JP4856403B2 - Vehicle interior material and method for manufacturing the same - Google Patents

Description

  The present invention relates to a multi-layer fiber press board that is pressed and has a multi-layer structure of two or more layers, and relates to a multi-layer fiber press board in which the density of each layer is different, a manufacturing method thereof, and a fiber product using the multi-layer fiber press board. is there.

  Conventionally, for various uses such as building materials such as wall materials and floor materials, whiteboards used in offices and schools, partition boards used to partition spaces where advanced AV equipment is installed, and molded ceiling materials for automobiles. Board is being used. As such boards, veneer boards and press boards made of pulp and papermaking sludge have been known for a long time.

  Recently, a board in which only the surface layer is hardened has been proposed in order to attach a poster or the like to the surface of the board. For example, Patent Document 1 proposes laminating a film on a surface layer of a nonwoven fabric containing heat-sealing fibers. Patent Document 2 proposes a board that uses a heating conveyor belt and has a density of the front and back layers larger than that of the intermediate layer.

  However, the board with a film attached to the surface layer has a problem of lack of air permeability. On the other hand, a board that uses a heating conveyor belt and has a density of the front and back layers larger than that of the intermediate layer has a problem that it is difficult to control the density.

JP 2004-291549 A JP 2004-293019 A

  The present invention has been made in view of the above background, and its purpose is to provide a multilayer fiber press board that is breathable, has high surface hardness, is lightweight, has a different density of each layer, and can easily control the density of each layer. It is to provide a manufacturing method and a textile product.

  As a result of intensive studies to achieve the above-mentioned problems, the present inventors obtained a multilayer fiber press board by laminating and hot pressing a web composed of polyester-based fibers and heat-adhesive fibers, The density of the layer containing the heat-adhesive fiber in which the fiber-forming polymer having a low melting point is exposed on the fiber surface by making the melting points of the fiber-forming polymer exposed on the fiber surface of the heat-adhesive fiber included in each layer different from each other On the other hand, it has been found that the density of the layer containing the heat-adhesive fiber exposed to the fiber surface by the fiber-forming polymer having a high melting point is reduced, and considering the fiber arrangement etc. The present invention was completed by overlapping.

Thus, according to the present invention, “a multi-layer fiber press board that has been pressed and has a multilayer structure of two or more layers, including at least the following A layer and B layer, and the average density of the A layer is higher than the average density of the B layer: is also a large, and the average density of the layer a is in the range of 0.20~0.70g / cm ^3, and the average density of the layer B is in the range of 0.01~0.08g / cm ³ There is provided a vehicle interior material using a multilayer fiber pressboard characterized in that the A layer is positioned on the surface side .
(A layer)
Thermally-adhesive fiber (A2) having at least 5 to 80% by weight of polyester fiber (A1) and fiber-forming polymer a having a melting point 40 ° C. lower than the melting point of the polyester forming the polyester fiber exposed on the fiber surface It consists of 95 to 20% by weight, and part of the contact points between the heat-adhesive fibers (A2) and / or the heat-adhesive fibers (A2) and the polyester fibers (A1) are thermally bonded.
(B layer)
30% to 95% by weight of the polyester fiber (B1), and a fiber-forming polymer b having a melting point 40 ° C. or more lower than the melting point of the polyester forming the polyester fiber and 10 ° C. or more higher than the fiber-forming polymer a It consists of at least 70 to 5% by weight of the heat-adhesive fiber (B2) exposed on the fiber surface, and the contact point between the heat-adhesive fibers (B2) and / or the heat-adhesive fiber (B2) and the polyester fiber (B1). (T) is the total number of fibers in which a part of the contact points is thermally bonded and arranged parallel to the thickness direction of the B layer , and is perpendicular to the thickness direction of the B layer. When the total number of arranged fibers is (H), T / H is 1.5 or more.

In that case , it is preferable that the thickness of A layer exists in the range of 0.5 mm-5 mm. On the other hand, it is not preferable the thickness of the B layer is in the range of 2 to 30 mm.

Further, according to the present invention, “the fiber-forming polymer a having a polyester fiber (A1) 5 to 80% by weight and a melting point 40 ° C. lower than the melting point of the polyester forming the short fiber is exposed at least on the fiber surface. A web comprising 95 to 20% by weight of the heat-adhesive fiber (A2),
30% to 95% by weight of the polyester fiber (B1), and at least a fiber-forming polymer b having a melting point 40 ° C. or more lower than the melting point of the polyester forming the short fiber and 10 ° C. or more higher than the fiber-forming polymer a A web composed of 70 to 5% by weight of the heat-adhesive fiber (B2) exposed on the fiber surface;
The method for producing an interior material for a vehicle as described above, wherein at least the two are laminated and hot-pressed. Is provided.

  ADVANTAGE OF THE INVENTION According to this invention, the multilayer fiber press board which does not impair air permeability, is high in surface hardness, is lightweight, the density of each layer differs, and the density of each layer is easy to control, its manufacturing method, and a textile product are obtained.

  Hereinafter, embodiments of the present invention will be described in detail. First, as the polyester fiber (A1) contained in the A layer, polyethylene terephthalate, polybutylene terephthalate, polyhexamethylene terephthalate, polytetramethylene terephthalate, poly-1,4-dimethylcyclohexane terephthalate, polyethylene naphthalate, polypivalo Examples thereof include short fibers composed of lactones or copolymers thereof, mixed cotton of these short fibers, or composite short fibers composed of two or more of the above polymer components. Further, it may be a polyester side-by-side composite fiber having latent crimpability, a polyester fiber provided with a hydrophilic oil agent, a polyester fiber subjected to moisture absorption processing, a polymer-modified moisture absorption, or a water-absorbing polyester fiber. Among these, short fibers made of polyethylene terephthalate, polytrimethylene terephthalate, or polybutylene terephthalate are particularly preferable from the viewpoint of fiber forming property and the like.

  Such polyester fibers (A1) are preferably crimped. At this time, as a method for imparting crimps, spiral crimps are imparted using composite fibers obtained by bonding polymers having different heat shrinkage rates to side-by-side types, spiral crimps are imparted by anisotropic cooling, and the number of crimps is 3 Various methods such as imparting mechanical crimping by a conventional indentation crimper method so as to be ˜25 pieces / 25 mm (preferably 5-20 pieces / 25 mm) may be used, but from the viewpoint of bulkiness, production cost, etc. It is optimal to provide mechanical crimp.

  If the single yarn fineness of the polyester fiber (A1) is too small, the bulkiness and the resilience are lowered, and the card property may be lowered. On the other hand, if it is too large, the texture and touch may be lowered, so that it is preferably 0.8 to 40 (more preferably 1 to 30 dtex). The fiber length is preferably cut to 3 to 150 mm (more preferably 5 to 76 mm). Note that it is preferable that the airlaid method has a shorter fiber length and the card method has a longer fiber length. The single fiber cross-sectional shape of the polyester fiber (A1) may be any of a normal round shape, a flat shape, an irregular shape, a hollow shape, and the like.

  In the polyester polymer forming the polyester fiber (A1), various stabilizers, ultraviolet absorbers, thickening and branching agents, matting agents, coloring agents, and other various improving agents are blended as necessary. May be.

  On the other hand, the heat-adhesive fiber (A2) contained in the layer A has at least a fiber-forming polymer a having a melting point 40 ° C. lower than the melting point of the polyester forming the polyester fiber (A1) as a heat-adhesive component. There is no particular limitation as long as it is a heat-bondable fiber exposed on the fiber surface. If the difference in melting point between the fiber-forming polymer a and the polyester forming the polyester fiber is less than 40 ° C., the stability during the fusion processing by heat treatment is lowered and the productivity is insufficient, which is not preferable. Furthermore, there is a possibility that the mechanical properties of the polyester-based fiber and the heat-adhesive fiber are deteriorated. In the present invention, if the melting point is not clearly observed, the softening point is taken as the melting point.

  Examples of the fiber-forming polymer a include polyurethane elastomers, polyester elastomers, copolymer polyester polymers and copolymers thereof, polyolefin polymers and copolymers thereof, polyvinyl alcohol polymers, low melting point polyamides, and the like. be able to. Especially, when a copolyester polymer is used for the A layer, a hard layer is preferably obtained.

Examples of such copolyester polymers include aliphatic dicarboxylic acids such as adipic acid and sebacic acid, aromatic dicarboxylic acids such as phthalic acid, isophthalic acid and naphthalenedicarboxylic acid, and / or hexahydroterephthalic acid and hexahydroisophthalic acid. Contains a predetermined number of alicyclic dicarboxylic acids and aliphatic and alicyclic diols such as diethylene glycol, polyethylene glycol, propylene glycol, and paraxylene glycol, and oxyacids such as parahydroxybenzoic acid are added as desired. Examples include polyesters such as polyesters obtained by adding and copolymerizing isophthalic acid and 1,6-hexanediol in terephthalic acid and ethylene glycol.
In addition, various stabilizers, ultraviolet absorbers, thickening branching agents, matting agents, coloring agents, other various improving agents, and the like may be blended in the above-described polymer as necessary.

  The heat-bondable fiber (A2) may be composed of the fiber-forming polymer a alone, or has a fiber-forming polymer a and a melting point higher than that of the fiber-forming polymer a (preferably higher by 40 ° C. or more). It may be a composite fiber bonded with another fiber-forming polymer. In that case, examples of other fiber-forming polymers are preferably non-elastic polyesters such as polyethylene terephthalate, polytetramethylene terephthalate, and polytrimethylene terephthalate in terms of heat resistance, heat shrinkability, and fiber formation. In that case, it is preferable that the heat fusion component occupies at least a half of the surface area. The weight ratio is suitably in the range of 30/70 to 70/30 as a composite ratio of the heat fusion component and the counterpart component. As the form of the composite fiber, the heat-sealing component and the counterpart component are preferably side-by-side and core-sheath, more preferably core-sheath. In this core-sheath type composite fiber, the fiber-forming polymer a becomes the sheath part, but the core part may be concentric or eccentric. In particular, the heat-adhesive conjugate fiber having an eccentric shape is more preferable than the one having a concentric shape because a coiled elastic crimp is developed.

  In the heat-adhesive fiber (A2), the single yarn fineness is preferably 0.5 to 30 dtex (more preferably 2 to 13 dtex, particularly preferably 2 to 7 dtex). When the single yarn fineness is less than 0.5 dtex, the card spinning property in the fiber press board manufacturing process may be deteriorated. On the contrary, if the single yarn fineness is larger than 30 dtex, the entanglement property of the web is poor and the texture as a fiber press board may be deteriorated. Like the polyester fiber (A1), the heat-bondable fiber (A2) is preferably crimped. The number of crimps is 3-25 pieces / 25 mm (preferably 5-20 pieces / 25 mm). Further, the fiber length of the heat-bondable fiber (A2) is not particularly limited, but the fiber length may be cut to 3 to 150 mm (more preferably 5 to 76 mm) as in the case of the polyester fiber (A1). preferable.

  In the multilayer fiber press board of the present invention, the A layer is composed of 5 to 80% by weight of the polyester-based fiber (A1) and 95 to 20% by weight of the heat-adhesive fiber (A2). A part of the contact point and / or the contact point between the heat-adhesive fiber (A2) and the polyester fiber (A1) is thermally bonded.

  Here, when the ratio of the heat-bondable fibers (A2) is less than this range, the number of heat fixing points is reduced, not only the strength as a fiber pressboard product is lowered, but also the shape stability due to compression or the like. Decreasing and not preferable. On the other hand, when the ratio of the heat-adhesive conjugate fiber (A2) is more than this range, the shrinkage becomes large during heat treatment and wrinkles and irregularities are easily generated on the surface, which is not preferable.

The average density of the A layer is preferably in the range of 0.20 to 0.70 g / cm ³ . If the average density of the A layer is less than 0.20 g / cm ³ , sufficient hardness may not be obtained. Conversely, if the average density of the A layer is greater than 0.70 g / cm ³ , production may be difficult. The thickness of the A layer is preferably in the range of 0.5 mm to 5 mm.

In the multilayer fiber press board of the present invention, the polyester fiber (B1) contained in the B layer may be the same as the polyester fiber contained in the A layer.
Moreover, as the heat-adhesive fiber (B2) contained in the B layer, the melting point is 40 ° C. or more lower than the melting point of the polyester forming the polyester fiber (B1) and 10 ° C. or more higher than the fiber-forming polymer a. There is no particular limitation as long as the fiber-forming polymer b has a heat-adhesive fiber exposed at least on the fiber surface. If the melting point of the fiber-forming polymer b is not higher than the fiber-forming polymer a by 10 ° C. or more, the average density of the B layer cannot be made lower than that of the A layer, which is not preferable.

  Examples of such fiber-forming polymer b include polyurethane elastomers, polyester elastomers, copolymer polyester polymers and copolymers thereof, polyolefin polymers and copolymers thereof, polyvinyl alcohol polymers, low melting point polyamides, and the like. be able to. Adoption of these polymers is preferable because the elastic recovery and durability of the multilayer fiber pressboard are improved.

  Here, as the polyurethane-based elastomer, a low-melting-point polyol having a molecular weight of about 500 to 6000, such as dihydroxy polyether, dihydroxy polyester, dihydroxy polycarbonate, dihydroxy polyester amide, and the like, and an organic diisocyanate having a molecular weight of 500 or less, such as p, p'- Diphenyl methane diisocyanate, tolylene diisocyanate, isophorone diisocyanate hydrogenated diphenyl methane isocyanate, xylylene isocyanate, 2,6-diisocyanate methyl caproate, hexamethylene diisocyanate and the like, and chain extenders having a molecular weight of 500 or less, such as glycol amino alcohol Alternatively, it is a polymer obtained by reaction with triol. Among these polymers, particularly preferred is a polyurethane using polytetramethylene glycol, poly-ε-caprolactam or polybutylene adipate as a polyol. Examples of the organic diisocyanate in this case include p, p'-bishydroxyethoxybenzene and 1,4-butanediol.

  In addition, as a polyester-based elastomer, a polyetherester copolymer obtained by copolymerizing thermoplastic polyester as a hard segment and poly (alkylene oxide) glycol as a soft segment, more specifically, terephthalic acid, isophthalic acid, phthalic acid Alicyclic dicarboxylic acids such as naphthalene-2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid, diphenyl-4,4′-dicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, succinic acid, oxalic acid, At least one dicarboxylic acid selected from aliphatic dicarboxylic acids such as adipic acid, sebacic acid, dodecanedioic acid, dimer acid, or ester-forming derivatives thereof, 1,4-butanediol, ethylene glycol trimethylene glycol, Tetramethylene glycol, Aliphatic diols such as tamethylene glycol, hexamethylene glycol neopentyl glycol, decamethylene glycol, or alicyclic diols such as 1,1-cyclohexanedimethanol, 1,4-cyclohexanedimethanol, tricyclodecane methanol, or the like At least one diol component selected from ester-forming derivatives and the like, and polyethylene glycol, poly (1,2- and 1,3-polypropylene oxide) glycol, poly (tetramethylene oxide) having an average molecular weight of about 400 to 5000 ) Consists of at least one of poly (alkylene oxide) glycols such as glycols, copolymers of ethylene oxide and propylene oxide, copolymers of ethylene oxide and tetrahydrofuran, etc. It can be mentioned terpolymer.

  In particular, from the viewpoint of adhesiveness, temperature characteristics, and strength, a block copolymer polyether ester having polybutylene terephthalate as a hard component and polyoxybutylene glycol as a soft segment is preferable. In this case, the polyester portion constituting the hard segment is polybutylene terephthalate in which the main acid component is terephthalic acid and the main diol component is a butylene glycol component. Of course, part of this acid component (usually 30 mol% or less) may be substituted with another dicarboxylic acid component or oxycarboxylic acid component, and part of the glycol component (usually 30 mol% or less) is also butylene. It may be substituted with a dioxy component other than the glycol component. Further, the polyether portion constituting the soft segment may be a polyether substituted with a dioxy component other than butylene glycol.

Examples of the polyolefin polymer include low density polyethylene, high density polyethylene, and polypropylene.
In addition, various stabilizers, ultraviolet absorbers, thickening branching agents, matting agents, coloring agents, other various improving agents, and the like may be blended in the above-described polymer as necessary.

The heat-adhesive fiber (B2) contained in the B layer may be composed of the fiber-forming polymer b alone or higher than the fiber-forming polymer b and the fiber-forming polymer b (preferably higher by 40 ° C. or more). ) A composite fiber bonded with another fiber-forming polymer having a melting point may be used. In that case, examples of other fiber-forming polymers are preferably non-elastic polyesters such as polyethylene terephthalate, polytetramethylene terephthalate, and polytrimethylene terephthalate in terms of heat resistance, heat shrinkability, and fiber formation. In that case, it is preferable that the heat fusion component occupies at least a half of the surface area. The weight ratio is suitably in the range of 30/70 to 70/30 as a composite ratio of the heat fusion component and the counterpart component. As the form of the composite fiber, the heat-sealing component and the counterpart component are preferably side-by-side and core-sheath, more preferably core-sheath. In this core-sheath type composite fiber, the fiber-forming polymer b is a sheath part, but the core part may be concentric or eccentric. In particular, the heat-adhesive conjugate fiber having an eccentric shape is more preferable than the one having a concentric shape because a coiled elastic crimp is developed.
In the heat-adhesive fiber (B2) included in the B layer, the single yarn fineness, fiber length, number of crimps, and the like may be the same as those of the heat-adhesive fiber included in the A layer.

  In the multilayer fiber press board of the present invention, the B layer is composed of 30 to 95% by weight of the polyester-based fiber (B1) and 70 to 5% by weight of the heat-adhesive fiber (B2). A part of the contact point and / or the contact point between the heat-bondable fiber (B2) and the polyester fiber (B1) is thermally bonded.

  Here, when the ratio of the heat-bondable fibers (B2) is less than this range, it is not preferable because it is difficult to maintain the shape of the layer. On the other hand, when the ratio of the heat-adhesive conjugate fiber (B2) is more than this range, the shrinkage increases during the heat treatment processing, the density is increased, and the cushioning property and lightness are impaired.

The average density of the B layer is preferably in the range of 0.01 to 0.15 g / cm ³ . If the average density of the B layer is greater than 0.15 g / cm ³ , the B layer may become hard and cushioning may not be obtained, and at the same time, the weight will not be reduced. Conversely, if the average density of layer B is less than 0.01 g / cm ^3, it may be difficult to maintain the shape of the layer. Moreover, it is preferable that it is in the range of 2-30 mm as thickness of B layer.

  In this B layer, the total number of fibers arranged in parallel to the thickness direction of the B layer is (T), and the total number of fibers arranged perpendicular to the thickness direction of the B layer is (H) When T / H is 1.5 or more, since the rigidity in the thickness direction is increased, the A layer is preferentially pressed during molding, and the A layer is more likely to have a higher density. .

As a method of arranging the fibers in the thickness direction in this way, polyester fiber and heat-adhesive conjugate fiber are mixed and spun as a uniform web with a roller card, and then a heat treatment machine as shown in FIG. Preferred examples include a method in which the web is heated while being folded into an accordion to form a fixing point by heat fusion. For example, it can be produced by using an apparatus (such as a Struto equipment manufactured by Struto Co., Ltd., which is commercially available) disclosed in Japanese Patent Publication No. 2002-516932.
The A layer may be formed by the same method as the B layer.

In the multilayer fiber press board of the present invention, the number of layers is not limited as long as the A layer and the B layer are included. For example, two layers of the A layer and the B layer, or the A layer, the B layer, and the A layer. The three layers are suitable.
The multilayer fiber press board of the present invention can be manufactured by the following manufacturing method. That is, 5 to 80% by weight of the polyester fiber (A1) and a heat-bondable fiber in which a fiber-forming polymer a having a melting point lower by 40 ° C. or more than the melting point of the polyester forming the polyester fiber is exposed at least on the fiber surface. (A2) 95 to 20 wt% web (for layer A);
Fiber-forming polymer b having 30 to 95% by weight of the polyester fiber (B1) and a melting point 40 ° C. or more lower than the melting point of the polyester forming the polyester fiber and 10 ° C. or more higher than the fiber-forming polymer a A multilayer fiber pressboard of the present invention is obtained by laminating at least a web (for B layer) composed of 70 to 5% by weight of a heat-adhesive fiber (B2) exposed on the fiber surface and hot pressing the both. can get.

  For example, polyester-based fibers and heat-adhesive fibers can be blended and opened with a card or the like to form a web, or after a short fiber is dispersed with air using an air array method to form a web, the webs are laminated and heat treated to produce fibers. A method in which the gaps are fused and then heat-pressed with a calender roll or a heated molding die, a method in which the fibers are entangled with a needle punch and then processed with a heat calender roller having a certain gap, An example is a method in which a predetermined amount of web is packed in a mold having a predetermined shape, and compression and heat molding (heat press) is performed.

  In this way, when two or more webs are laminated and hot-pressed, the fiber-forming polymer having a low melting point is obtained by making the melting points of the fiber-forming polymers exposed on the fiber surface of the heat-bonding fibers contained in each layer different from each other. The density of the layer (A layer) containing the heat-adhesive fiber (A2) exposed on the fiber surface is increased, while the fiber-forming polymer having a high melting point is exposed to the heat-adhesive fiber (B2) exposed on the fiber surface. The density of the containing layer (B layer) becomes small, and the density of each layer can be easily controlled.

Here, before heat pressing, if the web is heat-treated and the fibers are fused together to form hard cotton, the density of the A layer can be reduced compared to the case where the web that has not been fused at all is directly hot pressed. It can be easily improved and is preferable. Further, it is preferable to arrange the fibers of the B layer in the thickness direction as described above, since the rigidity of the B layer is high, so that the A layer is further preferentially hot pressed and the density is improved. In addition, when the fibers are arranged in the thickness direction in this way, a cleaner shape can be obtained when a three-dimensional molded product is obtained. In addition, the metal mold | die used in the case of a hot press may heat up and down, and may heat only the metal mold | die of the A layer side.
In the multilayer fiber press board thus obtained, since the density of the A layer is larger than that of the B layer, the A layer is harder than the B layer.

  The multilayer fiber press board may be subjected to normal dyeing or raising. Furthermore, known functional processing such as water repellent processing, flameproof processing, flame retardant processing, and negative ion generation processing may be added. Furthermore, by using an adhesive resin or adhesive sheet, the woven or knitted fabric or nonwoven fabric is bonded to the surface side, or the same as when thermoforming, or the woven or knitted fabric or nonwoven fabric is bonded to the surface side without an adhesive layer. Can also be made excellent.

  Next, a textile product according to the present invention is a partition board, a vehicle interior material, a human body protector, a shoe core, and the multilayer fiber pressboard, wherein the layer A is positioned on the surface side. Any textile product selected from the group of insoles. In these textile products, since the surface side is hard, it is possible to stick a poster on the surface with pins.

Next, although the Example and comparative example of this invention are explained in full detail, this invention is not limited by these. In addition, each measurement item in an Example was measured with the following method.
(1) Melting point Using a differential thermal analyzer 990 manufactured by Du Pont, measured at a temperature increase of 20 ° C./min, and obtained a melting peak. If the melting temperature is not clearly observed, the melting point is the temperature at which the polymer softens and starts to flow (softening point) using a trace melting point measuring device (manufactured by Yanagimoto Seisakusho). In addition, the average value was calculated | required by n number 5.
(2) Number of crimps The number of crimps was measured by the method described in JIS L 1015 7.12. In addition, the average value was calculated | required by n number 5.
(3) T / H
The fiber structure is cut in the thickness direction, and the total number of fibers (0 ° ≦ θ ≦ 45 ° in FIG. 2) arranged in parallel to the thickness direction in the cross section is defined as (T). T / H was calculated with (H) being the total number of fibers (45 ° <θ ≦ 90 ° in FIG. 2) arranged perpendicular to the thickness direction of the structure. In addition, the measurement of the number was carried out by observing 30 fibers for each of 10 arbitrary positions with a transmission optical microscope, and counting the number.
(4) Average density Average density (g / cm < ³ >) was computed by the following formula.
Average density (g / cm ³ ) = Web weight (g / cm ² ) / Layer thickness (cm)
(5) Rigidity (surface hardness)
The surface hardness was measured with an Asker rubber hardness meter F type.
(6) Breathability Breathability was measured in accordance with JIS L 1096-79-6.27 Breathability Method A (Fragile type).

[Example 1]
As a copolyester of a thermal adhesive component, an acid component obtained by mixing terephthalic acid and isophthalic acid at 60/40 (mol%), and a diol component obtained by mixing ethylene glycol and diethylene glycol at 85/15 (mol%). A copolyester was obtained. Since the softening point of the copolyester was 110 ° C., the melting point was taken as 110 ° C. The pellet was dried under reduced pressure and then used for the sheath. On the other hand, polyethylene terephthalate having a glass transition point of 67 ° C. and a melting point of 256 ° C. is dried under reduced pressure, then the core is supplied to a core-sheath type composite melt spinning apparatus, and the spinning temperature is 290 ° C. at a composite ratio of 50/50 by volume. Melt spinning was performed from a spinneret having a spinning hole number of 450 at an amount of 650 g / min. An oil agent was applied and taken out at 900 m / min to obtain an unstretched core-sheath type composite fiber.

  The unstretched fibers are bundled to make a 110,000 dtex (100,000 denier) tow, first stretched 2.5 times in warm water at 72 ° C., and further stretched 1.15 times in warm water at 80 ° C. After applying the oiling agent, crimping was performed with an indentation type crimper naturally cooled to 35 ° C., and cut into a fiber length of 51 mm to obtain a heat-adhesive composite short fiber having a single yarn fineness of 4.4 dtex. The number of crimps at this time is 11 pieces / 25 mm.

60% (weight) of this heat-adhesive composite short fiber (A2), the thickness of a single fiber obtained by a conventional method is 11.7 dtex (10.5 denier), the fiber length is 64 mm, and the number of crimps is 8 / 210cm hollow cross-section polyethylene terephthalate short fiber (melting point of polyethylene terephthalate 256 ° C, hollow rate 32%) (A1) 40% (weight) is mixed with a card, using a roller card, Chloraire and air-through type heating equipment The heat-adhesive fibers (A2) are fused, and the contact points between the heat-adhesive fibers (A2) and / or a part of the contact points between the heat-adhesive fibers (A2) and the polyester fibers (A1) are thermally bonded. A hard cotton (for layer A) having a basis weight of 400 g / m ² was obtained.

On the other hand, 38% (by weight) of polybutylene terephthalate obtained by polymerizing an acid component obtained by mixing terephthalic acid and isophthalic acid at 80/20 (mol%) and tetramethylene glycol was further added to polybutylene terephthalate ( A molecular weight 2000) was reacted with 62% (weight) by heating to obtain a thermoplastic block copolymer polyether ester elastomer. The melting point of this thermoplastic elastomer was 152 ° C. The heat-adhesive composite short fiber (B2) 60 is the same as the heat-adhesive composite short fiber except that the thermoplastic elastomer is disposed in the sheath component and polybutylene terephthalate having a melting point of 230 ° C. is disposed in the core component. % (Weight) and a hollow cross section polyethylene terephthalate short fiber (polyethylene having a monofilament thickness of 11.7 dtex (10.5 denier), a fiber length of 64 mm, and a crimp number of 8/25 mm). By blending terephthalate with a melting point of 256 ° C., a hollow rate of 32%) (B1) of 40% (weight) with a card, and heat-treating using a strut facility, the basis weight is 600 g / m ² and T / H is 4.1. Hard cotton (for layer B) was obtained.

  Next, the layer A hard cotton is laminated on top and the layer B hard cotton is on the bottom, sandwiched between metal flat plates heated to 190 ° C., hot pressed, and cooled at room temperature. A multilayer fiber press board was obtained.

In the obtained multilayer fiber press board, as a whole, the basis weight was 1000 g / m ² , the thickness was 10 mm, the air permeability was 41 cm ³ / cm ² / s, the A layer thickness was 1.5 mm, and the A layer average density was 0.26 g / cm ³ , the thickness of the B layer was 8.5 mm, the average density of the B layer was 0.07 g / cm ³ , and the rigidity of the surface on the A layer side was 98.

  When the layer A side surface of such a multilayer fiber press board was pressed by hand, it was very hard, while the back side was soft. Moreover, when the partition board was produced using the multilayer fiber press board so that the A layer was positioned on the surface side, it was easy to attach the poster with a push pin.

[Example 2]
Stacked in Example 1, under the B layer, 'placed (for layer, A layer from the top, B layer, A A layer hardness of basis weight 200 g / m ² in the same formulation as cotton Katawata A)' layer A multilayer fiber press board was obtained in the same manner as in Example 1 except that.

In the obtained multilayer fiber press board, the overall weight is 1200 g / m ² , the thickness is 11 mm, the air permeability is 30 cm ³ / cm ² / s, the thickness of the A layer is 1.5 mm, and the average density of the A layer is 0.26 g / cm ³ , B layer thickness 8.5 mm, B layer average density 0.07 g / cm ³ , A ′ layer thickness 1.0 mm, A ′ layer average density 0.20 g / cm ³ , A layer side The surface rigidity was 98.

[Example 3]
In Example 1, regarding the heat-adhesive fiber for layer B (B2), an acid component obtained by mixing terephthalic acid and isophthalic acid at 80/20 (mol%) as a copolyester of the heat-adhesive component, and ethylene glycol Copolyester was obtained from a diol component mixed with tetramethylene glycol at 50/50 (mol%). The melting point of the copolyester was 155 ° C.

  This copolymer polyethylene terephthalate is placed in the sheath as a thermal adhesive component, while polyethylene terephthalate having a glass transition point of 67 ° C. and a melting point of 256 ° C. is placed in the core (single yarn fineness 4.4 dtex, fiber length 51 mm). A multilayer fiber press board was obtained in the same manner as in Example 1 except that was used.

In the obtained multilayer fiber press board, the overall weight is 950 g / m ² , the thickness is 9 mm, the air permeability is 35 cm ³ / cm ² / s, the thickness of the A layer is 2.0 mm, and the average density of the A layer is 0.20 g / cm ³ , the thickness of the B layer was 7.0 mm, the average density of the B layer was 0.08 g / cm ³ , and the rigidity of the surface on the A layer side was 97. The back surface had a cushion feeling.

[Example 4]
In Example 1, the hard cotton for layer A was produced by a strut facility, so that the fibers were arranged in the thickness direction (T / H was 4.8) and a kamaboko type mold was used. In the same manner as above, a multilayer fiber press board was obtained.
In the obtained multilayer fiber pressboard, the surface of the layer A side was a very hard and clean-shaped pressboard. The back surface had a cushion feeling.

[Comparative Example 1]
80% waste paper pulp and 20% paper sludge in a raw material weight ratio are kneaded with a pulper together with a large amount of water, and water is further added to this to produce a press board with a final thickness of 10 mm. The press board was produced through the drying process.
In the obtained press board as a whole, the basis weight was 2000 g / m ² , the thickness was 10 mm, the air permeability was 5 cm ³ / cm ² / s, the average density was 0.20 g / cm ³ , and the surface / back surface rigidity was 100.

[Comparative Example 2]
A 65% waste paper pulp, 20% paper sludge, 3.3% viscose rayon 15% viscose rayon, kneaded with a pulper, water is added to this, and the final thickness is 2mm. Paper was made to form a board, and a press board was obtained through a pressing and drying process.
In the obtained press board as a whole, the basis weight was 1800 g / m ² , the thickness was 10 mm, the air permeability was 10 cm ³ / cm ² / s, the average density was 0.18 g / cm ³ , and the surface / back surface rigidity was 100.

[Comparative Example 3]
In Example 1, a press board was obtained using only the A-layer hard cotton. In the obtained press board as a whole, the basis weight was 1500 g / m ² , the thickness was 7.5 mm, the air permeability was 8 cm ³ / cm ² / s, the average density was 0.20 g / cm ³ , and the rigidity of the front and back surfaces was 80. It was.

  According to the present invention, a multi-layer fiber press board that does not impair air permeability, has a different density and can easily control the density of each layer, and a manufacturing method thereof, and a textile product such as a partition board and a human body protector are obtained. Its industrial value is extremely large.

It is a side view which shows an example of the heat processing machine used by this invention. It is a schematic diagram for demonstrating the measuring method of T / H.

Explanation of symbols

1: Web 2: Conveyor 3: Heater 4: Fiber structure

Claims (4)

A multilayer fiber press board that is pressed and has a multilayer structure of two or more layers, and includes at least the following A layer and B layer, and the average density of the A layer is larger than the average density of the B layer, and the A layer multilayer fiber press average density of in the range of 0.20~0.70g / cm ^3, and the average density of the layer B is being in the range of 0.01~0.08g / cm ³ A vehicle interior material using a board so that the A layer is positioned on the surface side .
(A layer)
Thermally-adhesive fiber (A2) having at least 5 to 80% by weight of polyester fiber (A1) and fiber-forming polymer a having a melting point 40 ° C. lower than the melting point of the polyester forming the polyester fiber exposed on the fiber surface It consists of 95 to 20% by weight, and part of the contact points between the heat-adhesive fibers (A2) and / or the heat-adhesive fibers (A2) and the polyester fibers (A1) are thermally bonded.
(B layer)
30% to 95% by weight of the polyester fiber (B1), and a fiber-forming polymer b having a melting point 40 ° C. or more lower than the melting point of the polyester forming the polyester fiber and 10 ° C. or more higher than the fiber-forming polymer a It consists of at least 70 to 5% by weight of the heat-adhesive fiber (B2) exposed on the fiber surface, and the contact point between the heat-adhesive fibers (B2) and / or the heat-adhesive fiber (B2) and the polyester fiber (B1). (T) is the total number of fibers in which a part of the contact points is thermally bonded and arranged parallel to the thickness direction of the B layer , and is perpendicular to the thickness direction of the B layer. When the total number of arranged fibers is (H), T / H is 1.5 or more. The vehicle interior material according to claim 1, wherein the thickness of the A layer is within a range of 0.5 mm to 5 mm. The vehicle interior material according to claim 1 or 2, wherein the thickness of the B layer is in a range of 2 to 30 mm. Thermally-adhesive fiber (A2) having at least 5 to 80% by weight of polyester fiber (A1) and fiber-forming polymer a having a melting point 40 ° C. lower than the melting point of the polyester forming the polyester fiber exposed on the fiber surface A web of 95-20% by weight;
30% to 95% by weight of the polyester fiber (B1), and a fiber-forming polymer b having a melting point 40 ° C. or more lower than the melting point of the polyester forming the polyester fiber and 10 ° C. or more higher than the fiber-forming polymer a A web comprising at least 70 to 5% by weight of the heat-adhesive fiber (B2) exposed on the fiber surface;
The method for manufacturing an interior material for a vehicle according to claim 1, wherein both are laminated and hot-pressed at least.

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