JP2699502B2 - Structural material and its manufacturing method - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a structural material having excellent sound absorbing properties and heat insulating properties, and more particularly to interior materials such as automobiles and buildings, and surfaces of structures. The present invention relates to a structural material suitable for a material and the like and a method for manufacturing the same.

[Conventional technology]

In recent years, the development of technology in the automobile industry and intensifying competition have led to the continuous improvement of interior materials, such as improvement of product performance, luxurious sensation, rationalization of manufacturing and processing processes, and rationalization of mounting and assembly processes. Has made the request.

That is, in interior materials such as automobiles, especially in headlining, so-called wire fishing ceilings of PVC leather, which have been used very often in the past, are low in raw material cost, but are inferior in PVC leather's unique stickiness, sound absorption properties, insulation properties, and mounting. There are many defects such as troublesome assembly process, light and handy,
The appearance of a headlining with excellent aesthetics and excellent sound absorption characteristics and step heat characteristics has been expected.

On the other hand, there is also known a head line in which a so-called resin felt or a corrugated cardboard in which a wool product is impregnated with a resin and a brushed knit or a non-woven fabric is adhered on the upper surface thereof, but these are man-hours for manufacturing and processing steps. In the former, there is a problem that sufficient weight reduction cannot be performed, and in the latter, there are problems such as difficulty in formability, formability, shape retention during lubrication such as during rainfall, and there is a cost competitiveness. It has not been possible to provide integrally molded automotive interior materials.

Also, for interior materials of buildings, surface materials of structures, etc., the production thereof requires two steps of a sheet forming step and a forming step of a supporting member such as a fiber layer, and is further performed by heat compression of embossing of a surface pattern. There is a disadvantage that the molding process is a separate process, and it takes time and expense for processing.

[Problems to be solved by the invention]

The present invention solves these problems, and the manufacturing and processing steps are streamlined, and the mounting and assembling steps are streamlined, which is excellent in cost competitiveness, and retains a leather-like appearance and a fiber tone. Excellent aesthetics, sound absorption characteristics,
An object of the present invention is to provide a structural material having excellent heat insulating properties, particularly a structural material suitable for an interior material of an automobile or the like, a headlining (ceiling material), an interior material of a building, and a surface material of a structure, and a method of manufacturing the same.

[Means for solving the problem]

In order to solve the above-mentioned problems, the present invention provides a synthetic long fiber web layer, a composite fiber web layer or a surface member in which a blended web layer composed of a composite short fiber and a synthetic short fiber is entangled and integrated, and a reinforcement made of SMC. A structural material formed by integrally molding the member and a composite fiber web layer or a blended web layer composed of composite short fibers and synthetic short fibers is laminated on the upper surface of the synthetic long fiber web layer, and needle punching or water jet entanglement is performed. Forming a surface member comprising a nonwoven fabric layer which is entangled and integrated by a method, and then laminating SMC on the lower surface of the surface member, followed by heating and compression molding to constitute a method for producing a structural material. .

Here, the water jet confounding method is, for example, Nonwov
As shown in FIG. 1 which is also introduced in ens world 3 No.2.p.62-68 (March 1988), a high-pressure fine jet from a high-pressure water jet device (11) is converted into a nonwoven web (W). Inject continuously,
In this method, the fibers constituting the web are entangled with each other, the jet stream is sucked from the suction box (12), the web is dried by the dryer (13), and the web is wound by the winder (14).

In the present invention, preferably, as shown in FIG. 2, synthetic fibers composed of long fibers, preferably 100 g / m ² ~
A polymer having a melting point lower by 30 ° C. or more than the synthetic fiber component polymer and a polymer having a melting point higher by 30 ° C. or more than the synthetic fiber component polymer on the upper surface of the synthetic long fiber web layer (1) of 2,000 g / m ^2. 100/0 to 2 of a composite fiber web layer (2) or a composite staple fiber and a synthetic staple fiber having a melting point higher by at least 30 ° C. than the low melting point component of its component.
Any blend web layer (3) having a blend ratio of 0/80, preferably by laminating a web layer of ^{40g / m 2 ~200g / m 2} ,
As shown in FIG. 3, a synthetic continuous fiber web layer (1) and a composite fiber web layer (2) or a blended web layer (3) are entangled by needle punching or water jet entanglement to form a surface member integrated. On the lower surface of the nonwoven fabric layer (4),
Fourth serving reinforcing members 300g / m ² ~2,000g / m ² as shown in FIG.
A structure in which the SMC layer (5) is laminated.

This structure has extremely good compression moldability and can be used for so-called deep drawing.
Laminated on the underside of the web layer made of synthetic long fibers
Since the SMC partially penetrates and hardens, the hardening of the SMC layer (5) is completed while the non-woven fabric layer (4) and the SMC layer (5) are firmly bonded, ensuring sufficient hardness, rigidity and shape retention. Is done.

Here, as a method of measuring the melting point of synthetic fibers and composite fibers,
According to JIS-K-7121-1987.

Further, on the upper surface of the synthetic long fiber web layer (1), a web layer (2) made of a conjugate fiber or a conjugate short fiber and a synthetic fiber having a melting point higher than the low melting point component of the conjugate short fiber by 30 ° C. or more.
A blended web layer (3) having a blending ratio of 0/0 to 20/80 is laminated and arranged to form a nonwoven fabric layer (4) integrated by needle punching or water jet entanglement. In the layer (2) or the blended web layer (3), the low melting point component of the conjugate short fiber is softened and flown by heat compression molding, and the densification of the constituent structure is performed. Forming a film corresponding to the skin layer, selecting the material polymer that forms the conjugate fiber, and selecting the surface shape of the compression molding die,
It can be finished into natural leather-like structural materials, especially interior materials such as ceiling materials and wall materials.

That is, more specifically, the constituent materials of the composite fiber web layer (2) and the blended web layer (3) and the heat compression molding conditions are selected, and the emboss pattern of the heat compression molding die is selected. Thereby, the surface condition and hand of the structural material can be adjusted to a more fiber tone or natural leather tone, and further by selecting the color tone of the constituent fibers of the composite fiber web layer (2) and the blended web layer (3). Interior materials that can easily respond to the color tone required for interior materials such as ceiling materials and wall materials, and are highly compatible with the just-in-time responsive system required in the automobile and housing industries. It is possible to produce such structural materials with high efficiency and high productivity.

Then, according to the method of the present invention, unlike the conventional manufacturing and processing steps of the integrally molded interior material, the base material for shape retention is first formed as in the conventional method, and then the skin material is attached thereon. Since the compression molding is performed in one shot without using a simple method, the number of processing steps is small and the cost competitiveness is excellent, and the number of processing steps is small.

The tissue construct of the present invention comprises a composite fiber web layer (2) or a blended web layer (3) corresponding to a skin layer of a leather in a densely compressed state as an uppermost surface layer, and then a consolidated synthetic long fiber web layer. (1) Since the lowermost layer is composed of the SMC layer (5) in which a part of the lower part of the synthetic continuous fiber web layer (1) is also impregnated and impregnated, it has excellent mechanical performance such as bending rigidity and tensile strength. If the rear air layer is properly selected and provided, it will be an interior material such as a ceiling material or a wall material which has extremely excellent sound absorbing and heat insulating properties and can be easily mounted.

The synthetic long fiber web layer (1) of the present invention is more preferably produced and supplied by a so-called spunbond method, but may be produced by another method of producing a long fiber nonwoven fabric.

The constituent fibers are general-purpose polyesters (polyethylene terephthalate, polybutylene terephthalate, etc.), their copolymers, and polyamides (nylon 66
Etc.) and its copolymers, polypropylene and the like are suitable, but any general-purpose synthetic fibers may be used.

Next, the composite fiber web layer (2) and the blended web layer (3)
The conjugate fiber constituting may be, for example, a conjugate fiber commercially available for a thermal bond process of short fiber nonwoven fabric,
For example, sea core type (sheath / core type) polyethylene / polypropylene, nylon 6 / nylon 66, polybutylene terephthalate / polyethylene terephthalate, etc., may be used. When the composite fiber of MID and the core portion are polyethylene terephthalate, it is natural that the composite fiber of various copolyesters is used for the sheath portion.

Naturally, side-by-side type composite fibers can also be used.

And the composite fiber web layer (2) can also be manufactured by a so-called spun bond method.

The selection of the material of the composite fiber is performed based on the appearance of the product, the feeling, and the heat compression conditions.

In other words, if a soft feel is desired, nylon is desirable.If the conditions of hot compression molding are severe, polyester or nylon composite fibers with a relatively high melting point for the sheath copolymer are selected. do it.

The blending ratio of the composite fiber in the blended web layer (3) and the synthetic fiber having a melting point higher than that of the composite fiber by 30 ° C. or more may be selected based on the feeling, denseness, and the like required for the skin layer of the product.

An SMC layer laminated on the lower surface of a nonwoven fabric layer (4) composed of a synthetic long fiber web layer (1) and a composite fiber web layer (2) or a blended web layer (3) integrated by needle punching or water jet entanglement. 5) means Sheet Mol
This is a ding compound, which is generally a putty compound made by adding a thickener, a filler, a curing agent (curing catalyst) and glass fiber to an unsaturated polyester resin to form a sheet. In the SMC layer, a compound containing no glass fiber, a compound using an organic synthetic fiber in place of the glass fiber, and a compound containing an epoxy resin in place of the unsaturated polyester resin are also included in the target product.

The mixing ratio of the SMC is selected so as to be appropriate according to the molding conditions and to obtain desired physical properties. That is, the compounding ratio of the thickener, the filler, the curing agent (curing catalyst), the glass fiber, and the like that satisfies the flow characteristics at the time of molding may be determined according to the molding conditions to be performed, and the molding to be set may be performed. What is necessary is just to select the curing catalyst amount which satisfies the time.

As described above, the laminate of the surface member composed of the nonwoven fabric layer (4) and the SMC layer (5) according to the present invention undergoes a heat compression molding process, whereby a part of the SMC layer partially penetrates below the nonwoven fabric layer (4). In order to complete the curing reaction while impregnating, the nonwoven fabric layer (4) and the SMC layer (5) are firmly adhered, and the structural material is given a desired shape and has a desired rigidity.

Next, the degree of consolidation in the heat compression molding is set by adjusting the temperature, pressure, compression time, etc. of the heat compression molding so that the obtained structural material is molded into a predetermined shape and exhibits the best sound absorbing properties, heat insulation properties, and rigidity. It is sufficient to select and determine various conditions,
The dominant factor in setting the apparent density of the molded product lies in the spacer setting of the heat compression molding die.

In general, the apparent density of the nonwoven fabric layer (4) is preferably in the range of 0.2 to 0.6 g / m ³ in order to sufficiently exhibit sound absorbing properties and heat insulating properties, and is selected from experimental results according to the working conditions.

 Hereinafter, details of the present invention will be described with reference to examples.

[Example 1] A sheath component (sheath) is composed of 25% of a copolyester composed of TPA / IPA = 55/45 and having a melting point of 130 ° C, and 75% of a PET core component. Eccentric sheath-core type cut length 45mm, 3den, pigmented in light gray
With 25 parts of ier's crimp developing composite fiber, similarly cut length 45 mm,
PET short fiber 75 pigmented in 3denier light gray with pigment
Parts, and a blended web layer (3) having a basis weight of 100 g / m ² and a synthetic continuous fiber web layer (1) manufactured by a conventional nonwoven fabric manufacturing method (for example, JP-B-53-32424).
No. 4denie manufactured by spunbond process
The spunbond web layer having a random loop structure of 250 g / m ² composed of PET filaments of r was laminated, and Needle FPD-1-40S manufactured by Organ Co., Ltd., and a needling depth of 12 mm,
Needling was performed at a needling density of 180 N / cm ² to obtain a nonwoven fabric layer (4).

On the other hand, 100 parts of unsaturated polyester resin “Yupika 7506” (manufactured by Nippon Yupika Co., Ltd.) 100 parts of Zn-stealate 1 part of t-Butyl perbenzoate 1 part of MgO # 40 2 parts of 60 parts of CaCO ₃ are mixed, and polyethylene is mixed using an SMC manufacturing apparatus. The film was coated to a thickness of 0.3 mm, and a surface mat SM3605E (100 g / m ² ) manufactured by Asahi Fiberglass Co., Ltd. was supplied from the upper surface of the coated sheet, and a polyethylene film was placed on the upper surface. The compound was sandwiched between upper and lower polyethylene films, pressed and wound while sufficiently performing defoaming, sealed, and aged at 40 ° C. for 48 hours to obtain a 500 g / m ² SMC layer (5). The nonwoven fabric layer (4) and the SMC layer (4) are placed in a metal mold for structural material in which the leather-like pattern is engraved and heated to 180 ° C. so that the blended web layer (3) is on the engraved surface of the mold. 5) was laminated, and press-formed at a clearance of 2.5 mm and a temperature of 180 ° C. for 30 seconds to obtain a structural material having a natural leather-like appearance and a shape that was faithful to the set forming die.

 The physical properties of the obtained structural material are as follows.

Surface taper wear (JIS-L-1096): Class 5 Lightfast (discoloration) fade meter 83 ° C x 200hr .: 4 to 5
Grade Bending rigidity (JIS-K-7203): 12.6 kg / mm ² Sound absorption characteristics: See Fig. 5 Heat insulation [Heat plate temperature almost in accordance with JIS-L-1096: 80 ℃,
Thermal pain area: 625 cm ^2, the sample area: 400 cm ^2, the sample - hot pain distance: 5
cm, environmental condition: 20 ° C, 65%, measurement time: 1 hour, heat loss was compared with blank without sample (heat insulating material) to make it heat insulating and insulating]: 55% In addition to the conventional needle punching, The web layers can be entangled by the water jet entanglement method. For example, in the embodiment, the needling depth of 12 mm and the needling density of 180 N / cm using the needle of FPD-1-40S are used.
Confounding corresponding to ^2, using the apparatus shown in FIG. 1, placing the web layer of 100 mesh wire gauze, a 0.1mm orifice 1m
A high-pressure water jet device (11) arranged at an m pitch jets a high-pressure fine jet from the upper surface and then jets from the lower surface. The jet is jetted at a nozzle back pressure of 1500 psi, and the confounding process is performed at a processing speed of 20 m / min. By doing so, an effect equivalent to needle punching could be obtained with higher productivity.

[Example 2] The basis weight of the blended web layer (3) forming the skin layer in Example 1 and the span of the random loop structure serving as a base material that shares many of the constituent structures, heat insulation and heat insulating properties, sound absorbing properties, molding performance, and the like. Bond web layer (1) and blended web layer (3)
Example in which the SMC layer (5) for changing the basis weight and / or the composition of the non-woven fabric layer to give the product rigidity and other mechanical properties, shapeability, etc. is the same as that in Example 1, and the effect of the basis weight of the nonwoven fabric layer (4) is examined. Are the following results.

In Table 1, grade 5 is the highest in the wear resistance.
The grade is the lowest grade. As shown in FIG. 5, the sound absorption was sufficiently satisfactory for soundproofing. [Example 3] In Example 1, the nonwoven fabric layer (4) was the same as that of Example 1 and the SMC layer was constant. The results of examining the effects by changing the basis weight of (5) and changing the heat compression molding processing conditions are as follows.

[Effects of the Invention] Since the present invention is configured as described above, the nonwoven fabric layer (4) composed of the synthetic long fiber web layer (1) and the composite fiber web layer (2) or the blended web layer (3), and the SMC The laminate with the layer (5) is formed of short fibers because the entanglement of the constituent tissues by needle punching or water jet entanglement is the only deformation resistance element, and the web layer (1) is made of long fibers of synthetic fibers. Concentration of deformation strain due to slippage of fibers does not occur at the time of deformation like a web layer, and the web layer is formed by entanglement of long fibers, so stress increases moderately with deformation, dispersion and equalization of deformation strain Is performed, and since the deformation tolerance is large, uniform desired molding can be easily performed.

Then, the composite fiber web layer (2) or the blended web layer (3) comes into contact with the mold during the thermal compression molding and receives consolidation, so that the low melting point component of the composite fiber softens and flows to form a dense skin layer. At this time, since the surface condition of the mold surface can be faithfully transferred, an arbitrary surface shape can be simultaneously given at the time of this molding, and a separate process such as attaching a sheet having a leather-like shape by Embossing as in the past is used. , And a very high-fidelity leather-like molded article can be produced in a very single step.

The molded article obtained in this way has excellent sound absorbing properties and heat insulating properties by itself, but its effectiveness can be further increased depending on the selection of the back air layer in the installation.

That is, the nonwoven fabric layer (4) of the structural material obtained by the present invention
Is preferably a porous material of an apparent density of 0.2 to 0.6 g / m ³ is moreover since a material having a density gradient, but is superior in very sound-absorbing characteristics, in order to exert its effect to the maximum Has a unique sound absorption characteristic (sound absorption rate to frequency relationship) for the combination with the back air layer according to its material, configuration, apparent density, etc. By selecting a condition that can most effectively absorb noise in a desired frequency range of the generated sound under the used environmental conditions, it is possible to exhibit a high efficiency and high level of sound absorption effect which has not been achieved in the past.

The same applies to the heat insulating properties. In other words, by mounting the rear air layer between the SMC layer and the ceiling or the wall surface while maintaining the air layer, the air layer formed between the SMC layer and the ceiling or the wall surface also acts as a heat insulating layer, and the temperature rise in the indoor space is reduced. Can be prevented.

In addition, a product in which the SMC layer such as aluminum powder and the like, which reflects radiant heat and electromagnetic waves, is added to SMC is a product having further improved heat insulation and electromagnetic wave shielding properties.

As described above, the present invention can be used not only for interior materials of automobiles and the like, ceiling materials, but also widely applicable to interior materials of buildings, surface materials of structures, and the like. Change of use, modification of the configuration within the described configuration,
Of course, changes are possible.

[Brief description of the drawings]

FIG. 1 is a schematic diagram of a water jet entanglement device, FIG. 2 is a cross-sectional explanatory view showing a laminated structure of an embodiment in a first stage of manufacturing a structural material of the present invention, and FIG. 3 is a structural material in FIG. FIG. 4 is a cross-sectional explanatory view showing a nonwoven fabric layer according to an embodiment in a second stage of manufacturing a nonwoven fabric, FIG. 4 is a cross-sectional explanatory view showing a configuration of an embodiment of a structural material according to the present invention, and FIG. It is a sound absorption characteristic figure in one Example. 1: Synthetic long fiber web layer, 2: Composite fiber web layer 3: Blended web layer, 4: Nonwoven fabric layer 5: SMC layer, 11: High pressure water jetting device 12: Suction box, 13: Dryer 14: Winder

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification number Agency reference number FI Technical display location B32B 27/12 B32B 27/12 // B29K 105: 06 B29L 9:00 31:10 31:58

Claims (2)

(57) [Claims] 1. A synthetic fibrous web layer, a composite fiber web layer or a surface member in which a composite short fiber and a blended web layer composed of synthetic short fibers are entangled and integrated, and a reinforcing member made of SMC are integrally formed. A structural material characterized by comprising. 2. A nonwoven fabric obtained by laminating a composite fiber web layer or a blended web layer composed of composite short fibers and synthetic short fibers on the upper surface of a synthetic long fiber web layer, and entangled and integrated by needle punching or water jet entanglement. A method for producing a structural material, comprising: forming a surface member made of a layer; and then laminating SMC on the lower surface of the surface member, followed by heat compression molding.