JP4071704B2 - Molding material made of stretchable nonwoven fabric and interior material made using the same - Google Patents

Description

The present invention molding material consisting of a nonwoven fabric obtained by the spunbond method, and to interior materials made by using the molding materials.

Conventionally, a needle nonwoven fabric has been frequently used as a skin material. However, the needle nonwoven fabric cannot be made thin.
Therefore, a thin nonwoven fabric is provided by a spunbond method (see, for example, Patent Document 1).

JP 2002-105832 A

  However, the nonwoven fabric obtained by the spunbond method has poor longitudinal and lateral elongation, and when the nonwoven fabric is bonded to a substrate as a skin material, there is a problem that wrinkles and cracks occur in the deep-drawn portion of the resulting molded product. is there.

The present invention provides, as means for solving the above problems, provided at a rate span ten pores of 0.1mm~2mm non-woven fabric to needle punching made by bond method / cm ² to 100 pieces / cm ² And a molding material comprising a stretchable nonwoven fabric impregnated with a thermosetting resin .
Moreover, this invention provides the interior material which adhere | attached on the base-material surface as a skin material, and was formed in the predetermined shape .

When the pores of pore size 0.1mm~2mm I by the porous by needle punching provided at a rate of 10 pieces / cm ² to 1 00 pieces / cm ^2, elongation of the vertical and horizontal molding material is non-woven fabric is improved. Therefore, even if the stretchable nonwoven fabric of the present invention is bonded to a base material and molded, no wrinkles or cracks are generated in the deep drawn portion.

The nonwoven fabric used in the present invention is produced by a spunbond method, that is, a method in which a thermoplastic resin is melted and extruded from a spinneret as a large number of filaments, and the filaments are fused together in a sheet form.
A nonwoven fabric obtained by laminating a plurality of nonwoven fabrics manufactured by the spunbond method and needle punching them may be used.

( Delete )

The thickness of the nonwoven fabric is usually 0.05 mm to 1 mm, fineness is 0.05Dtex～5dtex, basis weight is ^{10g / m 2 ~200g / m 2} .

The nonwoven fabric obtained by the spunbond method is provided with porosity by needle punching. The shape of the hole provided in the nonwoven fabric may be any shape such as a circle, an ellipse, and a rectangle. The pores provided in the nonwoven fabric need not all have the same shape, and may have a plurality of shapes.
The hole diameter is 0.1 mm to 2 mm, preferably 0.2 mm to 1.5 mm. When the hole is circular, the hole diameter is the diameter of the circle. When the hole is rectangular, the longest diagonal line is the hole diameter. The number of holes provided in the nonwoven fabric is 10 / cm ^{2 to} 100 / cm ² .

The nonwoven fabric of the present invention is impregnated with a synthetic resin. As the synthetic resin to be impregnated, for example,
There are thermosetting resins such as phenol resin, urethane resin, melamine resin, urea resin, epoxy resin, and thermosetting polyester.

Hereinafter, the phenol resin used in the present invention will be described.
[Phenolic resin]
The phenol resin is obtained by condensing a phenol compound with an aldehyde and / or an aldehyde donor. The phenolic resin may be sulfomethylated and / or sulfimethylated to impart water solubility.
The above-mentioned nonwoven fabric is impregnated with the phenol resin of the present invention as an initial condensate. The precondensate is usually prepared as an aqueous solution, but if desired, methanol, ethanol, isopropanol, n-propanol, isopropanol, n-butanol, isobutanol, sec-butanol, t-butanol, n-amyl alcohol, Isoamyl alcohol, n-hexanol, methyl amyl alcohol, 2-ethylbutanol, n-heptanol, n-octanol, trimethylnonyl alcohol, cyclohexanol, benzyl alcohol, furfuryl alcohol, tetrahydrofurfuryl alcohol, abiethyl alcohol, diacetone alcohol Alcohols such as acetone, methyl acetone, methyl ethyl ketone, methyl-n-propyl ketone, methyl-n-butyl ketone, methyl isobutyl ketone, diethyl , Di-n-propyl ketone, diisobutyl ketone, acetonyl acetone, methyl oxide, cyclohexanone, methyl cyclohexanone, acetophenone, camphor, and other ketones, ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, trimethylene glycol, polyethylene glycol Glycols such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol isopropyl ether, diethylene glycol monomethyl ether, triethylene glycol monomethyl ether and other glycol ethers, ethylene glycol diacetate, diethylene glycol monoethyl ether acetate and the above glycols Esters and their derivatives , Ethers and 1,4-dioxane, Jiechiruserorubu, diethyl carbitol, ethyl lactate, isopropyl lactate, diglycol diacetate, may be used water-soluble organic solvent such as dimethylformamide.

(Phenolic compounds)
The phenolic compound used in the phenol resin may be a monohydric phenol, a polyhydric phenol, or a mixture of a monohydric phenol and a polyhydric phenol, When only monohydric phenol is used, formaldehyde is easily released during and after curing. Therefore, polyhydric phenol or a mixture of monohydric phenol and polyhydric phenol is preferably used.

(Monohydric phenol)
Examples of the monohydric phenol include phenol, alkylphenols such as o-cresol, m-cresol, p-cresol, ethylphenol, isopropylphenol, xylenol, 3,5-xylenol, butylphenol, t-butylphenol, and nonylphenol, and o-fluoro. Phenol, m-fluorophenol, p-fluorophenol, o-chlorophenol, m-chlorophenol, p-chlorophenol, o-bromophenol, m-bromophenol, p-bromophenol, o-iodophenol, m-iodo Phenol, p-iodophenol, o-aminophenol, m-aminophenol, p-aminophenol, o-nitrophenol, m-nitrophenol, p-nitrophenol, 2,4-dinitro Examples include monohydric phenol substitutes such as enol and 2,4,6-trinitrophenol, and polycyclic monohydric phenols such as naphthol. These monohydric phenols may be used alone or in combination of two or more. Can do.

(Polyhydric phenol)
Examples of the polyhydric phenol include resorcin, alkylresorcin, pyrogallol, catechol, alkylcatechol, hydroquinone, alkylhydroquinone, phloroglucin, bisphenol, dihydroxynaphthalene, and the like. These polyhydric phenols are used alone or in combination of two or more. can do. Among the polyhydric phenols, preferred is resorcin or alkylresorcin, and particularly preferred is alkylresorcin, which has a higher reaction rate with aldehyde than resorcin.

Examples of the alkyl resorcin include, for example, 5-methyl resorcin, 5-ethyl resorcin, 5-propyl resorcin, 5-n-butyl resorcin, 4,5-dimethyl resorcin, 2,5-dimethyl resorcin, 4,5-diethyl resorcin, 2 , 5-diethyl resorcin, 4,5-dipropyl resorcin, 2,5-dipropyl resorcin, 4-methyl-5-ethyl resorcin, 2-methyl-5-ethyl resorcin, 2-methyl-5-propyl resorcin, 2 , 4,5-trimethylresorcin, 2,4,5-triethylresorcin and the like.
A polyhydric phenol mixture obtained by dry distillation of an Estonia oil shale is inexpensive and contains a large amount of highly reactive various alkylresorcins in addition to 5-methylresorcin. Therefore, it is a particularly preferable polyhydric phenol raw material in the present invention.

  In the present invention, the phenolic compound is condensed with an aldehyde and / or an aldehyde donor (aldehydes). The aldehyde donor means a compound or a mixture thereof which generates and donates an aldehyde when decomposed. Examples of such aldehyde include formaldehyde, acetaldehyde, propionaldehyde, chloral, furfural, glyoxal, n-butyraldehyde, caproaldehyde, allylaldehyde, benzaldehyde, crotonaldehyde, acrolein, phenylacetaldehyde, o-tolualdehyde, salicylaldehyde, etc. Examples of aldehyde donors include paraformaldehyde, trioxane, hexamethylenetetramine, tetraoxymethylene and the like.

  As described above, in order to improve the stability of the water-soluble phenol resin, it is desirable to sulfomethylate and / or sulfmethylate the phenol resin.

(Sulfomethylating agent )
Examples of sulfomethylating agents that can be used to improve the stability of water-soluble phenolic resins include sulfite, bisulfite or metabisulfite, and alkali metals or quaternary amines or quaternary compounds such as trimethylamine or benzyltrimethylammonium. Examples thereof include water-soluble sulfites obtained by reacting with ammonium and aldehyde adducts obtained by reacting these water-soluble sulfites with aldehydes.
Examples of the aldehyde adduct include formaldehyde, acetaldehyde, propionaldehyde, chloral, furfural, glyoxal, n-butyraldehyde, caproaldehyde, allylaldehyde, benzaldehyde, crotonaldehyde, acrolein, phenylacetaldehyde, o-tolualdehyde, salicylaldehyde, etc. An aldehyde adduct composed of formaldehyde and sulfite is, for example, hydroxymethanesulfonate.

(Sulfimethylating agent)
Sulfialkylating agents that can be used to improve the stability of water-soluble phenolic resins include aliphatic and aromatic aldehyde alkali metal sulfoxylates such as formaldehyde sodium sulfoxylate (Longalite) and benzaldehyde sodium sulfoxylate. And alkali metals such as sodium hydrosulfite and magnesium hydrosulfite, hydrosulfites (dithionates) of alkaline earth metals, and hydroxyalkanesulfinates such as hydroxymethanesulfinate.

(Third component)
When producing the above phenol resin, for example, hydrochloric acid, sulfuric acid, orthophosphoric acid, boric acid, oxalic acid, formic acid, acetic acid, butyric acid, benzenesulfonic acid, phenolsulfonic acid, paratoluenesulfonic acid, naphthalene-α-sulfone Acids, inorganic or organic acids such as naphthalene-β-sulfonic acid, esters of organic acids such as dimethyl oxalate, acid anhydrides such as maleic anhydride, phthalic anhydride, ammonium chloride, ammonium sulfate, ammonium nitrate, ammonium oxalate , Ammonium salts such as ammonium acetate, ammonium phosphate, ammonium thiocyanate, ammonium imide sulfonate, monochloroacetic acid or its sodium salt, organic halides such as α, α'-dichlorohydrin, triethanolamine hydrochloride, aniline hydrochloride, etc. The amine hydrochloride, sa Urea adducts such as urea tyrate adduct, urea stearate adduct, urea heptanoate adduct, acidic substances such as N-trimethyltaurine, zinc chloride, ferric chloride, ammonia, amines, sodium hydroxide, potassium hydroxide, water Alkali metals such as barium oxide and calcium hydroxide, hydroxides of alkaline earth metals, oxides of alkaline earth metals such as lime, weak acid salts of alkali metals such as sodium carbonate, sodium sulfite, sodium acetate, sodium phosphate, etc. These alkaline substances may be mixed as a catalyst or a pH adjuster.

(Manufacture of phenolic resin)
The above phenol resin (initial condensate) can be produced by a conventional method. Specifically, (a) monohydric phenol and / or polyhydric phenol and aldehydes are condensed, (b) monohydric phenol. A method of condensing an initial condensate obtained by condensing an aldehyde with an initial condensate and / or an initial condensate obtained by condensing a polyhydric phenol and an aldehyde with a monohydric phenol and / or a polyhydric phenol; A method of condensing an initial condensate obtained by condensing phenol, a polyhydric phenol and an aldehyde with a monohydric phenol and / or polyhydric phenol; (d) an initial condensate obtained by condensing a monohydric phenol and an aldehyde. And an initial condensate obtained by condensing polyhydric phenol and aldehydes, and (e) an initial condensate obtained by condensing monohydric phenol and aldehydes. And beauty / or precondensate obtained by condensation of polyhydric phenols with aldehydes, and initial condensates of monohydric phenol and polyhydric phenol and aldehydes condensation can be produced by a method such as condensation.

In the present invention, a desirable phenolic resin is a phenol-alkylresorcin cocondensate. The phenol-alkylresorcin cocondensate is stable in an aqueous solution of the cocondensate (initial cocondensate) and is stored for a long time at room temperature as compared to a condensate (initial condensate) composed only of phenol. There is an advantage that you can. Moreover, the nonwoven fabric is impregnated with a non-woven fabric, and is stable when pre-cured to form a B state. The nonwoven fabric does not lose moldability even when stored for a long period of time. Furthermore, since alkylresorcin is highly reactive with aldehydes and captures and reacts with free aldehydes, it also has the advantage of reducing the amount of free aldehydes in the resin.
A desirable method for producing the phenol-alkyl resorcin cocondensate is to first react phenol with an aldehyde to produce a phenol resin initial condensate, and then add alkyl resorcin to the phenol resin initial condensate. It is the method of adding and reacting.

  For example, in the above-mentioned condensation of (a) monohydric phenol and / or polyhydric phenol and aldehydes, usually 0.2 to 3 mol of aldehydes per mol of monohydric phenol and aldehydes per mol of polyhydric phenol 0.1 to 0.8 mol of the compound and, if necessary, a solvent and a third component are added, and the mixture is heated and reacted at a liquid temperature of 55 to 100 ° C. for 8 to 20 hours. At this time, the whole amount of aldehydes may be added at the start of the reaction, or may be added in portions or continuously.

When the above-mentioned phenol resin initial condensate is sulfomethylated and / or sulfimethylated, a sulfomethylating agent and / or a sulfimethylating agent may be added to the initial condensate at an optional stage to form a phenolic compound and / or initial condensate. Sulfomethylation and / or sulfimethylation.
The addition of the sulfomethylating agent and / or the sulfymethylating agent may be performed at any stage before, during or after the condensation reaction.

  The total amount of the sulfomethylating agent and / or sulfmethylating agent is usually 0.001 to 1.5 mol with respect to 1 mol of the phenol compound. When it is 0.001 mol or less, the hydrophilicity of the phenol resin is not sufficient, and when it is 1.5 mol or more, the water resistance of the phenol resin is deteriorated. In order to satisfactorily maintain performance such as curability of the initial condensate to be produced and physical properties of the resin after curing, the content is preferably about 0.01 to 0.8 mol.

  The sulfomethylating agent and / or sulfimethylating agent added to sulfomethylate and / or sulfmethylate the initial condensate reacts with the methylol group of the initial condensate and / or the aromatic ring of the initial condensate, A sulfomethyl group and / or a sulfiamethyl group is introduced into the initial condensate.

  The aqueous solution of the initial condensation product of the phenol resin thus sulfomethylated and / or sulfimethylated is stable in a wide range from acidic (pH 1.0) to alkaline, and is cured in any acidic, neutral or alkaline region. I can do it. In particular, when cured on the acidic side, residual methylol groups are reduced, and the cured product is not decomposed to generate formaldehyde.

  Furthermore, in the present invention, as the phenol resin, if desired, urea, thiourea, melamine, thiomelamine, dicyandiamine, guanidine, guanamine, acetoguanamine, benzoguanamine, and 2,6-diamino-1,3-diamine amino resin An initial condensate composed of a monomer and / or the amino resin monomer may be added and co-condensed with the phenolic compound and / or the initial condensate.

In addition, a curing agent such as an aldehyde and / or an aldehyde donor or an alkylolated triazone derivative may be added and mixed with the initial condensate (including the initial cocondensate) of the phenol resin of the present invention.
As the aldehyde and / or aldehyde donor, the same aldehyde and / or aldehyde donor used in the production of an initial condensate (initial cocondensate) of a phenol resin is used. It can be obtained by reacting a urea compound, an amine, and an aldehyde and / or an aldehyde donor. Examples of the urea compounds used in the production of alkylolated triazone derivatives include alkyl ureas such as urea, thiourea and methylurea, alkylthioureas such as methylthiourea, phenylurea, naphthylurea, halogenated phenylurea, and nitrated alkyl. Examples thereof include urea alone or a mixture of two or more. A particularly desirable urea compound is urea or thiourea. In addition, amines such as aliphatic amines such as methylamine, ethylamine, propylamine, isopropylamine, butylamine and amylamine, amines such as benzylamine, furfurylamine, ethanolamine, ethylenediamine, hexamethylenediamine and hexamethylenetetramine, as well as ammonia. These are used alone or as a mixture of two or more. The aldehyde and / or aldehyde donor used in the production of the alkylolated triazone derivative is the same as the aldehyde and / or aldehyde donor used in the production of the initial condensate of the phenol resin.
For synthesizing the alkylolated triazone derivative, usually 0.1 to 1.2 mol of amines and / or ammonia and 1.5 to 4 of aldehyde and / or aldehyde donor are used with respect to 1 mol of urea compound. The reaction is carried out at a rate of 0.0 mol. In the above reaction, the order of addition is arbitrary, but as a preferred reaction method, the required amount of aldehyde and / or aldehyde donor is first charged into the reactor, and the amines are usually kept at a temperature of 60 ° C. or lower. In addition, there is a method in which a required amount of ammonia is gradually added, a required amount of a urea compound is further added, and the reaction is performed by stirring and heating at 80 to 90 ° C. for 2 to 3 hours. As the aldehyde and / or aldehyde donor, 37% formalin is usually used, but a part thereof may be replaced with paraformaldehyde in order to increase the concentration of the reaction product. When hexamethylenetetramine is used, a reaction product having a higher solid content can be obtained. The reaction of a urea compound, an amine and / or ammonia, and an aldehyde and / or aldehyde donor is usually carried out in an aqueous solution, but methanol, ethanol, isopropanol, n-butanol, An alcohol such as ethylene glycol or diethylene glycol may be used alone or as a mixture of two or more kinds, and a water-soluble organic solvent such as ketones such as acetone and methyl ethyl ketone may be used alone or as a mixture of two or more kinds. . The addition amount of the curing agent is 10 to 100 parts by mass with respect to 100 parts by mass of the initial condensate (initial cocondensate) of the phenol resin of the present invention in the case of aldehyde and aldehyde donor, and in the case of an alkylolated triazone derivative. It is 10-500 mass parts with respect to 100 mass parts of initial condensates (initial cocondensate) of the said phenol resin.

The synthetic resin of the present invention is usually prepared as a solution. In this solution, polyvinyl alcohol, sodium alginate, starch, starch derivative, glue, gelatin, blood powder, methylcellulose, carboxymethylcellulose, polyacrylate, polyacrylamide Water-soluble polymers and natural gums such as calcium carbonate, magnesium carbonate, barium sulfate, calcium sulfate, calcium sulfite, calcium phosphate, calcium hydroxide, magnesium hydroxide, aluminum hydroxide, magnesium oxide, titanium oxide, iron oxide, oxidation Zinc, alumina, silica, diatomaceous earth, dolomite, gypsum, talc, clay, asbestos, mica, calcium silicate, bentonite, white carbon, carbon black, iron powder, aluminum powder, glass powder, stone powder, synthetic resin powder, Fillers such as furnace slag, fly ash, cement, zirconia powder, wood powder, wheat flour, walnut powder, den powder, coconut husk powder, rice flour; surfactants; higher fatty acids such as stearic acid and palmitic acid, partimine alcohol, stearyl alcohol Higher alcohols such as butyl stearate, glycerol monostearate, fatty acid amides, natural waxes such as carnauba wax, synthetic waxes, pigments, dyes, flame retardants, flame retardants, insect repellents, Preservatives, anti-aging agents, ultraviolet absorbers, fluorescent dyes, surfactants, foaming agents, oil repellents, and the like may be added.

  When the non-woven fabric of the present invention is impregnated with a thermosetting resin, the non-woven fabric may be dried in advance and the thermosetting resin in the non-woven fabric may be in the B-state.

  In the nonwoven fabric of the present invention, polyolefin resin such as polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, etc., or modified polyolefin resin, polyvinyl chloride, polyurethane, polyester, polyester copolymer You may apply | coat and laminate | stack the powder and film of hot-melt-adhesives, such as coalescence, polyamide, a polyamide copolymer, a cellulose derivative, and polyvinyl ether.

The stretchable nonwoven fabric (1) of the present invention (see FIG. 1) is easily bonded without forming wrinkles on other members because the stretchability in the length and breadth is improved by the perforation (2) by the needle punch. Even when bonding to the surface of a member having irregularities, the stretchable nonwoven fabric can be cleanly bonded.
The stretchable nonwoven fabric (1) can be used, for example, as the skin material (1) of the interior material (3).

  Although the nonwoven fabric of this invention is manufactured by the spunbond method, you may use the nonwoven fabric obtained by a melt blow method and a calendar process as a nonwoven fabric of this invention other than that, for example.

[Interior material]
An interior material can be manufactured by adhering the stretchable nonwoven fabric of the present invention as a skin material to the surface of a base material and molding it into a predetermined shape.
Examples of the base material include polyester fibers, polyethylene fibers, polypropylene fibers, polyamide fibers, acrylic fibers, urethane fibers, polyvinyl chloride fibers, polyvinylidene chloride fibers, and synthetic fibers such as acetate fibers, pulp, cotton, palm fibers, Plant fiber such as hemp fiber, bamboo fiber, kenaf fiber, inorganic fiber such as glass fiber, carbon fiber, ceramic fiber, asbestos fiber, or scraps of fiber products using these fibers are recovered and recovered. Knitted fabrics, nonwoven fabrics, felts, and their laminates, or polyurethane (soft polyurethane, hard polyurethane), polyethylene, polypropylene, polyamide, polyester, polychlorinated, made of mixed fibers using one or more fibers Plastic open-celled bodies such as vinyl, plastic Sintered body or the like of Kubizu is used.
The base material includes polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl acetate, fluororesin, thermoplastic acrylic resin, thermoplastic polyester. Resins, thermoplastic polyamide resins, acrylonitrile-butadiene copolymers, styrene-butadiene copolymers, thermoplastic resins such as acrylonitrile-styrene-butadiene copolymers, urethane resins, melamine resins, urea resins, thermosetting acrylic resins, A thermosetting resin such as a phenol resin, a resorcin resin, an alkyl resorcin resin, an epoxy resin, or a thermosetting polyester may be impregnated.
When the base material is impregnated with the thermosetting resin, the base material may be dried in advance so that the thermosetting resin in the base material is in the B-state.

The base material and the skin material are bonded together by superimposing the skin material made of the stretchable nonwoven fabric of the present invention on the surface of the base material and hot pressing or cold pressing after heating.
When forming into a predetermined shape, it is desirable to carry out simultaneously with adhesion of a base material and a skin material. When molding is performed at the same time as bonding, the skin material expands and contracts and adheres to the substrate surface cleanly.

The interior material of the present invention is used for, for example, automotive parts such as door trims, dashboards, ceiling materials, hood insulators, engine covers, heat insulating materials or sound insulating materials, building materials for buildings, wall materials, heat insulating materials, sound insulating materials, etc. Is done.
Hereinafter, the present invention will be described with reference to examples. In addition, this invention is not limited only to the Example shown below.

[Example 1]
A nonwoven fabric (fineness: 3.5 dtex, basis weight: 40 g / m ² ) made of polyester fiber obtained by the spunbond method was obtained. Next, in order to provide porosity in the nonwoven fabric, the nonwoven fabric was press-contacted with a roll in which needles having a maximum thickness of 1 mm were randomly installed.
In the obtained nonwoven fabric, 15 holes / cm ² having a hole diameter of 0.1 mm to 0.3 mm were formed.
Furthermore, the non-woven fabric was impregnated with a phenol-formaldehyde initial condensate (solid content: 30% by mass) so that the solid content was 30% by mass. After impregnation, the nonwoven fabric was dried at 150 ° C. for 3 minutes and precure to obtain a stretchable nonwoven fabric.

[Example 2]
A stretchable nonwoven fabric was obtained in the same manner as in Example 1 except that 50 holes / cm ² having a pore diameter of 0.1 mm to 0.3 mm were formed in the nonwoven fabric.

Example 3
A stretchable nonwoven fabric was obtained in the same manner as in Example 1 except that 100 holes / cm ² with a pore diameter of 0.1 mm to 0.3 mm were formed in the nonwoven fabric.

[Comparative Example 1]
A stretchable nonwoven fabric was obtained in the same manner as in Example 1 except that 8 holes / cm ² of pores having a diameter of 0.1 mm to 0.3 mm were formed in the nonwoven fabric.

[Comparative Example 2]
A stretchable nonwoven fabric was obtained in the same manner as in Example 1 except that 110 holes / cm ² of holes having a diameter of 0.1 mm to 0.3 mm were formed on the nonwoven fabric.

〔test〕
The stretchable nonwoven fabric (1) obtained in Examples 1 to 3 and Comparative Examples 1 and 2 was used as a skin material (1A), and these skin materials (1A) were coated with a phenol-formaldehyde initial condensate and precured. Glass wool (base material) (7) (weight per unit area: 800 g / m ² , thickness: 50 mm), and a mold (3) comprising the upper mold (4) and the lower mold (5) shown in FIG. By press molding under the conditions of 200 ° C. and 60 seconds, a molded product (6) (thickness 5 mm) was obtained (see FIG. 3).
A visual test of the appearance of each of the obtained molded articles (6) was performed. The test results are shown in Table 1.

Example 4
A nonwoven fabric (fineness: 0.1 dtex, basis weight: 30 g / m ² ) made of polypropylene fiber obtained by the spunbond method was obtained. Next, in order to provide porosity in the nonwoven fabric, the nonwoven fabric was press-contacted with a roll in which needles having a maximum thickness of 1 mm were randomly installed.
In the obtained nonwoven fabric, 25 holes / cm ² having a hole diameter of 0.8 mm to 1.2 mm were formed.
Furthermore, the non-woven fabric was impregnated with a phenol-formaldehyde initial condensate (solid content: 40% by mass) so that the solid content was 25% by mass. After impregnation, the nonwoven fabric was dried at 150 ° C. for 3 minutes and precured to obtain a stretchable nonwoven fabric.
The obtained stretchable nonwoven fabric was used as a skin material, and the skin material was superimposed on glass wool (weight per unit area: 600 g / m ² , thickness: 40 mm) coated with a phenol-formaldehyde initial condensate at 210 ° C. The molded product was obtained by hot press molding into a predetermined shape for 45 seconds. The molded product was free from wrinkles and other appearance defects.

Example 5
A nonwoven fabric (fineness: 2.0 dtex, basis weight: 60 g / m ² ) made of polyester fiber obtained by the spunbond method was obtained. Next, in order to provide porosity in the nonwoven fabric, the nonwoven fabric was press-contacted with a roll in which needles having a maximum thickness of 1 mm were randomly installed.
In the obtained nonwoven fabric, 18 holes / cm ² having a hole diameter of 0.5 mm to 0.8 mm were formed.
Further, the above-mentioned nonwoven fabric was impregnated with the phenol-alkylresorcin-formaldehyde initial condensate (solid content: 40% by mass) used in Example 4 so as to have a solid content of 30% by mass, and A polyamide-based hot melt adhesive having a melting point of 130 ° C. and having a particle size of 200 mesh was spray-coated on the back surface of the nonwoven fabric. Thereafter, the nonwoven fabric was dried at 150 ° C. for 2 minutes to obtain a stretchable nonwoven fabric having a hot melt powder adhesive.

[Comparative Example 3]
A stretchable nonwoven fabric was obtained in the same manner as in Example 5 except that the pore diameter of the nonwoven fabric in Example 5 was changed to 2.1 to 2.4 mm.

[Comparative Example 4]
Using a mixed fiber consisting of 90% by mass of the polyester fiber used in Example 5 and 10% by mass of a low melting point polyester fiber (fineness: 2.0 dtex, softening point: 110 ° C.), a nonwoven fabric (weight per unit area) is obtained by needle punching. : 60 g / m ² ) was obtained.
The nonwoven fabric was impregnated with the phenol-alkylresorcin-formaldehyde initial condensate (solid content: 40% by mass) used in Example 5 so as to have a solid content of 30% by mass. The polyamide-based hot melt adhesive used in 1 was spray-coated. Thereafter, the nonwoven fabric was dried at 150 ° C. for 2 minutes to obtain a stretchable nonwoven fabric having a hot melt adhesive.

The elastic nonwoven fabric obtained in Example 5 and Comparative Examples 3 and 4 was used as a skin material, and the skin material was coated with phenol-formaldehyde initial condensate and pre-cured glass wool (weight per unit area: 1000 g / m ^2). And a thickness of 70 mm), and hot press-molded into a predetermined shape at 200 ° C. for 50 seconds to obtain a molded product. A visual test of the appearance of each of the obtained molded products was performed. The test results are shown in Table 2.

Since the nonwoven fabric obtained by the conventional spunbond method has no longitudinal and lateral elongation, when the nonwoven fabric is adhered to another substrate as a skin material, wrinkles are formed on the skin material of the uneven portion of the other substrate. It turns out that it is easy to enter and it is easy to produce poor adhesion (floating).
In addition, the nonwoven fabric obtained by the needle punching method has good elongation in the vertical and lateral directions and good adhesion to other substrates, but fluffing occurs on the surface of the nonwoven fabric, so the appearance of the resulting molded product is Deteriorate.
The appearance of the molded product using the stretchable nonwoven fabric of the present invention as a skin material is good, and the moldability is excellent.

The stretchable nonwoven fabric of the present invention includes, for example, automobile interior materials such as door trims, dashboards, ceiling materials, hood insulators, engine covers, heat insulating materials or sound insulating materials, building materials for buildings, wall materials, heat insulating materials, sound insulating materials, etc. Can be used as a skin material.

Perspective view of stretchable nonwoven fabric Illustration of mold Side cross section of molded product

Explanation of symbols

1 Stretch nonwoven fabric
2 (multiple) holes

Claims (2)

A non-woven fabric manufactured by the spunbond method is provided with a hole having a hole diameter of 0.1 mm to ² mm by a needle punch at a rate of 10 holes / cm ^{2 to} 100 holes / cm ² and impregnated with a thermosetting resin. A molding material comprising a stretchable nonwoven fabric. The molding material according to claim 1 is used as a skin material and adhered to the surface of the base material to form a predetermined shape. Interior material to be collected.