JP2023106813A - Reinforcement material - Google Patents

Abstract

To provide a reinforcement material having high extensibility during heat press molding.SOLUTION: A reinforcement material 1A includes a surface layer 10 and a block layer 20. The surface layer 10 includes a needle-punch nonwoven fabric in which at least two types of synthetic resin short fibers including (A) a synthetic resin short fiber including a low-melting point component having a melting point lower than a temperature during heat press molding and a high melting point component having a melting point higher than the temperature during the heat press molding and (B) a synthetic resin short fiber having a melting point higher than the temperature during the heat press molding are entangled by a needle-punch method. The block layer 20 includes a thermal bond nonwoven fabric in which at least one type of synthetic resin short fiber including (A) the synthetic resin short fiber is partially fused by a thermal bond method. The surface layer 10 and the block layer 20 are entangled by the needle-punch method.SELECTED DRAWING: Figure 1

Description

The present invention relates to reinforcing materials for foam moldings.

BACKGROUND ART Foamed moldings such as foamed urethane are used as cushioning materials for vehicle seats (seats) and the like. A reinforcing material may be arranged on the surface of such a foamed molding. For example, a cushion material of a vehicle seat is provided with a reinforcing material for the purpose of preventing deterioration of the rigidity of the cushion material and also preventing friction noise generated by friction between the cushion material and a spring (Patent Document 1). , Patent Document 2).

Utility Model Registration No. 3207739 WO2015/034069

When producing the foam molded article, first, the reinforcing material is heat-press molded so as to match the shape of the mold for the foam molded article. After that, the molded reinforcing material is placed in a mold, a foaming component is poured into the mold, and the foaming component is foamed under heat and pressure. Thus, a foam molded article is completed. The reinforcing material requires high extensibility so that it can be molded into a predetermined three-dimensional shape during hot press molding.

Each of the reinforcements described in each of the references includes a layer of long-fiber nonwoven fabric. Long fiber nonwoven fabrics are generally made by spunbond or meltblown processes. All of these methods melt and spin a raw material resin to form a web, pass this web between a pair of heated embossing rolls or a pair of flat rolls, and bond the long fibers together to form a long fiber. A method for producing a fibrous nonwoven fabric. Due to such a manufacturing method, the long fiber nonwoven fabric has a high density and many crossing points between the long fibers, resulting in poor extensibility. Another reason for the poor extensibility of the long fiber nonwoven fabric is that the long fibers themselves do not crimp.

An object of the present invention is to provide a reinforcing material having high extensibility during hot press molding.

The present invention provides inventions of the following aspects.
(Item 1)
A reinforcing material that can be molded into a predetermined three-dimensional shape by hot press molding and that can be used to reinforce a foam molded product,
including a surface layer and a barrier layer;
The surface layer is
(A) a synthetic resin short fiber containing a low melting point component having a melting point lower than the temperature during hot press molding and a high melting point component having a melting point higher than the temperature during hot press molding;
(B) a synthetic resin short fiber having a melting point higher than the temperature during hot press molding;
At least two types of synthetic resin short fibers containing a needle-punched nonwoven fabric entangled by a needle-punching method,
The blocking layer comprises a thermally bonded nonwoven fabric to which at least one kind of synthetic resin staple fibers including the synthetic resin staple fibers of (A) is partially bonded,
The surface layer and the blocking layer are entangled by a needle punch method,
reinforcement.

(Item 2)
The blocking layer comprises at least two types of synthetic resin short fibers including the (A) synthetic resin short fibers and the (B) synthetic resin short fibers on the surface of the thermal bond nonwoven fabric opposite to the surface layer. is bound by a needle-punched nonwoven fabric that is entangled by a needle-punch method,
A reinforcement according to item 1.

(Item 3)
further comprising an anchor layer on the side of the barrier layer opposite to the surface layer;
The anchor layer includes a needle-punched nonwoven fabric in which at least two types of synthetic resin short fibers including the synthetic resin short fibers (A) and the synthetic resin short fibers (B) are entangled by a needle punching method.
A reinforcement according to item 1.

(Item 4)
The anchor layer contains 30% to 70% by mass of the synthetic resin short fibers of (A) and 70% to 30% by mass of the synthetic resin short fibers of (B).
A reinforcement according to item 3.

(Item 5)
The blocking layer further comprises the synthetic resin short fibers of (B).
5. Reinforcing material according to any one of items 1 to 4.

(Item 6)
The blocking layer contains 40% by mass to 100% by mass of the synthetic resin short fibers of (A) and 60% by mass to 0% by mass of the synthetic resin short fibers of (B).
6. Reinforcing material according to any one of items 1 to 5.

(Item 7)
The blocking layer has a basis weight of 0.003 to 0.008 g/cm ² ,
7. Reinforcing material according to any one of items 1-6.

(Item 8)
The surface layer contains 30% to 70% by mass of the synthetic resin short fibers of (A) and 70% to 30% by mass of the synthetic resin short fibers of (B),
Reinforcing material according to any one of items 1 to 7.

(Item 9)
The synthetic resin short fibers of (A) contain 40 to 60% by mass of the low-melting component.
9. Reinforcing material according to any one of items 1-8.

(Item 10)
elongation at any temperature between 130°C and 160°C is at least 40%;
10. Reinforcing material according to any one of items 1 to 9.

INDUSTRIAL APPLICABILITY According to the present invention, it is possible to provide a reinforcing material having high extensibility during hot press molding.

It is a schematic sectional drawing of the reinforcement material which concerns on 1st embodiment. (a) Cross-sectional view of a needle-punched nonwoven fabric, (b) Cross-sectional view of a thermal-bonded nonwoven fabric. It is a schematic sectional drawing of the reinforcement material which concerns on 2nd embodiment. FIG. 4 is a diagram showing specimen sizes for tensile testing; It is a figure which shows the mode of the tension test in 140 degreeC.

The reinforcing members 1A and 1B of the present invention will be explained.

Reinforcing members 1A and 1B can be used to reinforce foam molded articles such as vehicle seats. The foam molded body is made of urethane foam, for example. The reinforcing members 1A and 1B are molded into a predetermined three-dimensional shape by hot press molding in advance before being installed in a mold for foam molding. Thereby, the reinforcing members 1A and 1B can be arranged in the mold without gaps. Hot press molding methods include, for example, dry heat press, steam press, cold press, and vacuum molding. The temperature of hot press molding is, for example, 130.degree. C. to 160.degree.

[A. First embodiment]
A reinforcing member 1A according to the first embodiment will be described.

<A-1. Configuration of reinforcing material>
The reinforcing member 1A includes a surface layer 10 and a blocking layer 20, as shown in FIG.

The blocking layer 20 is a layer that prevents the foaming component from seeping out. The barrier layer 20 includes a thermally bonded nonwoven fabric made of synthetic resin staple fibers.

The surface layer 10 is a layer that faces the mold when producing a foam molded article, and is a layer that prevents the exudation from being visible from the outside when the foam component seeps out from the blocking layer 20. be. The surface layer 10 includes a needle-punched nonwoven fabric made of synthetic resin short fibers.

The synthetic resin staple fibers of the needle-punched nonwoven fabric of the surface layer 10 and the synthetic resin staple fibers of the thermal-bonded nonwoven fabric of the blocking layer 20 are entangled by a needle punching method.

The reinforcing member 1A preferably has a thickness of 0.10 to 0.45 cm and a basis weight of 0.010 to 0.022 g/cm ² . It is preferable to select a combination of the thickness and basis weight of the reinforcing material 1A so that the density of the reinforcing material 1A is 0.049 to 0.15 g/cm ³ . Density is a value obtained by dividing basis weight by thickness.

The reinforcing material 1A preferably has an elongation rate (that is, elongation at break) of at least 40%, more preferably at least 60%, at the temperature during hot press molding.

The details of each layer will be described below.

<A-2. surface>
The surface layer 10 includes a needle-punched nonwoven fabric in which at least two types of synthetic resin short fibers including synthetic resin short fibers (A) and (B) shown below are entangled by a needle punching method.
(A) Synthetic resin short fibers containing a low melting point component having a melting point lower than the temperature during hot press molding and a high melting point component having a melting point higher than the temperature during hot press molding (hereinafter referred to as "(A) (Synthetic resin short fibers).
(B) Synthetic resin short fibers having a melting point higher than the temperature during hot press molding (hereinafter sometimes referred to as "(B) synthetic resin short fibers").

The surface layer 10 preferably contains 30% to 70% by mass of the (A) synthetic resin short fibers and 70% to 30% by mass of the (B) synthetic resin short fibers. In one embodiment, the synthetic resin short fibers in the surface layer 10 consist only of (A) synthetic resin short fibers and (B) synthetic resin short fibers.

The surface layer 10 preferably has a thickness of 0.08 to 0.24 cm and a basis weight of 0.003 to 0.01 g/cm ² . A combination of the thickness and basis weight of the surface layer 10 is preferably selected so that the density of the surface layer 10 is 0.045 to 0.077 g/cm ³ .

The (A) synthetic resin staple fibers preferably contain 40% to 60% by mass of a low melting point component and 60% to 40% by mass of a high melting point component. The melting point of the low melting point component is preferably 90°C to 150°C. The length of the synthetic resin staple fibers (A) is preferably 7.5 cm or less. The thickness of the synthetic resin staple fibers (A) is preferably 1.5 to 6 dtex.

The low-melting-point component of the synthetic resin short fibers (A) is, for example, a polyester fiber having a melting point lower than the temperature during hot-press molding. Further, the high melting point component of the synthetic resin short fibers (A) is, for example, a polyester fiber having a melting point higher than the temperature during hot press molding. The synthetic resin staple fibers of (A) are, for example, synthetic resin staple fibers having a core-sheath structure in which the core is a high melting point component and the sheath is a low melting point component.

The length of the synthetic resin short fibers (B) is preferably 7.5 cm or less. The thickness of the synthetic resin staple fibers (B) is preferably 1.2 to 6 dtex. The (B) synthetic resin short fibers are, for example, polyester fibers having a melting point higher than the temperature during hot press molding.

<A-3. Blocking layer>
The blocking layer 20 includes a thermal bonded nonwoven fabric partially fused with at least one type of synthetic resin short fibers including the synthetic resin short fibers of (A). That is, the blocking layer 20 includes a thermally bonded nonwoven fabric in which at least one kind of synthetic resin short fibers are partially bonded by melting the low-melting-point component of the synthetic resin short fibers of (A) by a thermal bonding method.

The blocking layer 20 may be a thermal bonded nonwoven fabric in which at least two types of synthetic resin short fibers including (A) synthetic resin short fibers and (B) synthetic resin short fibers are partially bonded.

The blocking layer 20 preferably contains 40% to 100% by mass of the (A) synthetic resin short fibers and 60% to 0% by mass of the (B) synthetic resin short fibers. In one embodiment, the synthetic resin short fibers in the blocking layer 20 consist only of (A) synthetic resin short fibers. In another embodiment, the synthetic resin staple fibers in the blocking layer 20 consist only of (A) synthetic resin staple fibers and (B) synthetic resin staple fibers.

The material and characteristics of the (A) synthetic resin short fibers that can be used for the blocking layer 20 (for example, the mass ratio of the low-melting point component and the high-melting point component, the fiber length, and the fiber thickness) include, for example, the surface layer 10 The materials and properties described for the synthetic resin short fibers of (A) that can be used can be mentioned. The material and properties of the (A) synthetic resin staple fibers used in the blocking layer 20 may be the same as or different from the materials and properties of (A) the synthetic resin staple fibers used in the surface layer 10. .

The materials and properties of the (B) synthetic resin short fibers that can be used for the blocking layer 20 include, for example, the materials and properties described for the (B) synthetic resin short fibers that can be used for the surface layer 10 . The material and properties of the (B) synthetic resin staple fibers used in the blocking layer 20 may be the same as or different from the materials and properties of (B) the synthetic resin staple fibers used in the surface layer 10. .

In one embodiment, (A) the synthetic resin staple fibers used in the barrier layer 20 and (B) the synthetic resin staple fibers are used in the surface layer 10 to increase the density of the barrier layer 20 (A ) and the synthetic resin short fibers of (B).

The blocking layer 20 preferably has a thickness of 0.01-0.04 cm and a basis weight of 0.003-0.008 g/cm ² . The combination of the thickness and basis weight of the barrier layer 20 is preferably selected such that the density of the barrier layer 20 is 0.13-0.53 g/cm ³ .

<A-4. Features of reinforcing material>
Needle-punched nonwoven fabrics using short fibers have fewer intersections between short fibers and are more mobile than long-fiber nonwoven fabrics produced by the spunbond method or meltblown method. Therefore, by adopting a needle-punched nonwoven fabric using short fibers as the surface layer 10, the extensibility of the reinforcing material 1A during hot press molding can be increased. In general, the short fibers are provided with stretchable crimps (also called crimps). Therefore, during hot press molding, the crimps of the synthetic resin short fibers of the surface layer 10 are stretched, thereby increasing the reinforcing material 1A. expands significantly. In addition, since the surface layer 10 contains a low-melting point component, when the reinforcing material 1A is heat-press-molded and the reinforcing material 1A is three-dimensionally molded, the low-melting point component melts and the synthetic resin short fibers are separated from each other. physically connect. As a result, the three-dimensional shape of the reinforcing member 1A after hot press molding can be stabilized.

The blocking layer 20 including a high-density nonwoven fabric layer is obtained by fusing synthetic resin staple fibers together by a thermal bonding method. The blocking layer 20 having a high density can prevent the foam component from seeping out. Moreover, a thermally bonded nonwoven fabric using short fibers has fewer intersections between short fibers and is more mobile than a long-fiber nonwoven fabric produced by a spunbond method or a meltblown method. Therefore, by adopting a thermal bond nonwoven fabric using short fibers for the blocking layer 20, the extensibility of the reinforcing material 1A during hot press molding can be increased. In addition, as already described, since the short fibers are crimped so that they can be stretched, the reinforcing material 1A is greatly stretched by stretching the crimped synthetic resin short fibers of the blocking layer 20 . In addition, during hot press molding, the bonds between the synthetic resin short fibers are melted and the synthetic resin short fibers are dispersed separately, so that the blocking layer 20 is easily deformed. This increases the extensibility of the reinforcing material 1A.

<A-5. Manufacturing Method of Reinforcing Material>
Next, a method for manufacturing the reinforcing material 1A will be described.

A needle-punched nonwoven fabric X that will form the surface layer 10 is prepared (see FIG. 2(a)). The needle-punched nonwoven fabric X can be manufactured according to the manufacturing method described below. First, at least two kinds of synthetic resin short fibers including (A) synthetic resin short fibers and (B) synthetic resin short fibers are passed through a carding machine to form a web. The web is laminated with crosslayers to create a laminated web. Synthetic resin staple fibers are entangled with each other by needle punching the laminated web. Thus, the needle-punched nonwoven fabric X is produced. The needle-punched nonwoven fabric X preferably has a thickness of 0.08 to 0.35 cm, a basis weight of 0.003 to 0.016 g/cm ² and a density of 0.012 to 0.100 g/cm ³ .

A thermal bonded nonwoven fabric Y that will constitute the blocking layer 20 is prepared (see FIG. 2(b)). The thermal bond nonwoven fabric Y can be manufactured according to the manufacturing method described below. First, using at least one kind of synthetic resin staple fibers including the synthetic resin staple fibers of (A), a laminated web is produced in the same manner as described above. By heating the laminated web to, for example, 130° C. to 190° C., the short synthetic resin fibers are partially fused together. Thus, the thermal bond nonwoven fabric Y is produced. Flat sealing or point sealing can be used as a heating method in the thermal bonding method. The thermal bond nonwoven fabric Y preferably has a thickness of 0.01 to 0.04 cm, a basis weight of 0.003 to 0.008 g/cm ² and a density of 0.130 to 0.530 g/cm ³ .

The needle-punched nonwoven fabric X is overlaid on one side of the thermally bonded nonwoven fabric Y to form a laminate. The laminate is needle-punched to entangle the short synthetic resin fibers contained in the nonwoven fabric. Thus, the reinforcing member 1A can be produced. In addition, in order to improve the handleability of the reinforcing material 1A and stabilize the physical properties of the reinforcing material 1A, the reinforcing material 1A may be heat-treated as necessary.

<A-6. Modified Example of Reinforcing Material>
A modification of the reinforcing member 1A will be described. The blocking layer 20 has at least two types of synthetic resin short fibers including (A) synthetic resin short fibers and (B) synthetic resin short fibers entangled by a needle punch method on the surface opposite to the surface layer 10. The needle-punched nonwoven may be bonded. A reinforcing member 1A shown in such a modified example can be manufactured, for example, by the following method. First, the needle-punched nonwoven fabric X is overlaid on one side of the thermal bond nonwoven fabric Y to form a laminate. The laminate is needle-punched so that a part of the needle-punched nonwoven fabric X protrudes to the opposite side of the thermal-bonded nonwoven fabric Y. By passing the laminate through a pair of rolls heated to, for example, 130° C. to 190° C., the low-melting-point component of the synthetic resin short fibers (A) contained in the needle-punched nonwoven fabric X and the thermal-bonded nonwoven fabric Y is melted. , the synthetic resin short fibers of the needle-punched nonwoven fabric X protruding out are bonded to the thermal bond nonwoven fabric Y by thermocompression. In this way, the reinforcing material 1A in which the needle-punched nonwoven fabric X is fused to the surface of the thermally bonded nonwoven fabric Y of the blocking layer 20 opposite to the surface layer 10 can be produced. Since the blocking layer 20 is made of the thermally bonded nonwoven fabric to which the needle-punched nonwoven fabric is fused, the blocking layer 20 has a higher density, so that the urethane exudation prevention effect can be improved.

<A-7. Modified Example of Reinforcing Material Manufacturing Method>
A modification of the method for manufacturing the reinforcing member 1A will be described. First, using at least two types of synthetic resin short fibers including (A) synthetic resin short fibers and (B) synthetic resin short fibers, a laminated web is produced in the same manner as described above. This laminated web will constitute the surface layer 10 . Preferably, the laminated web has a thickness of 2-15 cm and a basis weight of 0.003-0.016 g/cm ² . The combination of thickness and basis weight of the laminated web is preferably selected such that the laminated web has a density of 0.0006 to 0.006 g/cm ³ . The non-needle-punched laminated web is overlaid on one side of the thermal bond nonwoven fabric Y to form a laminate. By needle-punching the laminate, the synthetic resin staple fibers in the laminated web are entangled, and the synthetic resin staple fibers of the laminated web and the synthetic resin staple fibers of the thermal bond nonwoven fabric Y are entangled. The reinforcing material 1A can also be produced by such a method.

[B. Second embodiment]
Next, the reinforcing member 1B according to the second embodiment will be explained. Below, it demonstrates centering on difference with 1 A of reinforcement materials which concern on 1st embodiment, attaches|subjects the same code|symbol about the structure same as 1 A of reinforcement materials, and abbreviate|omits description suitably.

<B-1. Configuration of reinforcing material>
As shown in FIG. 3, the reinforcing member 1B according to the second embodiment further includes an anchor layer 30. As shown in FIG. That is, the reinforcing member 1B includes the surface layer 10, the blocking layer 20, and the anchor layer 30 in this order.

The anchor layer 30 is a layer that is integrated with the foam-molded article by an anchoring effect when the foam component is soaked therein, and prevents the reinforcing material 1B from peeling off from the foam-molded article. The anchor layer 30 includes a needle-punched nonwoven fabric made of synthetic resin short fibers.

The short synthetic resin fibers contained in the surface layer 10, the blocking layer 20 and the anchor layer 30 are entangled with each other by a needle punching method.

The reinforcing member 1B preferably has a thickness of 0.10 to 0.45 cm and a basis weight of 0.010 to 0.022 g/cm ² . It is preferable to select a combination of the thickness and basis weight of the reinforcing material 1B so that the density of the reinforcing material 1B is 0.049 to 0.15 g/cm ³ .

The reinforcing material 1B preferably has an elongation of at least 40%, more preferably at least 60%, at the temperature during hot press molding.

The anchor layer 30 includes a needle-punched nonwoven fabric obtained by entangling at least two types of synthetic resin short fibers including (A) the synthetic resin short fibers and (B) the synthetic resin short fibers by a needle punching method.

The material and properties of the (A) synthetic resin short fibers that can be used for the anchor layer 30 include, for example, the materials and properties described for the (A) synthetic resin short fibers that can be used for the surface layer 10 . The material and properties of the (A) synthetic resin staple fibers used in the anchor layer 30 may be the same as or different from the materials and properties of (A) the synthetic resin staple fibers used in the surface layer 10. .

The material and properties of the (B) synthetic resin short fibers that can be used for the anchor layer 30 include, for example, the materials and properties described for the (B) synthetic resin short fibers that can be used for the surface layer 10 . The material and properties of the (B) synthetic resin staple fibers used in the anchor layer 30 may be the same as or different from the materials and properties of (B) the synthetic resin staple fibers used in the surface layer 10. .

In one embodiment, the (A) synthetic resin staple fibers and (B) synthetic resin staple fibers used in the barrier layer 20 are used in the surface layer 10 and the anchor layer 30 to increase the density of the barrier layer 20. It may be thinner than the synthetic resin staple fibers of (A) and the synthetic resin staple fibers of (B).

<B-2. Features of reinforcing material>
The reinforcing member 1B has the following features in addition to the features of the reinforcing member 1A.

Needle-punched nonwoven fabrics are not as dense as thermal-bonded nonwoven fabrics, so the foaming component easily permeates them. Therefore, by providing the anchor layer 30 composed of the needle-punched nonwoven fabric, the foaming component permeates into the anchor layer 30, and the anchor layer 30 is firmly bonded to the foam molded body, so that the reinforcing material 1B is peeled off from the foam molded body. can be prevented. Needle-punched nonwoven fabrics using short fibers have fewer intersections between short fibers and are more mobile than long-fiber nonwoven fabrics produced by the spunbond method or meltblown method. Therefore, by adopting a needle-punched nonwoven fabric using short fibers for the anchor layer 30, the extensibility of the reinforcing material 1B during hot press molding can be increased. In addition, as already described, since the short fibers are crimped so that they can be stretched, the reinforcing material 1B is greatly stretched by stretching the crimped synthetic resin short fibers of the anchor layer 30 . In addition, since the anchor layer 30 contains a low-melting point component, when the reinforcing material 1B is heat-press-molded and the reinforcing material 1B is three-dimensionally molded, the low-melting point component melts and the short synthetic resin fibers are separated from each other. Join partially. As a result, the three-dimensional shape of the reinforcing member 1B after hot press molding can be stabilized.

<B-3. Manufacturing Method of Reinforcing Material>
Next, a method for manufacturing the reinforcing material 1B will be described.

A needle-punched nonwoven fabric X that will form the surface layer 10 and the anchor layer 30 is prepared (see FIG. 2(a)). The method for manufacturing the needle-punched nonwoven fabric X is as described above.

A thermal bonded nonwoven fabric Y that will constitute the blocking layer 20 is prepared (see FIG. 2(b)). The method for producing the thermal bond nonwoven fabric Y is as described above.

The needle-punched nonwoven fabric X is overlaid on one side of the thermally bonded nonwoven fabric Y to form a laminate. Next, the laminate is needle-punched to entangle the synthetic resin short fibers contained in the nonwoven fabrics, and a portion of the synthetic resin short fibers of the needle-punched nonwoven fabric X are projected onto the other surface of the thermal bond nonwoven fabric Y. . As a result, a layer of the needle-punched nonwoven fabric is also formed on the other side of the thermal bond nonwoven fabric Y. As shown in FIG. Through such a procedure, the reinforcing member 1B having the surface layer 10 provided on one surface of the blocking layer 20 and the anchor layer 30 provided on the other surface of the blocking layer 20 can be manufactured. In addition, in order to improve the handleability of the reinforcing member 1B and stabilize the physical properties of the reinforcing member 1B, the reinforcing member 1B may be heat-treated as necessary.

<B-4. Modified Example of Reinforcing Material Manufacturing Method>
Below, the modification of the manufacturing method of the reinforcing material 1B is demonstrated.

(1) As another manufacturing method of the reinforcing material 1B, the needle-punched nonwoven fabric X that will constitute the surface layer 10 is laminated on one surface of the thermal bond nonwoven fabric Y, and the other surface of the thermal bond nonwoven fabric Y is A method of laminating the needle-punched nonwoven fabric X that will constitute the anchor layer 30 and needle-punching the laminate obtained in this way can be used.

(2) Another manufacturing method of the reinforcing member 1B is the following method. First, a laminated web is produced using at least two types of synthetic resin short fibers including (A) synthetic resin short fibers and (B) synthetic resin short fibers. As will be described later, this laminated web will constitute the anchor layer 30 and the surface layer 10 . Preferably, the laminated web has a thickness of 2-15 cm and a basis weight of 0.003-0.016 g/cm ² . The combination of thickness and basis weight of the laminated web is preferably selected such that the laminated web has a density of 0.0006 to 0.006 g/cm ³ . The non-needle-punched laminated web is overlaid on one side of the thermal bond nonwoven fabric Y to form a laminate. By needle-punching the laminate, the synthetic resin staple fibers in the laminated web are entangled, and the synthetic resin staple fibers of the laminated web and the synthetic resin staple fibers of the thermal bond nonwoven fabric Y are entangled. Some of the entangled synthetic resin staple fibers in the laminated web protrude to the other surface of the thermal bond nonwoven fabric Y. As shown in FIG. In this way, needle-punched nonwoven fabric layers (that is, the surface layer 10 and the anchor layer 30) in which the synthetic resin short fibers of the laminated web are entangled by needle punching are formed on both sides of the thermal bond nonwoven fabric Y, respectively.

(3) As another method of manufacturing the reinforcing material 1B, a laminated web that will constitute the surface layer 10 is laminated on one surface of the thermal bond nonwoven fabric Y, and an anchor layer is laminated on the other surface of the thermal bond nonwoven fabric Y. 30, and needle-punching the resulting laminate.

<C. Example>
EXAMPLES The present invention will be specifically described below with reference to examples, but the present invention is not limited to the examples shown below.

<C-1. Production of reinforcing material>
Example reinforcements were manufactured by the following method.

[Preparation of needle-punched nonwoven fabric]
A synthetic resin short fiber (A) having the following properties and a synthetic resin short fiber (B) having the following properties were passed through a carding machine to prepare a web. The webs were cross-layered to create a laminated web. A needle-punched nonwoven fabric was produced by needle-punching the laminated web and entangling the synthetic resin short fibers. The mass ratio of the synthetic resin short fibers (A) and the synthetic resin short fibers (B) is 40:60.
[Synthetic resin short fibers of (A)]
・Bicomponent polyester fiber containing 50% by mass of low melting point polyester (melting point: 110°C) as a low melting point component and 50% by mass of high melting point polyester (melting point: 260°C) as a high melting point component ・Thickness: 4.0 dtex
・Length: 5.1cm
[Synthetic resin short fibers of (B)]
・ Regular polyester fiber (melting point: 260°C)
・Thickness: 2.0dtex
・Length: 5.1cm

The needle-punched nonwoven fabric thus produced had a thickness of 0.15 cm, a basis weight of 0.005 g/cm ² and a density of 0.033 g/cm ³ .

[Preparation of thermal bonded nonwoven fabric]
A synthetic resin short fiber (A) having the following properties and a synthetic resin short fiber (B) having the following properties were passed through a carding machine to prepare a web. The webs were cross-layered to create a laminated web. A thermal bonded nonwoven fabric was produced by passing the laminated web between a pair of rolls heated to 170° C., melting the low melting point component, and partially fusing the short synthetic resin fibers. The mass ratio of the synthetic resin short fibers (A) and the synthetic resin short fibers (B) is 50:50.
[Synthetic resin short fibers of (A)]
・Bicomponent polyester fiber containing 50% by mass of low melting point polyester (melting point: 110°C) as a low melting point component and 50% by mass of high melting point polyester (melting point: 260°C) as a high melting point component ・Thickness: 2.0 dtex
・Length: 5.1cm
[Synthetic resin short fibers of (B)]
・ Regular polyester fiber (melting point: 260°C)
・Thickness: 1.5dtex
・Length: 5.1cm

The thermally bonded nonwoven fabric produced had a thickness of 0.012 cm, a basis weight of 0.0038 g/cm ² and a density of 0.317 g/cm ³ .

[Production of reinforcing material]
A needle-punched nonwoven fabric is layered on one side of the thermal-bonded nonwoven fabric, and a needle-punched nonwoven fabric is layered on the other side of the thermal-bonded nonwoven fabric. entangled with fibers. Thus, the reinforcing member of the embodiment in which the surface layer made of the needle-punched nonwoven fabric is provided on one side of the barrier layer made of the thermally bonded nonwoven fabric, and the anchor layer made of the needle-punched nonwoven fabric is provided on the other side of the barrier layer. Got.

<C-2. Comparative example>
The Comparative Example reinforcement is the same as the Example reinforcement except that the barrier layer consists of a spunbond nonwoven fabric.

[Preparation of needle-punched nonwoven fabric]
The manufacturing method of the needle-punched nonwoven fabric that will constitute the surface layer and the anchor layer, and the synthetic resin short fibers used are the same as in the examples.

[Preparation of spunbond nonwoven fabric]
A melted polyester pellet (melting point: 260° C.) was discharged from a nozzle and spun to prepare a web. A web was passed between a pair of rolls heated to 235° C. to bond the synthetic resin long fibers to form a sheet. Thus, a spunbonded nonwoven fabric made of synthetic resin long fibers was produced.

The spunbond nonwoven fabric produced had a thickness of 0.019 cm, a basis weight of 0.0041 g/cm ² and a density of 0.216 g/cm ³ .

[Production of reinforcing material]
The manufacturing method of the reinforcing member of the comparative example is the same as the manufacturing method of the reinforcing member of the example except that the thermal bond nonwoven fabric is changed to the spunbond nonwoven fabric. Thus, the reinforcing material of the comparative example in which the surface layer made of the needle-punched nonwoven fabric was provided on one side of the barrier layer made of the spunbond nonwoven fabric and the anchor layer made of the needle-punched nonwoven fabric was provided on the other side of the barrier layer was obtained. Got.

<C-3. Evaluation method>
[Thickness, basis weight, density]
The thickness and basis weight of the reinforcing material of the example and the reinforcing material of the comparative example were measured. In addition, the basis weight of the blocking layers of the reinforcing members of the examples and the reinforcing members of the comparative example was measured.

[Tensile test]
A tensile tester (AGS-500B manufactured by Shimadzu Corporation) was used to examine the mechanical properties of the reinforcing material at 25°C and 140°C.

Rectangular specimens 200 mm long and 50 mm wide were cut from the reinforcement, as shown in FIG. As a test piece, the flow direction of the manufacturing process (hereinafter referred to as "MD direction") is a test piece whose longitudinal direction (tensile direction) and a direction perpendicular to the MD direction (hereinafter referred to as "CD direction" ) was prepared in the longitudinal direction. A chuck having a width of 20 mm was attached to each end of the test piece, and the gauge length was set to 80 mm. A tensile test was performed at a tensile speed of 100 mm / min, and the tensile strength σ30 (N / 50 mm) when the test piece was stretched by 30%, the tensile strength σ50 (N / 50 mm) when the test piece was stretched by 50%, and at break. Tensile strength σmax (N/50mm) and elongation at break (mm) were measured. The tensile test was performed 5 times in the MD direction, 5 times in the CD direction, and a total of 10 tensile tests were performed. adopted. The elongation rate φ (%) is φ={(L−L ₀ )/L ₀ where L ₀ (=80 mm) is the gauged length before the test and L is the gauged length (elongation at break) after breaking. }×100.

A tensile test at 140°C was performed according to the following procedure. FIG. 5 shows the state of the tensile test at 140°C. Two hair irons each having a pair of clamping portions with a width of 25 mm are prepared. Two curling irons are placed adjacent to each other and fixed with a fixture so as not to separate from each other. The total width of the clamping portion is 50 mm. A cushion sheet is adhered to the inner side of the holding parts so that when the pair of holding parts are closed, the pair of holding parts do not come into contact with each other and a gap of 3 mm to 5 mm is formed between the pair of holding parts. The center of the test piece set in the tensile tester is sandwiched between two curling irons heated to 140° C. and maintained for 10 seconds. As described above, since the total width of the clamping portion is 50 mm, the test piece is also heated over a width of 50 mm. In addition, since there is a gap between the pair of holding parts, each holding part of the hair iron does not come into contact with the test piece. After 10 seconds had passed, the tensile test was started with the test piece sandwiched between the curling irons.

[Measurement of seepage rate]
The urethane exudation rates of the reinforcing materials of Examples and Comparative Examples were measured. Using a color difference meter (CR-410 manufactured by Konica Minolta Co., Ltd.), the x value and y value (Yxy color system, hereinafter the same) of urethane (yellow), foamed in a reinforcing material that is not impregnated with urethane The x-value and y-value of the layered urethane layer and the x-value and y-value of the reinforcing material after the urethane was impregnated and foamed were measured three times, and the arithmetic mean of the three measurements was calculated as described below. It was used to determine the exudation rate to be applied. The x value and y value of the foamed urethane layer on the reinforcing material that is not impregnated with urethane, and the x value and y value of the reinforcing material that has been impregnated with urethane and foamed are measured from the surface layer side. is the value The x-value and y-value represent hue and saturation in the Yxy color system, and the larger the x-value and y-value, the darker the yellow color. The x value and y value of urethane were (x, y)=(0.3507, 0.3616). The x value and y value of the foamed urethane layer on the reinforcing material not impregnated with urethane are set to 0%, and the x value and y value of the urethane are set to 100%. The x-value and y-value represent the x-value and y-value of the foamed urethane layered on the reinforcing material that has not been impregnated with urethane, and how much the distance is, expressed as a percentage, and this is defined as the seepage rate. bottom. That is, for example, the x value and y value of urethane are (x, y) = (0.3507, 0.3616), and the x value and y value of the foamed urethane layer on the reinforcing material that is not impregnated with urethane is (x, y) = (0.3259, 0.3311), and the x and y values of the reinforcing material after impregnation with urethane and foaming are (x, y) = (0.3343, 0.3400) , the distance L1 of the x and y values between the foamed urethane on the reinforcing material not impregnated with urethane and the foamed reinforcing material impregnated with urethane is
L1=√((0.3343−0.3259) ² +(0.3400−0.3311) ² )=0.01226,
The distance L2 of the x value and the y value between the urethane and the reinforcing material after impregnating and foaming the urethane is
L2=√((0.3507−0.3259) ² +(0.3616−0.3311) ² )=0.03928,
From this, the exudation rate of the reinforcing material after impregnated with urethane and foamed is
(L1/L2)×100=(0.01226/0.03928)×100=31.2%.

[Permeability measurement]
Based on the JIS L1906 Frazier method, the air permeability of the reinforcing materials of Examples and Comparative Examples was measured.

<C-3. Results>
Table 1 shows the test results. The reinforcing material of the example had an elongation of 94.1% at 140°C. From these results, it was found that the reinforcing materials of Examples had high extensibility during hot press molding.

1A, 1B Reinforcing material 10 Surface layer 20 Blocking layer 30 Anchor layer

Claims (10)

A reinforcing material that can be molded into a predetermined three-dimensional shape by hot press molding and that can be used to reinforce a foam molded product,
including a surface layer and a barrier layer;
The surface layer is
(A) a synthetic resin short fiber containing a low melting point component having a melting point lower than the temperature during hot press molding and a high melting point component having a melting point higher than the temperature during hot press molding;
(B) a synthetic resin short fiber having a melting point higher than the temperature during hot press molding;
At least two types of synthetic resin short fibers containing a needle-punched nonwoven fabric entangled by a needle-punching method,
The blocking layer comprises a thermally bonded nonwoven fabric to which at least one kind of synthetic resin staple fibers including the synthetic resin staple fibers of (A) is partially bonded,
The surface layer and the blocking layer are entangled by a needle punch method,
reinforcement. The blocking layer comprises at least two types of synthetic resin short fibers including the (A) synthetic resin short fibers and the (B) synthetic resin short fibers on the surface of the thermal bond nonwoven fabric opposite to the surface layer. is bound by a needle-punched nonwoven fabric that is entangled by a needle-punch method,
A reinforcement according to claim 1 . further comprising an anchor layer on the side of the barrier layer opposite to the surface layer;
The anchor layer includes a needle-punched nonwoven fabric in which at least two types of synthetic resin short fibers including the synthetic resin short fibers (A) and the synthetic resin short fibers (B) are entangled by a needle punching method.
A reinforcement according to claim 1 . The anchor layer contains 30% to 70% by mass of the synthetic resin short fibers of (A) and 70% to 30% by mass of the synthetic resin short fibers of (B).
A reinforcement according to claim 3 . The blocking layer further comprises the synthetic resin short fibers of (B).
A reinforcement according to any one of claims 1 to 4. The blocking layer contains 40% by mass to 100% by mass of the synthetic resin short fibers of (A) and 60% by mass to 0% by mass of the synthetic resin short fibers of (B).
A reinforcement according to any one of claims 1 to 5. The blocking layer has a basis weight of 0.003 to 0.008 g/cm ² ,
A reinforcement according to any one of claims 1 to 6. The surface layer contains 30% to 70% by mass of the synthetic resin short fibers of (A) and 70% to 30% by mass of the synthetic resin short fibers of (B),
A reinforcement according to any one of claims 1 to 7. The synthetic resin short fibers of (A) contain 40 to 60% by mass of the low-melting component.
A reinforcement according to any one of claims 1 to 8. elongation at any temperature between 130°C and 160°C is at least 40%;
A reinforcement according to any one of claims 1 to 9.