JP5638865B2 - Composite fiber sheet, method for producing the same, and fiber product - Google Patents

Description

  The present invention relates to a composite fiber sheet excellent in not only cushioning properties but also three-dimensional appearance, a method for producing the same, and a fiber product using the composite fiber sheet.

Conventionally, in the field of vehicle chairs, a composite fiber sheet in which a polyurethane foam is joined to a woven or knitted fabric made of polyester fiber and a spunbond nonwoven fabric is joined, or a low-melting polyester binder and crimped polyester fiber A composite fiber sheet (for example, see Patent Document 1) in which a skin member made of polyester fibers is bonded to a polyester nonwoven fabric constituted by a polyester resin layer has been proposed.
However, the composite fiber sheet using polyurethane foam is not sufficient in terms of air permeability, and further has problems such as yellowing. On the other hand, in the composite fiber sheet using the polyester nonwoven fabric, since the raw material is all polyester, it is excellent in recyclability, but is not sufficient in terms of cushioning properties.
In recent years, in order to improve recyclability, breathability, cushioning, and molding followability, elastic composite fibers with non-elastic polyester crimped short fibers as a matrix and thermoplastic elastomer exposed on the fiber surface have been dispersed and mixed. A composite fiber structure (see, for example, Patent Document 2, Patent Document 3, Patent Document 4, and Patent Document 5) in which a fabric is bonded to an elastic fiber structure has been proposed.
However, recently, there has been a further demand for luxury orientation and it has not yet been satisfactory.

JP-A-6-270341 JP-A-8-230084 Japanese Patent Laid-Open No. 9-201481 JP-A-8-318066 Japanese Patent Publication No. 2006-103128

  The present invention has been made in view of the above-described background, and the object thereof is to provide a composite fiber sheet excellent in not only cushioning properties but also three-dimensional appearance, a method for producing the same, and a fiber product using the composite fiber sheet. There is to do.

Thus, according to the present invention, “a heat-adhesive composite in which a non-elastic crimped short fiber and a polymer having a melting point lower by 40 ° C. or more than the polymer constituting the non-elastic crimped short fiber are arranged on the surface as a heat-fusion component. The fixing points and / or the heat-adhesive composite shorts blended with the short fibers so as to have a weight ratio of 90/10 to 10/90 and heat-sealed in a state where the heat-adhesive composite short fibers intersect with each other. A composite fiber sheet comprising a fiber structure in which fibers and fixing points thermally fused in a state where the inelastic crimped short fibers intersect with each other and a fabric bonded to the fiber structure. Thus, a composite fiber sheet characterized by being embossed is provided.
At that time, it is preferable that the inelastic crimped short fibers and the heat-bondable composite short fibers are arranged in the thickness direction of the fiber structure. In addition, it is preferable that the heat-adhesive composite short fiber is a heat-adhesive composite short fiber composed of a thermoplastic elastomer having a melting point of 120 ° C. or more and an inelastic polyester, and the former is exposed at least on the fiber surface. Further, it is preferable that the inelastic crimped short fiber has a micro crimp formed of two kinds of polyesters different from each other in intrinsic viscosity and expressing latent crimps. Moreover, in the said fiber structure, it is preferable that the average density exists in the range of 0.010-0.10 g / cm < ³ >. Moreover, it is preferable that the said fabric consists of a polyester fiber.
Moreover, according to this invention, the manufacturing method of the said composite fiber sheet which performs embossing in the state which heated the said fiber structure and the fabric is provided.
Further, according to the present invention, the above-described composite fiber sheet is used, from the group consisting of a vehicle seat skin material, a vehicle ceiling material, a bust pad, a shoulder pad, a hip pad, an office chair, a partition, and a supporter. Any selected fiber product is provided.

  ADVANTAGE OF THE INVENTION According to this invention, not only cushioning property but the composite fiber sheet which is excellent also in a three-dimensional feeling, its manufacturing method, and the textiles using this composite fiber sheet are obtained.

It is a side view which shows an example of the heat processing machine for obtaining the fiber structure used by this invention. It is a side view of the composite fiber sheet after embossing. It is a figure for demonstrating the direction of the arrangement | sequence of a heat bondable composite staple fiber or an inelastic staple fiber in a fiber structure.

Hereinafter, embodiments of the present invention will be described in detail.
First, in the fiber structure used in the present invention, a non-elastic crimped short fiber and a polymer having a melting point lower by 40 ° C. or more than the polymer constituting the non-elastic crimped short fiber are arranged on the surface as a heat-sealing component. The fixing point and / or the heat that is mixed with the heat-adhesive composite short fibers so that the weight ratio is 90/10 to 10/90, and is heat-sealed in a state where the heat-adhesive composite short fibers cross each other. This is a fiber structure in which adhesive composite short fibers and the non-elastic crimped short fibers intersect with heat-bonded fixing points.

Here, examples of the inelastic crimped short fibers include polyesters such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polytrimethylene terephthalate (PTT), and polylactic acid (PLA). The short fiber which consists of these copolymers, the mixed cotton of these short fibers, or the composite short fiber which consists of 2 or more types of the said polymer component etc. can be mentioned. Examples of such polyester include material-recycled or chemical-recycled polyester, and polyethylene terephthalate using a monomer component obtained by using biomass, that is, a biological material as a raw material, described in JP-A-2009-091694. May be. Furthermore, the polyester obtained using the catalyst containing the specific phosphorus compound and titanium compound which are described in Unexamined-Japanese-Patent No. 2004-270097 and 2004-21268 may be sufficient. Further examples include polyamides such as nylon 6 and nylon 66, other polyamides, synthetic fibers such as polyolefin, acrylic and modacrylic, and rayon, and natural fibers such as silk, cotton, hemp and wool. Furthermore, the repellent fiber etc. by cloth, such as clothing and a vehicle seat, can also be used.
Among these, from the viewpoint of fiber forming property, preferably, short fibers made of polyethylene terephthalate, composite short fibers made of two or more of the above polymer components, and the like can be mentioned.

  In particular, the inelastic crimped short fibers are composed of two kinds of polyesters having different intrinsic viscosities, and 30 to 70/25 mm (preferably 40 to 65/25 mm) of microscopically manifested latent crimps. A composite short fiber having a crimp is preferred. By such a micro crimp, it has a structure rich in elasticity and elasticity like a spring. Further, since the fibers are intertwined in a complicated manner, the fiber structure has particularly excellent softness and elasticity. Furthermore, when the fibers are planted in the thickness direction as described later, the fibers can be closely entangled to prevent cracks between the webs, and the fiber structure can be prevented from being cut during the slicing process. This is preferable.

  Here, if the number of the microcrimps is less than 30/25 mm, sufficient softness and elasticity cannot be obtained, which is not preferable. On the contrary, if the number of the micro crimps is more than 60/25 mm, the heat shrinkage during the thermoforming process is large, so that troubles such as wrinkles and dimensional fluctuations are likely to occur and molding may be difficult. is there.

  The two kinds of polyesters different from each other in the intrinsic viscosity are not particularly limited as long as the microcrimp can be obtained, but the difference in intrinsic viscosity is preferably in the range of 0.1 to 0.4. If the intrinsic viscosity difference is smaller than 0.1, microcrimps are not sufficiently developed, and the number of microcrimps may be smaller than the above range. On the contrary, when the intrinsic viscosity difference is larger than 0.4, the number of micro crimps may be larger than the above range.

  Preferred examples of the two kinds of polyesters having different intrinsic viscosities include polyethylene terephthalate polyester, polybutylene terephthalate polyester, and polytrimethylene polyester. Here, the polyethylene-based polyester is based on all repeating units of the polyester, and the ethylene terephthalate repeating unit is 90 mol% or more (preferably 95 mol% or more), and the polytrimethylene terephthalate-based polyester is all the repeating units of the polyester. Is a trimethylene terephthalate repeating unit of 90 mol% or more (preferably 95 mol% or more), and a polybutylene terephthalate-based polyester is a polybutylene terephthalate repeating unit of 90 mol% or more (based on all repeating units of polyester) Polyester preferably occupying 95 mol% or more).

  In order to select two kinds of polyesters having different intrinsic viscosities, those having different degrees of polymerization in the same kind of polyesters and those having different acid components and diol components in the different kinds of polyesters may be selected.

  If necessary, the polyester may be copolymerized with a terephthalic acid component or an ethylene glycol component with a third component in a range of 5 mol% or less. For example, isophthalic acid, 5-sodium sulfoisophthalic acid , Aromatics such as naphthalenedicarboxylic acid, orthophthalic acid, diphenyldicarboxylic acid, diphenyletherdicarboxylic acid, diphenylsulfonedicarboxylic acid, benzophenonedicarboxylic acid, phenylindanedicarboxylic acid, metal salt of 5-sulfoxyisophthalic acid, phosphonium salt of 5-sulfoxyisophthalic acid Aliphatic dicarboxylic acids such as aliphatic dicarboxylic acid, adipic acid, heptanedioic acid, octanedioic acid, azelaic acid, sebacic acid, undecanedioic acid, dodecanedioic acid, cyclohexanedicarboxylic acid, dichlorohexanedimethylenedicarboxylic acid, etc. Aliphatic glycols such as dicarboxylic, trimethylene glycol, tetramethylene glycol, pentamethylene glycol, hexamethylene glycol, octamethylene glycol, decamethylene glycol, neopentylene glycol, diethylene glycol, triethylene glycol, polyethylene glycol, polytetramethylene glycol, Cycloaliphatic glycols such as cyclohexanediol and cyclohexanedimethanol, o-xylylene glycol, m-xylylene glycol, p-xylylene glycol, 1,4-bis (2-hydroxyethoxy) benzene, 1,4-bis ( 2-hydroxyethoxyethoxy) benzene, 4,4′-bis (2-hydroxyethoxy) biphenyl, 4,4′-bis (2-hydroxyethoxyethoxy) Phenyl, 2,2-bis [4- (2-hydroxyethoxy) phenyl] propane, 2,2-bis [4- (2-hydroxyethoxyethoxy) phenyl] propane, 1,3-bis (2-hydroxyethoxy) Benzene, 1,3-bis (2-hydroxyethoxyethoxy) benzene, 1,2-bis (2-hydroxyethoxy) benzene, 1,2-bis (2-hydroxyethoxyethoxy) benzene, 4,4′-bis ( Aromatic glycols such as 2-hydroxyethoxy) diphenylsulfone and 4,4′-bis (2-hydroxyethoxyethoxy) diphenylsulfone, hydroquinone, 2,2-bis (4-hydroxyphenyl) propane, resorcin, catechol, dihydroxynaphthalene , Dihydroxybiphenyl, dihydroxydiphenyl sulfone And the like. These may be used alone or in combination of two or more.

  Further, in the polyester, a small amount of additives as necessary, for example, lubricants, pigments, dyes, antioxidants, solid phase polymerization accelerators, fluorescent brighteners, antistatic agents, antibacterial agents, ultraviolet absorbers, A light stabilizer, a heat stabilizer, a light-shielding agent, a matting agent, and the like may be contained. In particular, titanium oxide or the like is preferably added as a matting agent.

The composite short fiber preferably has a side-by-side composite form or an eccentric core-sheath composite form. Among these, the side-by-side composite form is particularly preferably used, and two kinds of polyesters having different intrinsic viscosities are appropriately selected and bonded to each other so as to have latent crimps. Crimps develop and microcrimps are obtained.
Here, the weight ratio of the two polyesters is preferably 20:80 to 80:20 (more preferably 40:60 to 60:40).

  In the non-elastic crimped short fibers, as a method for imparting crimps, a spiral crimp is imparted by using a composite fiber in which polymers having different heat shrinkage rates are bonded to a side-by-side type, and spiral crimp is imparted by anisotropic cooling. Various methods may be used, such as applying mechanical crimping by an ordinary indentation crimper method so that the number of crimps is 3 to 40 pieces / 2.54 cm (preferably 7 to 15 pieces / 2.54 cm). From the viewpoint of bulkiness, production cost, etc., it is optimal to impart mechanical crimp.

  In the non-elastic crimped short fiber, the single fiber diameter is preferably in the range of 10 to 100 μm. If the single fiber diameter is smaller than 10 μm, sufficient rigidity may not be obtained and handling may be difficult. On the other hand, if the diameter of the single fiber is larger than 100 μm, the appearance uniformity may be insufficient. In the case of polyethylene terephthalate, the single fiber fineness is preferably in the range of 1.3 to 90 dtex.

  The single fiber cross-sectional shape of the inelastic crimped short fiber may be a normal round cross section, or an irregular cross section such as a triangle, a square, or a flat shape. In addition, when the single fiber cross-sectional shape is atypical, the single fiber diameter uses a value converted to a round cross section. Furthermore, in the case of a round hollow cross section, the outer diameter dimension shall be measured.

  The fiber length of the inelastic crimped short fiber is preferably in the range of 3 to 100 mm. If the fiber length is less than 3 mm, sufficient rigidity may not be obtained. Conversely, if the fiber length is greater than 100 mm, process stability may be impaired.

  The fiber structure includes the inelastic crimped short fibers and the heat-bondable composite short fibers. In that case, the inelastic crimped short fiber may be composed of a fiber having a micro crimp in which the latent crimp as described above is expressed and / or another fiber.

  Next, the heat-sealing component of the heat-adhesive composite staple fiber needs to have a melting point that is 40 ° C. or more (preferably 70 ° C. or more) lower than the polymer component constituting the inelastic crimped staple fiber. If this temperature difference is less than 40 ° C., the adhesion becomes insufficient, and the fiber structure is hard to handle and has no possibility of achieving the object of the present invention.

  Here, examples of the polymer disposed as the heat-fusion component include polyurethane elastomers, polyester elastomers, inelastic polyester polymer copolymers, polyolefin polymers and copolymers thereof, polyvinyl alcohol polymers, and the like. Can do.

  Among these, polyurethane elastomers include low melting point polyols having a molecular weight of about 500 to 6,000, such as dihydroxy polyether, dihydroxy polyester, dihydroxy polycarbonate, dihydroxy polyester amide, and the like, and organic diisocyanates 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 It is a polymer obtained by reaction with glycol amino alcohol or 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.

  Polyester elastomers include polyether ester copolymers obtained by copolymerizing thermoplastic polyester as a hard segment and poly (alkylene oxide) glycol as a soft segment, and more specifically, terephthalic acid, isophthalic acid, phthalate. Alicyclic dicarboxylic acids such as acid, 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 and dimer acid, or ester-forming derivatives thereof, 1,4-butanediol, ethylene glycol trimethylene glycol , Tetramethylene glycol Aliphatic diols such as pentamethylene 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 the ester-forming derivatives, and the like, and polyethylene glycol, poly (1,2- and 1,3-polypropylene oxide) glycol having an average molecular weight of about 400 to 5,000, poly ( Tetramethylene oxide) glycol, ethylene oxide / propylene oxide copolymer, ethylene oxide / tetrahydrofuran copolymer, etc. It can be mentioned terpolymer that.

  In particular, from the viewpoint of adhesiveness, temperature characteristics, and strength, block copolymer polyether esters having polybutylene terephthalate as a hard component and polyoxybutylene glycol as a soft segment are 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, a part of this acid component (usually 30 mol% or less) may be substituted with another dicarboxylic acid component or an oxycarboxylic acid component, and similarly a part of the glycol component (usually 30 mol% or less). May be substituted with a dioxy component other than the butylene 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 copolymer polyester polymers (copolymers of inelastic polyester 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 hexa Contains a predetermined number of alicyclic dicarboxylic acids such as hydroterephthalic acid and hexahydroisophthalic acid, and aliphatic and alicyclic diols such as diethylene glycol, polyethylene glycol, propylene glycol, and paraxylene glycol. Examples thereof include copolymerized esters to which oxyacids such as hydroxybenzoic acid are added. For example, polyester obtained by adding and copolymerizing isophthalic acid and 1,6-hexanediol in terephthalic acid and ethylene glycol can be used.

Examples of the polyolefin polymer include low density polyethylene, high density polyethylene, polypropylene, and polymers obtained by modifying them.
Among the above heat-sealing components, an elastomeric polymer is particularly preferable from the viewpoint of cushioning properties and durability.

  In the above-mentioned polymer, various stabilizers, ultraviolet absorbers, thickening and branching agents, matting agents, colorants and various other improving agents may be blended as necessary.

  In the heat-bondable composite short fiber, the non-elastic polyester as described above is preferably exemplified as the counterpart component of the heat-sealing component. In that case, it is preferable that the heat fusion component occupies at least a half of the surface area. It is appropriate that the weight ratio of the heat fusion component and the counterpart component is in the range of 10/90 to 70/30 as a composite ratio. Although it does not specifically limit as a form of a heat bondable composite staple fiber, It is preferable that a heat-fusion component and the other party component are a side-by-side and a core-sheath type, More preferably, it is a core-sheath type. In this core-sheath type heat-adhesive composite short fiber, the heat fusion component is the sheath portion and the counterpart component is the core portion, but the core portion may be concentric or eccentric.

  In such a heat-adhesive composite short fiber, the single fiber diameter is preferably in the range of 10 to 70 μm. The single yarn fineness is preferably in the range of 2 to 40 dtex. Such heat-adhesive composite short fibers are preferably cut to a fiber length of 3 to 100 mm.

  In the present invention, the non-elastic crimped short fibers and the heat-adhesive composite short fibers are mixed and heat-treated, so that the heat-adhesive composite short fibers are heat-sealed in a crossed state, and A fiber structure is formed in which the heat-bonded composite short fibers and the inelastic crimped short fibers intersect with heat-bonded fixing points.

  At this time, the weight ratio between the inelastic crimped short fibers and the heat-bonded composite short fibers needs to be 90/10 to 10/90. The weight ratio is preferably 60/40 to 20/80. When the ratio of the heat-bonding composite short fibers is less than this range, the fixing points are extremely reduced, the fiber structure is not loose, and the moldability is poor. On the other hand, when the ratio of the heat-bonding composite short fibers is larger than this range, the number of bonding points becomes excessive, and the handling property and moldability in the heat treatment process are lowered.

In the fiber structure, it is preferable that the inelastic crimped short fibers and the heat-bondable composite short fibers are arranged in the thickness direction of the fiber structure. When fibers are arranged in the thickness direction of the fiber structure, the embossed pattern is generally pushed in the thickness direction of the fiber during embossing. However, since only the convex part of the emboss is deformed and a clean pattern is easy to enter, and the concave part of the emboss is arranged in the thickness direction, the fiber pushes up the concave part conversely, and the difference in unevenness is clear Therefore, the three-dimensional effect is expressed and it is preferable. Cross-ray nonwoven fabrics and urethane products are less susceptible to embossing due to the fibers around the embossed part and the resilience of urethane.
Here, “arranged in the thickness direction” means that the total number of fibers arranged in parallel to the thickness direction of the fiber structure is (T), and the thickness of the fiber structure When the total number of fibers arranged perpendicular to the direction is (W), T / W is 1.5 or more.

A method for producing such a fiber structure is not particularly limited, and a conventionally known method may be arbitrarily employed. For example, a non-elastic crimped short fiber and a heat-bondable composite short fiber are mixed to form a roller card. As shown in FIG. 1, after spinning as a uniform web, the web is folded parallel to the thickness direction using a cross lay, etc., then subjected to needle punching if necessary, and then heat-treated. It can be produced by using a STRUTO equipment manufactured by STRUTO Corporation, folding the web after the roller card into an accordion, and then heat-treating and bonding the fibers. Furthermore, short cut length fibers can also be prepared by using a heat-treated after forming a web using an air laid equipment of Dow-Web.
In FIG. 1, reference numeral 1 is a web, reference numeral 2 is a conveyor, reference numeral 3 is a heater, and reference numeral 4 is a fiber structure.

The average density of the fiber structure thus obtained is preferably in the range of 0.010 to 0.10 g / cm ³ . If the density is less than 0.010 g / cm ³ , the composite fiber sheet may be too soft and difficult to handle. On the other hand, if it exceeds 0.10 g / cm ³ , it becomes plate-shaped and softness may be impaired. The density can also be adjusted by pressing or the like. Further, if necessary, this fiber structure can be used by cutting it with a slicer facility or the like substantially perpendicularly to the thickness direction.

Furthermore, if necessary, a hot melt type resin binder that is melted and bonded for the first time by heat may be applied to the surface of the fiber structure in the form of powder, sheet, or net. The resin binder may be a urethane-based or acrylic-based resin, but the same polyester-based adhesive or adhesive sheet as the fiber structure is preferable from the viewpoint of recyclability. Further, other fabrics such as a woven fabric and a non-woven fabric can be bonded to the side opposite to the surface to be bonded to the fabric, if necessary. The amount of the resin binder, usually, 10 to 80 g / ^{m 2,} preferably 20 to 40 g / ^{m 2} approximately.

In the composite fiber sheet of the present invention, the cloth to be bonded is preferably a cloth made of polyester fiber having a melting point higher than that of the resin binder, but is not particularly limited. The composition of the fabric is preferably made of polyethylene terephthalate, polytrimethylene terephthalate, or a composite thereof. The fabric is preferably a woven or knitted fabric, but may be a nonwoven fabric or the like. Note that the bonding surface may be subjected to processing such as buffing. The fabric 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.
In addition, the fabric weight of a fabric is 100-600 g / m < ² > normally, Preferably it is about 200-400 g / m < ² >.

Next, the fiber structure and the fabric are prepared, and the fiber structure and the fabric are bonded and embossed. At that time, it is preferable to perform embossing in a state where the fiber structure and the fabric are preheated or preheated respectively.
Here, the preheating method is not particularly limited, but heating by a hot roll, heating by far infrared rays, heating by a gas burner or the like is possible, and embossing is preferably performed immediately after heating.
The preheating temperature is preferably 160 to 230 ° C., and the time is preferably 10 to 60 seconds. Further, the embossing is preferably heat embossing. The embossing roll temperature is preferably 190 to 230 ° C., the time is 10 to 60 seconds, and the linear pressure is preferably 50 to 170 kg / cm. Further, the pattern area ratio is preferably 5% or more. At that time, the clearance and pressure of the roll can be changed according to the target thickness. Then wind up.

Prior to the bonding of the fiber structure and the fabric, at the same time as the bonding, or after the bonding, on the opposite side of the bonded fabric, for example, as shown in FIG. Other fabrics such as woven fabric and knitted fabric may be bonded together. In this way, the fibers constituting the fiber structure do not fray, and the unevenness can be changed by changing the balance of heat shrinkage between the front side fabric and the back side nonwoven fabric, woven fabric, or knitted fabric. There is also an advantage of being able to do it. The basis weight of the other fabric is usually about 15 to 50 g / m ² .
In addition, as long as the method of bonding the lower surface of a fiber structure and another fabric is the same method as the above, or the state which has adhered lightly, it may not be an adhesive agent.

  The side view of the composite fiber sheet which is one embodiment of this invention is shown in FIG. In this embodiment, embossing is performed simultaneously with the bonding of the fiber structure 4 and the fabric 5, and the nonwoven fabric 6 is separately bonded to the lower surface of the fiber structure 4.

  The composite fiber sheet thus obtained contains the fiber structure and the fabric and is embossed, so that it is excellent not only in cushioning properties but also in three-dimensionality. In particular, when the inelastic crimped short fibers and the heat-bondable composite short fibers are arranged in the thickness direction of the fiber structure, the embossing can be easily performed because the heat embossed pattern is easily deformed. In addition, the adhesion between the fabric and the fiber structure is improved. Furthermore, after embossing, since the fibers are arranged in the thickness direction, the fabric having a low embossed pattern is pushed up, so that a three-dimensional appearance can be obtained.

  Such a composite fiber sheet can be sewed as a sheet and used as a skin material (wading) of a urethane pad of a vehicle, or can be used as a molded product using a mold. For example, car ceiling materials, bust pads, shoulder pads, hip pads, etc., office chairs, trains, airplane seats, and partitions and supporters that require cushioning. It can also be used for a structure having a surface covered with a cloth.

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 to obtain a melting peak. When the melting temperature was not clearly observed, the melting point was defined as the temperature at which the polymer softened and started to flow (softening point) using a micro melting point measuring device (manufactured by Yanagimoto Seisakusho). In addition, the average value was calculated | required by n number 5.
(2) Microcrimp, number of crimps 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 / W
The fiber structure is cut in the thickness direction, and in its cross section, the heat-adhesive composite short fiber A and the matrix fiber B (0 ° ≦ θ ≦ 45 ° in FIG. 3) are arranged parallel to the thickness direction. ) Is the total number of thermal adhesive composite short fibers A and matrix fibers B (45 ° <θ ≦ 90 ° in FIG. 3) arranged perpendicular to the thickness direction of the fiber structure. T / W was calculated with W being the total number. 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.
In FIG. 3, reference numeral F is a heat-adhesive composite short fiber or inelastic crimped short fiber, reference numeral _DT is a thickness direction of the fiber structure, and reference sign D _F is a heat-adhesive composite short fiber or inelastic crimped short fiber. Indicates the direction of arrangement.

(4) Intrinsic viscosity Measured at 35 ° C. using orthochlorophenol as a solvent. In addition, the average value was calculated | required by n number 5.
(5) Density The density was measured according to JIS K-6401. In addition, the average value was calculated | required by n number 5.
(6) Appearance of the fabric surface The appearance of the fabric surface of the composite fiber sheet was determined by visual judgment in terms of the flatness of the surface, in three stages of ○, Δ, and ×.
○: The surface is very three-dimensional.
(Triangle | delta): There exists a somewhat three-dimensional feeling on the surface.
X: There is no stereoscopic effect on the surface.

[Example 1]
Core / sheath type thermo-adhesive composite short fiber having a single yarn fineness of 6.6 dtex and a fiber length of 51 mm using a thermoplastic polyetherester elastomer having a melting point of 154 ° C. as a sheath component and a melting point of 230 ° C. polybutylene terephthalate as a core component (Core / sheath ratio = 60/40: weight ratio) and a hollow polyethylene terephthalate fiber (non-elastic crimped short fiber) having a single-filament fineness of 13.3 dtex and a fiber length of 64 mm having three-dimensional crimps by anisotropic cooling, 70:30 1 in the order of roller card, cross lay, and roller card. Next, using the Struto equipment made by Struto, shown in FIG. 1, fold the web as shown in FIG. After arranging in the direction (T / W = 4.7, see also FIG. 3), a fiber structure is obtained by thermally bonding the fibers in a heat treatment furnace at a temperature of 200 ° C. .
The obtained fiber structure had a thickness of 10 mm and a density of 20 kg / m ³ . Furthermore, 100% polyester short fibers of 2.2 dtex are opened, passed through a roller card to form a thin sheet, and the fibers are entangled with a water jet needle to produce a low-weight nonwoven fabric with a basis weight of 20 g / m ² , laminating equipment And bonded to the fiber structure. In this case, a polyester powder (spraying amount: 20 g / m ² ) was used for adhesion.

On the other hand, an automotive skin material (woven fabric made of only polyethylene terephthalate fiber having a basis weight of 300 g / m ² , a thickness of 1.5 mm) obtained by a conventional method is superposed on the above fiber structure, and the temperature of the base material is 225 After indirectly passing through the heating roll at 40 ° C. for 40 seconds, it was immediately embossed into a heated embossing roll having a temperature of 210 ° C. and a linear pressure of 130 kg / cm for 30 seconds and then cooled. The embossed pattern area ratio is 6.5%. Table 1 shows the physical properties of the obtained composite fiber sheet.
Subsequently, when the composite fiber sheet was used as an automobile skin material (wading) and a railcar skin material (wading), it was excellent not only in cushioning properties but also in a three-dimensional effect.

[Example 2]
The heat-adhesive composite short fibers are the same as those used in Example 1, and as non-elastic crimped short fibers, polyethylene terephthalate (melting point 256 ° C.) having an intrinsic viscosity of 0.65 as high-viscosity polyester, and polyester as low-viscosity side A side-by-side type composite fiber yarn was spun by a conventional method using polyethylene terephthalate having an intrinsic viscosity of 0.45 (melting point: 256 ° C.) (inherent viscosity difference: 0.20) so that the weight ratio was 50/50. After this side-by-side type composite fiber yarn is stretched approximately twice to give a surface treatment agent (oil agent), 10 crimps / 25 mm of mechanical crimps are applied using a normal crimper device, and further cut to 51 mm to form a matrix fiber. As B, an inelastic crimped short fiber having a latent crimping performance of a single yarn fineness of 5.0 dtex was obtained.

50% (weight) of the heat-adhesive composite short fibers and 50% (weight) of the non-elastic crimped short fibers are mixed, and a fiber structure (T / W = 3.9) is obtained through the same process as in Example 1. , Thickness 9 mm, density 25 kg / m ³ ). Moreover, it was thin and the nonwoven fabric was bonded together like Example 1. In addition, a polyester tented crimped yarn is used as the outer material, a polyester tricot knitted fabric (a fabric weight of 300 g / m ² , a thickness of 1.5 mm) is used as the lining, and the polyester is placed between the fiber structure and the fabric. Type net-like heat-bonding melt sheet (manufactured by Kurashiki Boseki Co., Ltd., span fab, basis weight 25 g / m ² ) is inserted into 3 layers, indirectly heated to a 225 ° C. heating roll for 40 seconds as a preheating of the substrate, and then immediately heated to temperature It was embossed for 30 seconds on a heated embossing roll at 210 ° C. and a linear pressure of 130 kg / cm for cooling. Table 1 shows the physical properties of the obtained composite fiber sheet.
Subsequently, when the composite fiber sheet was used as an automobile skin material (wading) and a railcar skin material (wading), it was excellent not only in cushioning properties but also in a three-dimensional effect.

[Comparative Example 1]
In Example 2, embossing was performed in the same manner as in Example, using a urethane foam sheet (Achilles, thickness 5 mm, basis weight 110 g / m ² ) instead of the fiber structure. Table 1 shows the physical properties of the obtained composite fiber sheet.

[Example 3]
In Example 1, instead of an automobile skin material, a non-woven fabric (mesh weight: 150 g / m) obtained by spreading 100% black polyester short fibers of 2.2 dtex and laminating thin webs with a roller card, crosslay, and needle punch. ² ) was prepared and the same processing as in Example 1 was performed. Table 1 shows the physical properties of the obtained composite fiber sheet.

  The composite fiber sheet obtained by the present invention is required to have a cushioning property, such as a car ceiling material, a bust pad, a shoulder pad, a pad such as a hip pad, a seat for an office chair, a train, an airplane, etc. It can be used for a partition or supporter that has a fiber structure inside and whose surface is covered with a cloth.

DESCRIPTION OF SYMBOLS 1 Web 2 Conveyor 3 Heater 4 Fiber structure 5 Fabric 6 Non-woven fabric F Thermal adhesive composite short fiber or inelastic crimped short fiber _DT Thickness direction of _T fiber structure _DF Thermal adhesive composite short fiber or inelastic crimped short fiber Array direction

Claims (7)

The weight ratio of the inelastic crimped short fiber and the heat-adhesive composite short fiber in which a polymer having a melting point lower by 40 ° C. or more than the polymer constituting the inelastic crimped short fiber is disposed on the surface as a heat-fusible component / 10 to 10/90 blended and heat-bonded in a state where the heat-adhesive composite short fibers cross each other and / or the heat-adhesive composite short fibers and the inelastic crimped short fibers The fiber structure is formed by interspersing the fixing points that are heat-sealed in the state of crossing and the inelastic crimped short fibers and the heat- bondable composite short fibers arranged in the thickness direction of the fiber structure. A composite fiber sheet comprising a body and a fabric bonded to the fiber structure , wherein the composite fiber sheet is embossed. A thermoplastic elastomer thermally adhesive composite short fibers have a melting point of at least 120 ° C., consists of a non-elastic polyester, a thermally adhesive composite short fibers exposed on at least the fiber surface is the former, the composite of claim 1 Fiber sheet. 3. The composite fiber sheet according to claim 1 , wherein the inelastic crimped short fibers are made of two kinds of polyesters having different intrinsic viscosities, and have a micro crimp formed of latent crimps. The composite fiber sheet according to any one of claims 1 to 3 , wherein the fiber structure has an average density within a range of 0.010 to 0.10 g / cm ³ . The composite fiber sheet according to any one of claims 1 to 4 , wherein the fabric is made of polyester fibers. The manufacturing method of the composite fiber sheet in any one of Claims 1-5 which performs embossing in the state which heated the said fiber structure and the fabric. A group consisting of a skin material for a vehicle seat, a ceiling material for a vehicle, a bust pad, a shoulder pad, a hip pad, an office chair, a partition, and a supporter, comprising the composite fiber sheet according to any one of claims 1 to 5. Any textile product selected from.

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