematic cross-sectional view which showed the other molding base material which concerns on this invention.

In the present invention, various configurations such as the following configurations can be appropriately selected. Unless otherwise specified or specified, the various measurements described in the present invention were carried out under normal pressure under 25 ° C. temperature conditions. Then, unless otherwise specified or specified, the various measurement results described in the present invention were obtained by measurement up to a value one digit smaller than the desired value, and the value to be obtained was calculated by rounding off the value. As a specific example, if the value up to the first decimal place is the value to be obtained, the value up to the first decimal place is calculated by finding the value up to the second decimal place by measurement and rounding off the obtained value to the second decimal place. Then, this value was used as the desired value. Further, each upper limit value and each lower limit value exemplified in the present invention can be arbitrarily combined.

The present invention will be described mainly with reference to FIGS. 1 and 2, which are schematic cross-sectional views of the molding base material (100, 200) according to the present invention.

The molding substrate (100, 200) includes a fiber substrate layer (10, 20). Although details will be described later, the molding base material (100) shown in FIG. 1 includes a portion (11a) of the fiber base material layer (10) including one main surface and the other main surface. It has a portion (11b), a portion (11c) sandwiched between the portion (11a) and the portion (11b), and the density of the portion (11a) is higher than the density of the portion (11c). .. Further, although the details will be described later, the molding base material (200) shown in FIG. 2 includes a portion (21a) of the fiber base material layer (20) including one main surface and the other main surface. It has a portion (21b), a portion (21c) sandwiched between the portion (21a) and the portion (21b), and the density of the portion (21a) and the portion (21b) is the portion (21b). It is higher than the density of 21c).

The fiber base material layer (10, 20) as used in the present invention refers to a layer of fibers in which fibers are entangled with each other, for example, made of a fiber web, a non-woven fabric, or a cloth such as a woven fabric or knitting. By including the fiber base material layer (10, 20), it is possible to provide a molding base material (100, 200) having excellent moldability because it is highly flexible and easily follows a mold or the like. In order to provide a molding base material (100, 200) having more excellent moldability, the fiber base material layer (10, 20) constituting the molding base material (100, 200) is a fiber in which fibers are randomly entangled with each other. The layer is preferably composed of a web or a non-woven fabric, and more preferably composed of only a fiber web or a non-woven fabric.

The fiber base material layer (10, 20) contains a core-sheath type composite fiber in which the sheath portion is a polypropylene-based resin and the core portion is a polyester-based resin. Provided are a molding base material (100, 200) capable of realizing an exterior material in which attached snow and ice are easily peeled off by containing the core-sheath type composite fiber in the fiber base material layer (10, 20). can.

Well-known types of polypropylene-based resins constituting the sheath portion of the core-sheath type composite fiber according to the present invention can be adopted, for example, polypropylene, polymethylpentene, and a part of hydrocarbons such as nitrile group or fluorine or chlorine. Polypropylene having a structure substituted with halogen can be adopted. Further, the melting point of the polypropylene-based resin can be higher than 80 ° C, higher than 90 ° C, and higher than 100 ° C.

Further, a well-known type of polyester resin constituting the core portion of the core-sheath type composite fiber according to the present invention can be adopted, for example, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, poly. Butylene terephthalate, polycarbonate, polyarylate, all-aromatic polyester resin, etc. can be adopted. The melting point of the polyester resin can be higher than 80 ° C, higher than 90 ° C, and higher than 100 ° C. The melting point of the polyester-based resin constituting the core portion of the core-sheath type composite fiber according to the present invention is higher than the melting point of the polypropylene-based resin constituting the sheath portion.

The area ratio of the core portion to the sheath portion in the fiber cross section of the core-sheath type composite fiber can be appropriately adjusted, but can be 1: 9 to 9: 1, and can be 2: 8 to 8: 2. It can be 3: 7-7: 3 and can be 4: 6-6: 4.

Various values such as fiber length and fineness of the core-sheath type composite fiber are appropriately adjusted so as to provide a molding base material (100, 200) capable of solving the problem according to the present invention. The fineness can be 1-100 dtex, 1.5-50 dtex, 2-30 dtex, 3-10 dtex.

Further, it can be a fiber having a specific length such as a short fiber, and the fiber length can be 20 to 150 mm, 25 to 100 mm, 30 to 90 mm, 40. It can be ~ 80 mm.

The fiber length may be longer than 150 mm and may be a fiber having a continuous length for which it is difficult to specify the fiber length (a concept including a constituent fiber of a melt blow nonwoven fabric, a constituent fiber of a spunbonded nonwoven fabric, and the like). However, the core-sheath type composite fiber is preferably a short fiber so that a molding base material (100, 200) having a dense main surface portion can be easily prepared.

The core-sheath type composite fiber may be a fiber prepared by kneading a pigment or a dyed fiber or the like.

Since the mass percentage of the core-sheath type composite fiber according to the present invention in the fibers constituting the fiber base material layer (10, 20) is more than 70% by mass, the attached snow and ice are easily peeled off. It is possible to provide a molding base material (100, 200) capable of realizing the above. If the value is more than 70% by mass, it can be appropriately adjusted, and it can be 75% by mass or more, preferably 80% by mass or more. If all the constituent fibers of the fiber base layer (10, 20) are core-sheath type composite fibers (the value is 100% by mass), it is possible to realize an exterior material in which attached snow and ice are easily peeled off. It is more preferable to provide a molding base material (100, 200).

In the present invention, the mass percentage (unit: mass%) of the core-sheath type composite fiber in the fibers constituting the fiber base material layer (10, 20) can be calculated from the following formula.
X = 100 × B / A
X: Mass percentage of core-sheath type composite fiber in the fibers constituting the fiber base material layer (10, 20) (unit: mass%)
A: Mass of fibers constituting the fiber base material layer (10, 20) (unit: g / m ² )
B: Mass of core-sheath type composite fiber contained in the fiber base material layer (10, 20) (unit: g / m ² )

The fibers were extracted from the fiber substrate layer (10, 20) and analyzed using various analyzers such as a melting point measuring instrument and FT-IR, optical analysis using an electron microscope, and kayastine staining. Using a well-known analyzer and analysis method such as dye analysis, the mass of the fibers constituting the fiber substrate layer (10, 20) and the mass of the core-sheath type composite fiber contained in the fiber substrate layer (10, 20) can be determined. You can ask. Specifically, 100 fibers are randomly extracted from the fiber substrate layer (10, 20), and the mass (A) of the 100 fibers is measured. Then, the mass (B) of the core-sheath type composite fiber contained in the 100 fibers is measured by using the well-known analyzer and analysis method described above.

Alternatively, 5 g (mass (A)) of fibers are randomly extracted from the fiber substrate layer (10, 20). Then, the mass (B) of the core-sheath type composite fiber contained in the 5 g of the fiber is measured by using the well-known analyzer and the analysis method described above.

From each mass thus obtained, the mass percentage (X) of the core-sheath type composite fiber in the fibers constituting the fiber base material layer (10, 20) can be obtained.

If the manufacturing process is known, the fiber base layer (10, 20) can be prepared by checking each type and mass of the blended fibers to prepare the fiber base layer (10, 20). The mass of the fibers constituting the fiber and the mass of the core-sheath type composite fiber contained in the fiber base material layers (10, 20) can be obtained.

It is preferable that the core-sheath type composite fibers are uniformly distributed and present in the fiber base material layer (10, 20). Specifically, in the fiber base material layer (10, 20), the mass percentage (X) of the portion (11a, 21a) including one main surface and the portion (11b, 11b, including the other main surface). The fiber substrate in which the mass percentage (X) of 21b) and the mass percentage (X) of the portions (11c, 21c) sandwiched between both portions (11a and 11b, 21a and 21b) show the same value. It is preferably a layer (10, 20). With the fiber base material layer (10, 20) in such an embodiment, it is possible to provide a molding base material (100, 200) capable of more efficiently realizing an exterior material in which attached snow and ice are easily peeled off. preferable.

In addition to the core-sheath type composite fiber, the fiber base layer (10, 20) includes other organic fibers composed of one type of organic resin, other organic fibers composed of a plurality of types of organic resins, and glass. It may contain inorganic fibers such as fibers.

Examples of such other organic fibers include polyolefin resins (for example, polyethylene, polypropylene, polymethylpentene, and polyolefin resins having a structure in which a part of hydrocarbon is replaced with a nitrile group or a halogen such as fluorine or chlorine). Styline-based resins, polyvinyl alcohol-based resins, polyether resins (eg, polyetheretherketone, polyacetal, modified polyphenylene ether, aromatic polyetherketone, etc.), polyester-based resins (eg, polyethylene terephthalate, polytrimethylene terephthalate, poly). Butylene terephthalate, polyethylene naphthalate, polybutylene naphthalate, polycarbonate, polyarylate, total aromatic polyester resin, etc.), polyimide resin, polyamideimide resin, polyamide resin (for example, aromatic polyamide resin, aromatic polyetheramide resin) , Nylon resin, etc.), Ditril group-bearing resin (eg, polyacrylonitrile, etc.), Urethane-based resin, Epoxy-based resin, Polysulfone-based resin (eg, polysulfone, polyethersulfone, etc.), Fluoro-based resin (eg, Polytetra). Fluoroethylene, polyvinylidene fluoride, etc.), cellulose-based resin, polybenzoimidazole resin, acrylic resin (for example, polyacrylonitrile-based resin obtained by copolymerizing acrylic acid ester or methacrylic acid ester, etc., acrylonitrile and vinyl chloride or vinylidene chloride together. Polymerized modal acrylic resin, etc.) and the like, and can be configured by using a known organic resin.

These organic resins may be made of either a linear polymer or a branched polymer, the organic resin may be a block copolymer or a random copolymer, and the three-dimensional structure and crystals of the organic resin may be used. The presence or absence of sex is not particularly limited. Further, it may be a mixture of a multi-component organic resin.

Further, these organic resins include, for example, flame retardants, fragrances, pigments, antibacterial agents, anti-mold materials, photocatalyst particles, emulsifiers, dispersants, surfactants, particles that foam when heated, inorganic particles, antioxidants and the like. May contain the additive of.

The fibers constituting the fiber base material layer (10, 20) may contain irregular cross-section fibers in addition to substantially circular fibers and elliptical fibers. In addition, as the irregular cross-sectional fiber, a polygonal shape such as a hollow shape or a triangular shape, an alphabet character shape such as a Y shape, an irregular shape, a multi-leaf shape, a symbolic shape such as an asterisk shape, or a plurality of these shapes. It may be a fiber having a fiber cross section such as a bonded shape.

The fiber base material layer (10, 20) is, for example, a dry method in which fibers are entangled by subjecting the fibers to a card device, an air array device, or the like, or a wet method in which the fibers are dispersed in a solvent and the fibers are entangled in a sheet shape. Using a direct spinning method (melt blow method, spunbond method, electrostatic spinning method, a method of discharging a spinning stock solution and a gas flow in parallel to spin (for example, a method disclosed in Japanese Patent Application Laid-Open No. 2009-287138)). It can be prepared by spinning fibers and collecting them.

In addition, the constituent fibers can be entangled and / or integrated. As a method of entwining and / or integrating the constituent fibers with each other, for example, a method of entwining with a needle or a water stream, or a fiber web being subjected to heat treatment, the constituent fibers are bonded, integrated or melted by a binder or an adhesive fiber. Examples include a method of integrating.

The method of heat treatment can be appropriately selected. For example, a method of heating or heating and pressurizing with a roll, a method of heating by applying to a heater such as an oven dryer, a far-infrared heater, a dry heat dryer, or a hot air dryer, and infrared rays under no pressure. A method of heating the contained resin by irradiating with the above can be used.

A binder may be used to bond the constituent fibers of the fiber base layer (10, 20) to each other. The type of binder that can be used is appropriately selected, and for example, polyolefins (modified polyolefins, etc.), ethylene vinyl alcohol copolymers, ethylene-acrylate copolymers such as ethylene-ethyl acrylate copolymers, various rubbers and derivatives thereof ( Styrene-butadiene rubber (SBR), fluororubber, urethane rubber, ethylene-propylene-diene rubber (EPDM), etc.), cellulose derivatives (carboxymethyl cellulose (CMC), hydroxyethyl cellulose, hydroxypropyl cellulose, etc.), polyvinyl alcohol (PVA), polyvinyl Butyral (PVB), polyvinylpyrrolidone (PVP), epoxy resin, polyvinylidene fluoride (PVdF), vinylidene fluoride-hexafluoropropylene copolymer (PVdF-HFP), acrylic resin (acrylic acid ester resin, acrylonitrile styrene co-weight) Combined resin, etc.), polyurethane resin, etc. can be used.

However, it is preferable that the fiber base material layer (10, 20) is not provided with a binder so that the molding base material (100, 200) in which the effect according to the present invention is exhibited as intended can be prepared.

Further, the fiber base material layer (10, 20) can be prepared by using the woven fabric or knitted fabric prepared by weaving or knitting the above-mentioned fibers. The fiber base material layer (10, 20) may be prepared by subjecting a fabric such as a woven fabric or a knit to the above-mentioned method of entwining and / or integrating the constituent fibers with each other.

The composition of the fiber base material layer (10, 20), for example, the thickness and the basis weight, is not particularly limited and is appropriately adjusted. The thickness can be 0.2 to 15 mm, 0.3 to 10 mm, and 1 to 3 mm. The basis weight can be, for example, 30 to 2000 g / m ² and 40 to 1500 g / m ² . In particular, the ^{molding base material (100, 200) provided with the fiber base material layer (10, 20) having a basis weight of more than 800 g / m 2} is excellent in bending strength and tensile strength in a high temperature atmosphere, and has a basis weight of 900 g. It is more preferable that the molding base material (100, 200) has a fiber base material layer (10, 20) of / m ^{2 or more. In the present invention, the thickness means the length in the vertical direction when a compression load of 20 g / cm 2} is applied in the direction perpendicular to the main surface, and the grain means the surface having the widest area of the object to be measured (main surface). ) Refers to the mass per 1 m ^2.

In another aspect of the present invention, the fiber substrate layer (10, 20) includes a portion including one main surface (11a, 21a), a portion including the other main surface (11b, 21b), and the above-mentioned portion. It has a portion (11c, 21c) sandwiched between (11a, 21a) and the portion (11b, 21b), and at least the density of the portion (11a, 21a) is the portion (11c, 21c). It is characterized by being higher than the density of.

Provided are a molding base material (100, 200) capable of realizing an exterior material in which adhered snow and ice are easily peeled off by satisfying the structure of the fiber base material layer (10, 20) according to the present invention. can.

The reason for this is that solids (snow and ice) and liquids (water and rainwater on the road surface) do not easily pass through the dense parts (11a, 21a), so that attached snow and ice as well as water and rainwater on the road surface However, it becomes difficult for the ice cubes (11a, 21a) to pass through the portions (11a, 21a) and enter the inside (11c, 21c) of the fiber substrate layer (10, 20).

As a result, it is considered that it is possible to provide a molding base material (100, 200) capable of realizing an exterior material in which the attached snow or ice only adheres to the surface of the exterior material and the attached snow or ice easily peels off. ..

The main surface of the molding base material (100, 200) on the portion (11a, 21a) side is arranged so as to face the side to which snow, ice, water, or rainwater adheres when used as an exterior material. Is preferable.

Further, by using the fiber base material layer (10, 20) satisfying the configuration according to the present invention, it is possible to realize an exterior material having excellent sound absorption performance and sound insulation performance and exhibiting high rigidity even in a high temperature atmosphere. It is possible to provide a molding base material (100, 200) having a secondary effect of being.

The density of the portion (11a, 21a) including one main surface in the fiber base material layer (10, 20), the density of the portion (11b, 21b) including the other main surface, and the above-mentioned portion (11a, The high and low densities of the portions (11c, 21c) sandwiched between the 21a) and the portions (11b, 21b) can be confirmed by using the following comparison method.

(Density comparison method)
1. 1. An electron micrograph of a cross section of the fiber base material layer (10, 20) constituting the molding base material (100, 200) in the thickness direction is taken. At this time, the photographing magnification is adjusted so that the entire thickness direction of the fiber base material layer (10, 20) is captured in the electron micrograph.
2. 2. On an electron micrograph, one main surface (for example, the main surface existing on the upward side on the paper surface in FIGS. 1 and 2) and the other main surface (for example, on the paper surface in FIGS. 1 and 2). A line segment is drawn that connects the main surface (existing on the downward side) parallel to the thickness direction of the molding base material (100, 200) at the shortest distance.
3. 3. On the electron micrograph, draw two straight lines (A1 and A2) that pass through the end of the line segment and are perpendicular to the line segment. Furthermore, two straight lines (B1, B2) are drawn so as to be perpendicular to the line segment and to divide the line segment into three equal parts.
4. The range a is defined as a range between the straight line (A1) and the straight line (B1) that exists at the position closest to the straight line (A1) among the straight lines that divide the line segment into three equal parts.
5. The range between the straight line (A2) and the straight line (B2) existing at the position closest to the straight line (A2) among the straight lines that divide the line segment into three equal parts is defined as the range b.
6. The range between the straight lines (B1, B2) is defined as the range c.
7. The percentage a of the area of the components constituting the fiber base material layer (10, 20) such as fibers and binders in the cross-sectional area of the fiber base material layer (10, 20) reflected in the range a is calculated.
8. The percentage b of the area of the components constituting the fiber base material layer (10, 20) such as fibers and binders in the cross-sectional area of the fiber base material layer (10, 20) reflected in the range b is calculated.
9. The percentage c of the area of the components constituting the fiber base material layer (10, 20) such as fibers and binders in the cross-sectional area of the fiber base material layer (10, 20) reflected in the range c is calculated.
When the percentage a calculated as described above is higher than the percentage c, the density of the portion (11a, 21a) including one main surface in the fiber substrate layer (10, 20) is the above-mentioned portion (11a). , 21a) and the portion (11c, 21c) sandwiched between the portion including the other main surface (11b, 21b) can be determined to be higher in density.

Further, when the percentage a and the percentage b calculated as described above are both higher than the percentage c, the portion (11a, 21a) including one main surface in the fiber base material layer (10, 20) and the other The density of the portion (11b, 21b) including one main surface is higher than the density of the portion (11c, 21c) sandwiched between the portion (11a, 21a) and the portion (11b, 21b). It can be judged that it is expensive.

In the molding substrate (100) according to the present invention, as shown in FIG. 1, even if only the portion (11a) including one main surface of the fiber substrate layer (10) is a dense portion. good. A molding base material (100) provided with the fiber base material layer (10) in such an embodiment has a secondary effect that an exterior material having more excellent sound absorption performance, sound insulation performance, and rigidity can be realized. It is possible to provide a molding base material (100) that more effectively achieves the above.

Further, as shown in FIG. 2, another molding base material (200) according to the present invention includes the above-mentioned part (21a) in addition to the portion (21a) of the fiber base material layer (20) including one main surface. The portion (21b) including the other main surface (the main surface existing on the lower side on the paper surface in FIG. 2) facing the 21a) may also be a dense portion. A molding base material (200) provided with the fiber base material layer (20) in such an embodiment has a secondary effect that an exterior material having more excellent sound absorption performance, sound insulation performance, and rigidity can be realized. It is possible to provide a molding base material (200) that more effectively achieves the above.

The method of forming the portions (11a, 21a, 21b) including the high-density main surface on the fiber base material layer (10, 20) is appropriately adjusted. For example, a method of applying a heating roll to the main surface of the fabric to apply heat or heat and pressure to increase the density of the portion including the main surface, or applying a heating roll to the main surface of the fabric to apply heat or heat and pressure to the main surface. A method of melting the part including the surface to form a porous film to increase the density, a method of applying a binder or an additive to the main surface of the fabric to increase the density of the portion including the main surface, the fabric. A method of increasing the density of the portion including the main surface by subjecting the main surface to a water flow entanglement treatment or a needle punching treatment to increase the fiber density can be mentioned.

In particular, it is preferable that the sheath portion of the core-sheath type composite fiber constituting the main surface is melted to form a portion (11a, 21a, 21b) including a high-density main surface. On the main surface, the melted sheath part closes a part of the voids existing on the main surface to reduce the air permeability and increase the density. Furthermore, on the main surface, the melted sheath part becomes a porous film. By lowering the air permeability and increasing the density, it is possible to realize an exterior material with better sound absorption performance, sound insulation performance, and rigidity, which is a secondary effect of the molding base material (100). , 200) can be provided.

The high-density portion of the fiber base material layer (10, 20) is a portion where the air permeability is reduced.

When lowering the air permeability of the portion including the main surface and increasing the density, it is preferable to apply heat and pressure at the same time. When only heat is applied to the main surface of the fabric without applying pressure, the portion including the main surface may not be sufficiently densified. Further, even if only heat is applied to the main surface of the fabric and then a heating roll is applied to the main surface of the fabric to apply heat and pressure, the portion including the main surface is not sufficiently densified. May remain.

As a result, it may be difficult to provide a molding substrate (100, 200) having excellent sound absorption characteristics (specifically, sound absorption characteristics in a frequency band of less than 2000 Hz).

Therefore, in the heat treatment for lowering the air permeability of the portion including the main surface and increasing the density, it is more preferable to first apply heat and pressure at the same time as the heat treatment for acting on the fabric.

The thickness of the molding base material (100, 200) is appropriately selected, but can be 20 mm or less, 10 mm or less, and 5 mm or less. On the other hand, the lower limit of the thickness is adjusted as appropriate, but it is realistic that it is 0.5 mm or more. The basis weight of the molding substrate (100, 200) is appropriately selected, ^{but can be 2000 g / m 2} or less, and can be 1500 g / m ² or less. On the other hand, the lower limit of the basis weight but is appropriately adjusted, a practical to be 10 g / ^{m 2} or more, preferably at 50 g / ^{m 2} or more, preferably at 100 g / ^{m 2} or more.

The molding base material (100, 200) of the present invention may be provided with another covering material such as a porous body, a film, or a foam. The type of the cover material can be appropriately selected depending on the physical characteristics required for the molding base material, and may be, for example, a cloth, a porous film or a non-porous film, a porous foam or a non-porous foam. Various configurations such as the basis weight and thickness of the cover material and the porosity can be appropriately selected depending on the required physical properties. In particular, a spunbonded non-woven fabric is preferable because it is easy to provide a base material for molding, which can realize an exterior material in which attached snow and ice are easily peeled off. Further, since it is easy to provide a molding base material that can realize an exterior material in which more adhered snow and ice can be easily peeled off, a molding base material (100, 200) having a spunbonded non-woven fabric on both main surfaces is used. It is preferable to have it.

The method of providing the cover material on the molding base material (100, 200) can be appropriately selected, but the mode in which the cover material is adhered and integrated by a binder, the main surface of the molding base material (100, 200) is melted to obtain the cover material. By laminating, the main surface of the cover material is melted and laminated with the molding base material (100, 200) in an embodiment in which the main surface is bonded by the components constituting the main surface (for example, the sheath portion of the core-sheath type composite fiber). By doing so, it is possible to have an aspect in which the main surface is adhered by the constituent components.

The molding base material may be provided with a print layer on the main surface and a top coat layer on the print layer. The printed layer refers to a layer of resin that exists on at least one main surface of the molding substrate and mainly plays a role of improving the design and / or tactile sensation of the molding substrate. The printed layer may contain the above-mentioned additives in addition to the resin. The molding substrate may have only one type of print, or may have a plurality of types of prints having different formulations such as the type of resin constituting the print and the type or presence / absence of the pigment. The mode of existence thereof can also be appropriately adjusted, and the top coat may be present on the entire surface of the main surface or may be partially present.

Further, the top coat layer refers to a layer of resin that exists on at least one main surface of the molding base material and mainly plays a role of protecting the main surface of the molding base material. The top coat layer may contain the above-mentioned additives in addition to the resin. The molding substrate may have only one type of topcoat, or may have a plurality of types of topcoats having different formulations such as the types of resins constituting the topcoat. The mode of existence can be appropriately adjusted, and the mode may be a mode existing on the entire main surface or a mode existing partially.

The type of resin constituting the print and the top coat layer can be appropriately selected, and the same resin as the above-mentioned binder can be used. In particular, since it is moderately softened during thermoforming such as heat pressing using a mold, it is possible to provide a molding base material that follows the mold and has excellent moldability. Therefore, it is preferable to contain an acrylic resin.

Hereinafter, the present invention will be specifically described with reference to Examples, but these do not limit the scope of the present invention. The physical properties of the molding base materials prepared in Examples and Comparative Examples were confirmed by subjecting them to the following evaluation methods.

(Evaluation method of ice peeling property)
A square-shaped sample (150 mm on a side) was collected from the molding substrate, and an icing force test device was installed on one main surface of the sample or on the other main surface. The icing force test device is a cylindrical jig (outer diameter: 48.6 mm, inner diameter: 44 mm, height: 30 mm, thickness: 2) prepared using the material of STK500 disclosed in JIS G3444: 2015. It is 3 mm and has a ring portion on the outer peripheral surface), and is installed so that the end portion of the cylinder faces the main surface of the sample. When the molding base material had a main surface derived from the spunbonded nonwoven fabric, it was installed so that the end portion of the cylinder faced the main surface of the sample.
Then, the main surface on the side where the icing force test device was installed was left in a test room at −15 ° C. for 1 hour or more with the main surface facing the side opposite to the direction of gravity.
While left in the test room, 5 ml of distilled water at 3 ° C. was injected into the inside of the icing force test device, and the distilled water was allowed to freeze for 15 minutes. After freezing, 5 ml of distilled water at 3 ° C. was further injected and left to freeze the distilled water. After freezing for 30 minutes, 5 ml of distilled water at 3 ° C. was further injected, and the mixture was left for 30 minutes to freeze the distilled water. Then, 15 ml of distilled water at 3 ° C. was injected and left for 3 hours to freeze the distilled water.
After that, with the sample fixed, a force gauge with a 500 mm wire attached was applied to the ring of the icing force measuring device, and the wire was pulled up in the direction opposite to the gravity direction until the icing force measuring device was peeled off from the sample. ..

If the maximum value of the peel strength measured by the icing force measuring device before peeling from the sample is 25 N or less, it is evaluated as "○" as a base material for molding having excellent ice peeling property, and is higher than 25 N. Those with a high value were evaluated as "x" as a base material for molding having poor ice peelability.

(Evaluation method of bending strength in high temperature atmosphere)
Using the measuring instrument described in How to determine the plastic bending characteristics of JIS K7171 in an atmosphere of 80 ° C, a sample (length: 150 mm, width: 50 mm) collected from a molding substrate is placed in an atmosphere of 80 ° C. After leaving for 1 hour, the sample was installed under the condition that the distance between the fulcrums was 100 mm, and a load was applied to the center between the fulcrums at a speed of 50 mm / min using an indenter having a tip radius of 5 mm. The maximum point load was obtained as the heat resistant flexural rigidity value from the load and deflection at this time.

Those having a heat resistant bending rigidity value of 10 N / 50 mm or more obtained by measurement were evaluated as "○" as having excellent bending strength in a high temperature atmosphere, and those having a heat resistant bending rigidity value of less than 10 N / 50 mm were evaluated in a high temperature atmosphere. It was evaluated as "x" because it was inferior in bending strength.

(Evaluation method of tensile strength)
A test piece was taken from the sample collected from the molding substrate in the shape of dumbbell No. 1 described in JIS K6251, and attached to a tensile measuring machine so that the chuck distance was 90 mm. Then, the maximum point load was measured at a tensile speed of 200 mm / min, and the tensile strength was determined.

Those having a tensile strength of 285 N / cm or more obtained by measurement are evaluated as "○" as having excellent tensile strength, and those having a tensile strength of less than 285 N / cm are evaluated as "x" as being inferior in tensile strength. bottom.

(Evaluation method of sound absorption)
A sample collected from the molding substrate was subjected to a vertical incident sound absorption coefficient measuring device manufactured by Brüel & Kjä, and the vertical incident sound absorption coefficient compliant with ISO354 was measured in the frequency range of 500 Hz to 6300 Hz. When measuring the sound absorption coefficient, when the molding base material is set in a small acoustic tube for high frequency, an air layer is provided behind the molding base material when viewed from the sound source side, and the molding base material is provided. The measurement was performed so that the total thickness of the air layer (diameter: 28 mm, thickness: 5 mm) and the thickness of the air layer was 15 mm. When the molding substrate had a main surface derived from a spunbonded nonwoven fabric, the measurement was performed so that the main surface was exposed to the side where sound waves were generated.

Regarding the measured molding substrate, those having a sound absorption coefficient of 40% or more at 1000 kHz, those having a sound absorption coefficient of 55% or more at 1600 Hz, and those having a sound absorption coefficient of 65% or more at 2000 Hz have sound absorption properties. It was evaluated as "○" for each frequency as being excellent. Further, those having a sound absorption coefficient lower than the above-mentioned sound absorption coefficient were evaluated as "x" for each frequency as being inferior in sound absorption property.

(Type of fiber used)
-Core-sheath type composite fiber (fineness: 4.4 dtex, fiber length: 51 mm, core: polyethylene terephthalate (melting point: 258 ° C.), sheath: polypropylene (melting point: 163 ° C.)): Hereinafter, PET / PP core-sheath type It is called a composite fiber.
Polyethylene terephthalate fiber 1 (fineness: 6.6 dtex, fiber length: 76 mm, melting point: 258 ° C.): Hereinafter referred to as PET single fiber.
-Polyethylene terephthalate fiber 2 (fineness: 4.4 dtex, fiber length: 51 mm, core: polyethylene terephthalate (melting point: 258 ° C.), sheath: low melting point polyethylene terephthalate (melting point: 163 ° C.)): Hereinafter, PET / Lo- It is called a PET core-sheath type composite fiber.

(Example 1)
A fiber web was prepared by supplying a PET / PP core-sheath type composite fiber to a card machine. Then, a needle punching web was prepared by subjecting a needle punching process from one main surface of the fiber web to the other main surface.
The needle punch web was applied to a heating roll adjusted to a heating temperature of 190 ° C., and the heating rolls were applied to both main surfaces of the needle punch web to apply heat and pressure at the same time. The nonwoven fabric prepared in this way was used as a substrate (weight: 1200 g / m ² , thickness: 12 mm). Furthermore, the base material is placed in a far-infrared heating furnace whose heating temperature is adjusted to 210 ° C., heated, and then molded using a cold press device to form a base material for molding (weight: 1200 g / m ² , thickness: 5 mm) was prepared.
The portion of the molding substrate including both main surfaces (corresponding to 21a and 21b in FIG. 2) is in the form of a porous film due to the melting of the sheath portion and has a high density, and both are sandwiched between the two portions. It was higher than the density of the part (corresponding to 21c in FIG. 2).

(Example 2)
^Two spunbonded non-woven fabrics (grain: 35 g / m 2) made of polyethylene terephthalate resin were prepared.
The spunbonded nonwoven fabric was superposed on both main surfaces of the needle punch web prepared in Example 1, and was subjected to a heating roll adjusted to a heating temperature of 190 ° C., and both main surfaces of the needle punched web were interposed between the spunbonded nonwoven fabrics. Heat and pressure were applied simultaneously using a heating roll to obtain a substrate (weight: 1270 g / m ² , thickness: 12 mm). Furthermore, the base material is placed in a far-infrared heating furnace whose heating temperature is adjusted to 210 ° C., heated, and then molded using a cold press device to form a base material for molding (weight: 1270 g / m ² , thickness:: 5 mm) was prepared.
Further, the portion of the fiber base material layer derived from the needle punch web including both main surfaces (corresponding to 21a and 21b in FIG. 2) is in the form of a porous film due to the melting of the sheath portion, and the density is increased as in Example 1. In each case, the density was higher than that of the portion sandwiched between the two portions (corresponding to 21c in FIG. 2).

(Example 3)
A fiber web was prepared by mixing 80% by mass of PET / PP core-sheath type composite fiber and 20% by mass of PET single fiber and feeding them to a card machine. ^{A molding substrate (weight: 1270 g / m 2} , thickness: 5 mm) was prepared in the same manner as in Example 2 except that the fiber web prepared in this manner was used.
Further, the portion of the fiber base material layer derived from the needle punch web including both main surfaces (corresponding to 21a and 21b in FIG. 2) is in the form of a porous film due to the melting of the sheath portion, although it is not as much as in Examples 1 and 2. The density was increased, and both were higher than the density of the portion sandwiched between the two portions (corresponding to 21c in FIG. 2).

(Comparative Example 1)
A fiber web was prepared by mixing 70% by mass of PET / PP core-sheath type composite fiber and 30% by mass of PET single fiber and feeding them to a card machine. ^{A molding substrate (weight: 1270 g / m 2} , thickness: 5 mm) was prepared in the same manner as in Example 2 except that the fiber web prepared in this manner was used.
Further, the portion of the fiber base material layer derived from the needle punch web including both main surfaces (corresponding to 21a and 21b in FIG. 2) is in the form of a porous film due to the melting of the sheath portion, although it is not as much as in Examples 1 to 3. The density was increased, and both were higher than the density of the portion sandwiched between the two portions (corresponding to 21c in FIG. 2).

(Comparative Example 2)
^{Molding substrate (weight: 1270 g / m 2} , thickness: 2) in the same manner as in Example 2 except that PET / Lo-PET core-sheath composite fiber was used instead of PET / PP core-sheath composite fiber. 5 mm) was prepared.
Further, the portion of the fiber base material layer derived from the needle punch web including both main surfaces (corresponding to 21a and 21b in FIG. 2) is in the form of a porous film due to the melting of the sheath portion, and the density is increased as in Example 1. In each case, the density was higher than that of the portion sandwiched between the two portions (corresponding to 21c in FIG. 2).

In Examples 2 and 3 and Comparative Examples 1 and 2, the needle punch web and the spunbonded nonwoven fabric were fiber-bonded by the molten sheath component.

Table 1 summarizes the composition and evaluation results of various physical properties of the molding base material prepared as described above. Items that are not provided are marked with a "-" in the table.

Since the molding base materials of Examples 1 to 3 satisfying the configuration of the present invention are excellent in ice peeling property, they are molding base materials capable of realizing an exterior material in which attached snow and ice are easily peeled off. rice field. Furthermore, since it was a base material for molding that was excellent in bending strength, tensile strength, and sound absorption in a high temperature atmosphere, it was a base material for molding that could realize an exterior material having high rigidity and excellent sound absorption performance. .. On the other hand, the molding base material of Comparative Examples 1 and 2 which does not satisfy the configuration of the present invention is a molding base material which cannot realize an exterior material in which attached snow and ice are easily peeled off because the ice peeling property is inferior. there were.

Further, from the results of comparing Example 2 and Comparative Example 2, the molding base material according to the present invention contains a core-sheath type composite fiber in which the sheath portion is a polypropylene-based resin and the core portion is a polyester-based resin. By providing a fiber base material layer, we have realized an exterior material that has the property of being able to exhibit high rigidity even in a high temperature atmosphere due to its high bending strength in a high temperature atmosphere, and it is easy for attached snow and ice to come off. It was a possible molding substrate.

Further, from the results of comparing Examples 2 to 3 and Comparative Example 1, the molding base material according to the present invention has a core-sheath type composite fiber having a mass percentage of 70% by mass in the fibers constituting the fiber base material layer. A molding base that can realize an exterior material that easily peels off attached snow and ice, which also has the property of exhibiting high rigidity even in a high temperature atmosphere due to its high bending strength in a high temperature atmosphere. It turned out to be a material.

(Example 4)
^{A molding substrate (weight: 870 g / m 2} , thickness: 5 mm) was prepared in the same manner as in Example 2 except that a lightweight fiber web was used.

(Example 5)
^{A molding substrate (weight: 970 g / m 2} , thickness: 5 mm) was prepared in the same manner as in Example 2 except that the lightweight fiber web was used.

(Example 6)
One piece of spunbonded non-woven fabric (grain: 35 g / m ^{2) made of polyethylene terephthalate resin was prepared.}
The spunbonded nonwoven fabric was superposed on one main surface of the needle punched web prepared in Example 1, and subjected to a heating roll adjusted to a heating temperature of 190 ° C., and both main surfaces of the needle punched web were interposed with the spunbonded nonwoven fabric in between. Heat and pressure were simultaneously applied to the surface using a heating roll to obtain a substrate (weight: 1235 g / m ² , thickness: 12 mm). Furthermore, the base material is placed in a far-infrared heating furnace whose heating temperature is adjusted to 210 ° C., heated, and then molded using a cold press device to form a base material for molding (weight: 1235 g / m ² , thickness: 5 mm) was prepared.

In Examples 4 to 6, the portion (corresponding to 21a and 21b in FIG. 2) of the fiber base material layer derived from the needle punch web is in the form of a porous film due to the melting of the sheath portion. The density was increased as in No. 2, and both were higher than the density of the portion sandwiched between the two portions (corresponding to 21c in FIG. 2). The needle punch web and the spunbonded non-woven fabric were fiber-bonded by the molten sheath component.

Table 2 summarizes the composition and evaluation results of various physical properties of the molding base material prepared as described above. For items that are not provided, "-" is shown in the table. In addition, the results of Example 2 are also described for ease of understanding.

Since the molding base materials of Examples 4 to 6 were excellent in ice peelability, they were molding base materials capable of realizing an exterior material in which attached snow and ice were easily peeled off.

Further, from the results of comparing Example 4 with Example 5 and Example 2, the ^{molding substrate provided with the fiber substrate layer having a basis weight of more than 800 g / m 2} has a bending strength in a high temperature atmosphere. It was found to be excellent in tensile strength.

From the above, it has been found that the present invention can provide a base material for molding, which can realize an exterior material in which attached snow and ice are easily peeled off.

Further, it has been found that a molding base material satisfying the configuration according to the present invention can provide a molding base material having a secondary effect that an exterior material having excellent sound absorption performance, sound insulation performance, and rigidity can be realized. bottom.

The molding base material of the present invention can be suitably used as a constituent member of an interior material or an exterior material.

100, 200 ... Molding base materials 10, 20 ... Fiber base material layers 11a, 21a ... Parts 11b, 21b ... In the fiber base material layer including one main surface of the fiber base material layer. Parts 11c, 21c including the other main surface ... A part of the fiber base material layer sandwiched between a portion including one main surface and a portion including the other main surface.

Claims (2)

A molding base material having a fiber base material layer,
The fiber base material layer contains a core-sheath type composite fiber in which the sheath portion is a polypropylene-based resin and the core portion is a polyester-based resin.
The mass percentage of the core-sheath type composite fiber in the fibers constituting the fiber base material layer is more than 70% by mass.
Base material for molding. A portion (a) of the fiber base material layer including one main surface, a portion (b) including the other main surface, and a portion sandwiched between the portion (a) and the portion (b). Has (c)
The density of the portion (a) is higher than the density of the portion (c).
The molding base material according to claim 1.

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