JP2023133244A - 構造部品用途のための持続可能な不織布積層体 - Google Patents
構造部品用途のための持続可能な不織布積層体 Download PDFInfo
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- JP2023133244A JP2023133244A JP2023036474A JP2023036474A JP2023133244A JP 2023133244 A JP2023133244 A JP 2023133244A JP 2023036474 A JP2023036474 A JP 2023036474A JP 2023036474 A JP2023036474 A JP 2023036474A JP 2023133244 A JP2023133244 A JP 2023133244A
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- Japan
- Prior art keywords
- nonwoven
- layers
- layer
- fibers
- laminate
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
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Abstract
Description
-多成分短繊維を含む不織布層(A)と、
-任意選択で、多成分短繊維または単成分短繊維を含む不織布層(B)と、
-単成分短繊維(c1)および多成分短繊維(c2)を含むニードリングされた不織布層(C)と、
-多成分短繊維または単成分短繊維を含む任意の不織布層(D)と、
-任意選択で、多成分短繊維を含む不織布層(E)と、
を備え、
層は、(A)~(E)の順に配置され、
層は、ニードリングによってではなく、メルトボンディングによって互いに結合され、
多成分繊維は、ポリエステル成分およびコポリエステル成分を含み、
層(C)中の単成分繊維は、ポリエステル繊維であり、
層(B)および(D)中の単成分繊維は、コポリエステル繊維であり、
任意の不織布層(B)および(D)中のコポリエステルの含有量は、不織布層(A)および任意の層(E)よりも高く、
不織布積層体の全ての繊維は、ポリエステル繊維および/またはコポリエステル繊維であり、
層(C)は、DIN EN 29073-1:1992-08に従って決定された500~2000g/m2の坪量を有しており、
不織布積層体は、2mmの撓みについてISO 178:2019に従って決定された少なくとも6Nの曲げ力を有する、
不織布積層体である。
-ASTM 5034:2009による≧800Nの引張強度、および/または
-DIN EN 29073-3:1992-08による≧100Nの引裂強度
の少なくとも1つを有することが好ましい。
-層(A)、(B)、(C)、(D)および(E)
-層(A)、(B)、(C)および(E)
-層(A)、(C)および(E)
-層(A)、(B)および(C)、または
-層(A)および(C)
を備えてよく、またはそれらから構成されてよい。
-DIN EN ISO 1973:2020-05に従って決定された2~9dtex、より好ましくは3~7dtex、さらにより好ましくは4~6dtexの繊度
-30~100mm、より好ましくは40~70mm、さらに好ましくは45~55mmの繊維長
-DIN EN 13844:2003-04に従って決定された1~6g/de、より好ましくは2~5g/de、さらにより好ましくは3~4g/deの強度
-DIN EN ISO 5079:2020-01に従って決定された20~60%、より好ましくは30~50%、さらにより好ましくは35~55%の伸度
-JIS L-1074に従って決定された4~10EA/inch、より好ましくは5~9EA/inch、さらに好ましくは6~8EA/inchの捲縮量
-DIN EN 13844:2003-04に従って決定された75℃×15分で3~7%、より好ましくは4~6%、さらにより好ましくは3.5~4.5%の熱収縮率
の少なくとも1つ、より好ましくは2つ以上、最も好ましくは全てを有することが好ましい。
-全ての層中のコポリエステルが、160~240℃の融点を有するポリエチレンテレフタレート(CoPET)のコポリマーである、
-層(B)および層(D)を含み、両方ともコポリエステルから構成され、DIN EN 29073-1:1992-08に従って5~30g/m2の坪量を有する、
-層(C)が、30~70%の単成分短繊維(c1)および30~70%の多成分短繊維(c2)から構成される、
が好ましい。
-層(B)および層(D)を含まない、
-層(A)、(C)および(E)中のコポリエステルが、ポリエチレンテレフタレートのコポリマーであり、コポリマーは、160~240℃の融点を有する、
-層(C)が、30~70%の単成分短繊維(c1)および30~70%の多成分短繊維(c2)から構成される、
が好ましい。
-本発明の不織布積層体を提供することと、
-不織布積層体を、コポリエステルが軟化または溶融する温度まで加熱することと、
-不織布積層体を成形物品に成形することと、
を含む、方法である。
-ニードリングによってニードリングされた安定な不織布層(C)を調製することと、
-層(A)ならびに任意選択で層(B)、(D)および(E)を提供することと、
-層を互いにメルトボンディングすることと、
を含む、方法に関する。
本発明の不織布積層体を、不織布層(A)、(C)および(E)から製造した。
100%二成分短繊維
材料:コア50%PET、シース50%PETのコポリエステル(CoPET、TM=180℃)
長さ51mm、繊度2.1den
坪量:50g/m2
50%単成分短繊維(c1)/材料:r-PET/短繊維長さ:67mm/繊度:6.7den
50%二成分短繊維
材料:コア50%PET、シース50%PETのコポリエステル(CoPET、TM=180℃)
長さ51mm、繊度4.4den
実施例1の不織布積層体から、冷間成形によって成形物品を製造した。シートカットされた不織布積層体を、CoPET成分が軟化するように、210℃まで加熱されたオーブンに3分間(通気オーブンの場合)または1分間(赤外線オーブンの場合)導入した。生地を直ちにコールドプレスに移し、そこで材料を高圧(50トン以上)で成形し、曲げ、形成した。成形物品は堅く、機械的に安定である。成形物品は、アンダーボディシールドなどの種々の技術的用途に適している。この結果は、本発明の不織布積層体を、所望の形状の安定した成形物品を形成するために便利に使用できることを実証するものである。
実施例1の不織布積層体の音響特性をアルファキャビン内で試験した。試料を、2mmの空隙を有する壁または地面のいずれかの近くに置いた。吸収係数は、キャビン内の一連のセンサによって測定される。結果を表1に要約する。図3は、音響周波数(横軸)対吸収係数αs(縦軸)の結果をグラフで示している。吸音係数αsが高いほど、試験された試料の音響性能は良好である。結果は、本発明の不織布積層体の吸音性が、短繊維から構成されるが、定義された層を含まない比較試料Aよりもはるかに良好であることを実証するものである。さらに、性能は、外側スパンボンド層を有する比較積層体に匹敵する。本発明の試料Eは、全体的に最良の性能を有している。特に、性能は、自動車のアンダーボディ用途に特に関連する400~800Hzの範囲で特に良好である。
実施例1の不織布積層体の機械的特性を調べた。結果を、4mmの厚みを有する不織布積層体については表2に、2mmの厚みを有する対応する不織布積層体については表3に要約する。曲げ強度はISO 178:2019-04に従って、引張強度はASTM 5034:2009に従って、引裂強度はDIN EN 29073-3:1992-08に従って決定した。
実施例1による不織布積層体の吸水率を調べた。試料を水に浸漬し、乾燥させた。吸収された水の量を秤量によってモニタした。結果を表4に要約する。結果は、本発明の不織布積層体の吸水性が、比較の単層短繊維不織布よりもはるかに良好であることを実証するものである。全体的に、吸水性は、アンダーボディシールドなどの技術的用途の要件を満たすのに十分に低い。
Claims (15)
- 不織布積層体であって、
-多成分短繊維を含む不織布層(A)と、
-任意選択で、多成分短繊維または単成分短繊維を含む不織布層(B)と、
-単成分短繊維(c1)および多成分短繊維(c2)を含むニードリングされた不織布層(C)と、
-多成分短繊維または単成分短繊維を含む任意の不織布層(D)と、
-任意選択で、多成分短繊維を含む不織布層(E)と、
を備え、
前記層は、(A)~(E)の順に配置され、
前記層は、ニードリングによってではなく、メルトボンディングによって互いに結合され、
前記多成分繊維は、ポリエステル成分およびコポリエステル成分を含み、
層(C)中の前記単成分繊維は、ポリエステル繊維であり、
層(B)および(D)中の前記単成分繊維は、コポリエステル繊維であり、
任意の不織布層(B)および(D)中の前記コポリエステルの含有量は、不織布層(A)および任意の層(E)よりも高く、
前記不織布積層体の全ての繊維は、ポリエステル繊維および/またはコポリエステル繊維であり、
層(C)は、DIN EN 29073-1:1992-08に従って決定された500~2000g/m2の坪量を有しており、
前記不織布積層体は、2mmの撓みについてISO 178:2019に従って決定された少なくとも6Nの曲げ力を有する、
不織布積層体。 - 前記層(A)および(E)は、前記層を組み合わせる前にニードリングされている、請求項1記載の不織布積層体。
- 層(A)、(C)および(E)を含むか、または層(A)、(C)および(E)から構成されている、請求項1または2記載の不織布積層体。
- -DIN EN ISO 9073-2に従って決定された1mm~10mmの厚み
-ASTM 5034:2009による≧800Nの引張強度、および/または
-DIN EN 29073-3:1992-08による≧100Nの引裂強度
の特徴のうちの少なくとも1つを有する、請求項1から3までの少なくとも1項記載の不織布積層体。 - 全ての層中の前記コポリエステルは、ポリエチレンテレフタレートのコポリマーであり、前記コポリマーは、≦240℃の融点を有する、請求項1から4までの少なくとも1項記載の不織布積層体。
- 層(A)、(C)および/または(E)中の前記多成分繊維は、30%~95%のポリエステルおよび5%~70%のコポリエステルを含む、請求項1から5までの少なくとも1項記載の不織布積層体。
- 層(A)および/または(E)は、それぞれDIN EN 29073-1:1992-08による20~200g/m2の坪量を有する、請求項1から6までの少なくとも1項記載の不織布積層体。
- 層(C)は、10~90%の単成分短繊維(c1)および10~90%の多成分短繊維(c2)から構成されている、請求項1から7までの少なくとも1項記載の不織布積層体。
- 請求項1から8までの少なくとも1項記載の不織布積層体を含む成形物品。
- 請求項9記載の成形物品を製造する方法であって、
-請求項1から8までの少なくとも1項記載の不織布積層体を提供することと、
-前記不織布積層体を、前記コポリエステルが軟化または溶融する温度まで加熱することと、
-前記不織布積層体を前記成形部品に成形することと、
を含む、方法。 - 少なくとも1つの不織布層が、前記層を組み合わせる前にカレンダー加工によってサーマルボンディングされている、請求項10記載の方法。
- 前記層を組み合わせる前に、層(C)が、ヒートセットおよび/または熱収縮によってサーマルボンディングされており、かつ/または前記層を組み合わせる前に、前記層(A)および/または層(E)が、カレンダー加工によってサーマルボンディングされている、請求項10記載の方法。
- 請求項1から9までの少なくとも1項記載の不織布積層体または成形物品の、特に自動車用途のための、アンダーボディシールド、ホイールアーチライナー、ルーフピラー、荷物または荷物室のための構造部品、カバーもしくはパネル材料、または他の構造部品としての使用。
- 請求項1から9までの少なくとも1項記載の不織布積層体または成形物品を含む、特に自動車用途のための、アンダーボディシールド、ホイールアーチライナー、ルーフピラー、荷物または荷物室のための構造部品、カバーまたはパネル材料、または他の構造部品。
- 請求項1から8までの少なくとも1項記載の不織布積層体を製造する方法であって、
-ニードリングによって層(C)を調製することと、
-層(A)ならびに任意選択で層(B)および(D)および(E)を提供することと、
-前記層を互いにメルトボンディングすることと、
を含む、方法。
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP22161277.3A EP4241979A1 (en) | 2022-03-10 | 2022-03-10 | Sustainable nonwoven laminate for structural part applications |
EP22161277 | 2022-03-10 |
Publications (1)
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JP2023133244A true JP2023133244A (ja) | 2023-09-22 |
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JP2023036474A Pending JP2023133244A (ja) | 2022-03-10 | 2023-03-09 | 構造部品用途のための持続可能な不織布積層体 |
Country Status (6)
Country | Link |
---|---|
US (1) | US20230286257A1 (ja) |
EP (1) | EP4241979A1 (ja) |
JP (1) | JP2023133244A (ja) |
KR (1) | KR20230133220A (ja) |
CN (1) | CN116728917A (ja) |
MX (1) | MX2023002880A (ja) |
Family Cites Families (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6048809A (en) * | 1997-06-03 | 2000-04-11 | Lear Automotive Dearborn, Inc. | Vehicle headliner formed of polyester fibers |
BR0009554A (pt) * | 1999-04-06 | 2002-01-29 | Knowlton Nonwovens Inc | Artigos adequados para uso em, moldagem em forros e em forro, de teto de automóvel |
KR100902180B1 (ko) * | 2008-03-11 | 2009-06-10 | 엔브이에이치코리아(주) | 자동차 내장용 흡음재 및 제조방법 |
US10259190B2 (en) | 2015-03-31 | 2019-04-16 | Freudenberg Performance Materials Lp | Moldable composite mat |
US10981606B2 (en) | 2015-05-12 | 2021-04-20 | Hanwha Azdel, Inc. | Underbody shield compositions and articles that provide enhanced peel strength |
MX2019010362A (es) * | 2017-03-02 | 2020-01-21 | Foss Performance Materials LLC | Sistemas compuestos moldeables mejorados resistentes al desprendimiento/no tejidos con propiedades acusticas sonoras agregadas. |
JP7191656B2 (ja) | 2017-11-27 | 2022-12-19 | 日本バイリーン株式会社 | 成型用基材不織布及びこれによって得られる成型体 |
EP3769954B1 (en) | 2019-07-22 | 2023-04-12 | Carl Freudenberg KG | Nonwoven laminate |
-
2022
- 2022-03-10 EP EP22161277.3A patent/EP4241979A1/en active Pending
-
2023
- 2023-03-07 US US18/179,401 patent/US20230286257A1/en active Pending
- 2023-03-08 KR KR1020230030538A patent/KR20230133220A/ko unknown
- 2023-03-08 CN CN202310215674.2A patent/CN116728917A/zh active Pending
- 2023-03-09 MX MX2023002880A patent/MX2023002880A/es unknown
- 2023-03-09 JP JP2023036474A patent/JP2023133244A/ja active Pending
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MX2023002880A (es) | 2023-09-11 |
CN116728917A (zh) | 2023-09-12 |
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US20230286257A1 (en) | 2023-09-14 |
KR20230133220A (ko) | 2023-09-19 |
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