JP5678987B2 - Nonwoven fabric for reinforcing foam molded products and products using the same - Google Patents
Nonwoven fabric for reinforcing foam molded products and products using the same Download PDFInfo
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本発明は、発泡成形品の補強布に用いられる不織布に関するものであり、特に車両用座席に用いられるシートパッドを補強するための発泡成形品補強用不織布（以下、「補強用不織布」という場合がある。）及びそれを用いた製品に関するものである。 The present invention relates to a nonwoven fabric used as a reinforcing fabric for foam molded products, and in particular, a nonwoven fabric for reinforcing foam molded products (hereinafter referred to as “reinforcing nonwoven fabric”) for reinforcing a seat pad used for a vehicle seat. And a product using the same.
車両用座席材として、発泡樹脂成形品（以下、「発泡成形品」という）の成形時に補強用不織布を一体化したものが用いられている。この補強用不織布は、発泡樹脂と金属スプリングとの間に位置し、金属スプリングのクッション作用を均等化すると共に、金属スプリングと発泡成形品との接触によって発生する摩擦音を防ぐ機能を有するものである。例えば、特許文献１には、空隙率が異なる長繊維不織布層、すなわち嵩高層と緻密層とを積層した補強用不織布が記載されている。この補強用不織布では、発泡成形品を成形する際、発泡性樹脂の滲み出しを緻密層で防ごうとするものである。 As a vehicle seat material, a reinforcing nonwoven fabric integrated with a foamed resin molded product (hereinafter referred to as “foam molded product”) is used. This reinforcing non-woven fabric is located between the foam resin and the metal spring, and has a function of equalizing the cushioning action of the metal spring and preventing frictional noise generated by contact between the metal spring and the foam molded product. . For example, Patent Document 1 describes a reinforcing nonwoven fabric in which long fiber nonwoven fabric layers having different porosity, that is, a bulky layer and a dense layer are laminated. In this reinforcing nonwoven fabric, when a foamed molded product is molded, it is intended to prevent bleeding of the foamable resin with a dense layer.
近年、消費者の要求品質が高まるにつれて、意匠性が高い深絞りタイプの発泡成形品が求められるようになってきた。ところが、特許文献１に記載された補強用不織布を深絞りタイプの発泡成形品に用いると、補強用不織布の金型追随性が劣るため、皺や浮き上がり等に起因した局所的な破れが発生し、この破れを通して発泡性樹脂が補強用不織布の嵩高層表面に滲み出してくるという問題があった。 In recent years, as the quality required by consumers has increased, a deep-drawing type foam molded product having a high design has come to be demanded. However, when the reinforcing non-woven fabric described in Patent Document 1 is used for a deep-drawing type foam molded article, the follow-up property of the reinforcing non-woven fabric is inferior, resulting in local tearing due to wrinkles or lifting. There was a problem that the foamable resin oozes out to the bulky layer surface of the reinforcing nonwoven fabric through this tearing.
かかる問題を回避するために、特許文献２には、緻密層と基材層とからなり、６５℃での５％伸長時応力が０．５〜２０Ｎ／５ｃｍ、かつ通気度が４００ｃｍ3／ｃｍ2・ｓｅｃ以下である補強用不織布が記載されている。特許文献２に記載された補強用不織布は、金型追随性は良好であるが、発泡性樹脂の種類によっては、成形時に不織布表面への発泡性樹脂の滲み出しが起こることがあり、さらに裁断・縫製工程での補強用不織布の寸法安定性が悪いという問題があった。 In order to avoid such a problem, Patent Document 2 includes a dense layer and a base material layer, a stress at 5% elongation at 65 ° C. of 0.5 to 20 N / 5 cm, and an air permeability of 400 cm 3 / cm. A reinforcing nonwoven fabric of 2 · sec or less is described. The reinforcing nonwoven fabric described in Patent Document 2 has good mold followability, but depending on the type of foamable resin, the foamable resin may ooze out to the nonwoven fabric surface during molding, and further cut -There was a problem that the dimensional stability of the reinforcing nonwoven fabric in the sewing process was poor.
また、特許文献３には、５％伸長時応力を１８Ｎ／５ｃｍ以上に高めた補強用不織布が記載されている。特許文献３に記載された補強用不織布は、裁断・縫製工程での寸法安定性が良好である反面、深絞りタイプの金型への追随性が悪いという問題があった。 Patent Document 3 describes a reinforcing nonwoven fabric in which the stress at 5% elongation is increased to 18 N / 5 cm or more. The reinforcing nonwoven fabric described in Patent Literature 3 has good dimensional stability in the cutting and sewing process, but has a problem of poor followability to a deep drawing type mold.
従来の補強用不織布として、発泡成形品において発泡性樹脂の滲み出しがなく、仕上がり形状が良好で、擦過音、屈曲音、屈折音などを制音する機能に優れる、という基本特性に加え、発泡成形時の金型追随性に優れるという特性を持つ不織布は知られている。 In addition to the basic characteristics of conventional reinforcing non-woven fabrics, there is no exudation of foaming resin in foamed molded products, the finished shape is good, and the function of suppressing scratching sound, bending sound, refraction sound, etc. is excellent. Nonwoven fabrics having the property of being excellent in mold followability during molding are known.
しかし、シートパッドを発泡成形する前の工程である発泡成形品の形状に補強用不織布を裁断・縫製する工程において、ロール状に巻回された補強用不織布を引き出して裁断する作業時に、発泡成形時の金型追従性を満足させるため不織布に過度な柔軟性を付与すると、引き出し時の加工張力により補強用不織布が変形し、作業性が低下するという問題を有するものであった。 However, in the process of cutting and sewing the reinforcing non-woven fabric into the shape of the foam-molded product, which is the process before foam-molding the seat pad, foam molding during the work of pulling out and cutting the reinforcing non-woven fabric wound in a roll shape If excessive flexibility is imparted to the nonwoven fabric in order to satisfy the mold following capability, there is a problem that the reinforcing nonwoven fabric is deformed by the processing tension at the time of drawing and the workability is lowered.
そこで、本発明は、発泡成形時の金型追随性に優れると共に、裁断・縫製工程における加工張力による補強用不織布の変形を抑制した補強用不織布を提供することを目的とする。さらに、発泡成形時の発泡性樹脂の滲み出しがなく、発泡成形品の仕上がり形状が良好であり、擦過音、屈曲音、屈折音などを制音する機能に優れた補強用不織布を提供することを目的とする。 Therefore, an object of the present invention is to provide a reinforcing nonwoven fabric that is excellent in mold followability at the time of foam molding and suppresses deformation of the reinforcing nonwoven fabric due to processing tension in the cutting and sewing processes. Furthermore, the present invention provides a reinforcing nonwoven fabric that has no exudation of foamable resin during foam molding, has a good finished shape of the foam molded product, and has an excellent function of suppressing scratching sound, bending sound, refraction sound, etc. With the goal.
本発明者らは上記課題を解決するため、鋭意検討した結果、以下の本発明に到達した。
（１）見掛け密度の異なる２層の長繊維不織布が積層された不織布であって、目付が５０〜１１０ｇ／ｍ2、厚みが０．５〜１．２ｍｍ、縦方向の５％伸長時応力が２３〜５０Ｎ／５ｃｍ、横方向の５％伸長時応力が１５Ｎ／５ｃｍ以下、通気度が５０〜２５０ｃｍ3／ｃｍ2・ｓｅｃであることを特徴とするものである。
（２）少なくとも見掛け密度が高い方の長繊維不織布の繊維配列角度は、５〜６０°であることが好ましい。
（３）前記長繊維不織布は、ポリエステル系繊維から構成されることが好ましい。
（４）（１）〜（３）のいずれかに記載の補強用不織布を補強布に用いたことを特徴とする発泡成形品である。
（５）見掛け密度の異なる２層の長繊維不織布のうち、見掛け密度が高い方の長繊維不織布を発泡成形品の発泡体側に配置することが好ましい。
As a result of intensive studies to solve the above problems, the present inventors have reached the following present invention.
(1) A nonwoven fabric in which two layers of long-fiber nonwoven fabrics having different apparent densities are laminated, having a basis weight of 50 to 110 g / m 2 , a thickness of 0.5 to 1.2 mm, and a longitudinal stress of 5% elongation. The stress is 23 to 50 N / 5 cm, the 5% elongation stress in the lateral direction is 15 N / 5 cm or less, and the air permeability is 50 to 250 cm 3 / cm 2 · sec.
(2) It is preferable that the fiber arrangement angle of the long-fiber nonwoven fabric having at least the apparent density is 5 to 60 °.
(3) It is preferable that the said long fiber nonwoven fabric is comprised from a polyester-type fiber.
(4) A foam-molded article using the reinforcing nonwoven fabric according to any one of (1) to (3) as a reinforcing cloth.
(5) Of the two-layer long fiber nonwoven fabrics having different apparent densities, it is preferable to dispose the long fiber nonwoven fabric having the higher apparent density on the foam side of the foam molded product.
本発明の補強用不織布を用いると、発泡成形品において発泡性樹脂の滲み出しがなく、発泡成形品と座席の金属スプリングとの間の摩擦によって発生する擦過音の制音性に優れたものとなる。また、本発明の補強用不織布は柔軟性を有しており、発泡成形時の金型追随性に優れ、裁断・縫製工程における補強用不織布の引き出し時の作業性が改善される。本発明の補強用不織布は比較的軽量なため、軽量で高品位な発泡成形品を安価に製造でき、その発泡成形品を用いた車両も安価に軽量化でき、車両運用上での省エネルギー化にも寄与できる。 When the reinforcing nonwoven fabric of the present invention is used, there is no exudation of the foamable resin in the foamed molded product, and it is excellent in the suppression of scratching noise generated by friction between the foamed molded product and the metal spring of the seat. Become. In addition, the reinforcing nonwoven fabric of the present invention has flexibility, is excellent in mold followability during foam molding, and improves workability when the reinforcing nonwoven fabric is pulled out in the cutting and sewing process. Since the reinforcing nonwoven fabric of the present invention is relatively lightweight, a lightweight and high-quality foam molded product can be manufactured at low cost, and a vehicle using the foam molded product can also be reduced in weight at low cost, saving energy in vehicle operation. Can also contribute.
本発明の補強用不織布は、見掛け密度の異なる２層の長繊維不織布が積層された不織布である。見掛け密度の異なる長繊維不織布のうち、見掛け密度が高い不織布からなる層（以下、「緻密層」という。）は、発泡体と接する層であり、形態保持機能、発泡成形時の発泡性樹脂遮断機能、及び裁断・縫製工程の取り扱い性の向上に寄与する層である。一方、見掛け密度が低い不織布からなる層（以下、「嵩高層」という。）は、座席の金属スプリングと接する層であり、擦過音、屈曲音、屈折音などを制音し、耐磨耗耐久性機能の付与に寄与する層である。 The reinforcing nonwoven fabric of the present invention is a nonwoven fabric in which two layers of long fiber nonwoven fabrics having different apparent densities are laminated. Among long-fiber non-woven fabrics having different apparent densities, a layer made of non-woven fabric having a high apparent density (hereinafter referred to as a “dense layer”) is a layer in contact with the foam and has a form-retaining function and a foam-resistant resin barrier during foam molding. It is a layer that contributes to improving the function and handling of the cutting and sewing processes. On the other hand, a layer made of non-woven fabric with a low apparent density (hereinafter referred to as “bulky layer”) is a layer in contact with the metal spring of the seat and suppresses scratching sound, bending sound, refraction sound, etc., and wear resistance and durability. This layer contributes to the provision of sexual function.
本発明の補強用不織布は、緻密層及び嵩高層で構成される。発泡成形品の発泡体と接する緻密層は、裁断工程の不織布の引き出し作業時における不織布の繊維配列方向の伸びを抑制し、発泡成形時の金型追随性を向上させる力学特性になるように繊維の配列を改良した長繊維不織布であり、さらに、発泡性樹脂遮断機能を有する長繊維不織布である。 The reinforcing nonwoven fabric of the present invention is composed of a dense layer and a bulky layer. The dense layer that is in contact with the foam of the foam-molded product suppresses the elongation in the fiber array direction of the nonwoven fabric during the drawing operation of the nonwoven fabric in the cutting process, and the fibers have mechanical properties that improve the mold followability during foam molding. Is a long-fiber nonwoven fabric having an improved arrangement, and further a long-fiber nonwoven fabric having a foaming resin blocking function.
他方の座席の金属スプリングと接する嵩高層は、擦過音、屈曲音、屈折音などを制音する機能、及び耐磨耗耐久性機能を有し、補強用不織布に柔軟性を付与する長繊維不織布である。 The bulky layer in contact with the metal spring of the other seat has a function of suppressing scratching sound, bending sound, refraction sound, and the like, and a wear-resistant durability function, and a long-fiber nonwoven fabric that imparts flexibility to the reinforcing nonwoven fabric It is.
そして、これら緻密層と嵩高層とを交絡接合して、緻密層の表面に嵩高層の長繊維不織布を構成する繊維が突出した構造（以下、「突出繊維構造」という。）を形成した補強用不織布とする。その結果、補強用不織布は、柔軟化して優れた金型追随性を有し、発泡成形の際には、突出繊維構造のアンカー効果で発泡成形品全体が一体化するので耐久性も向上した発泡成形品を得ることができる。この補強用不織布は、低伸度域での伸長応力を高くして伸びを抑制することで、不織布引出し作業時の取り扱い性を著しく向上させることができる上に、成形性、制音性、耐久性にも優れている。 The dense layer and the bulky layer are entangled and joined to form a structure in which the fibers constituting the bulky nonwoven fabric of the bulky layer protrude on the surface of the dense layer (hereinafter referred to as “protruded fiber structure”). Use non-woven fabric. As a result, the non-woven fabric for reinforcement is softened and has excellent mold followability. During foam molding, the entire foam molded product is integrated by the anchor effect of the protruding fiber structure, so that the foam is also improved in durability. A molded product can be obtained. This reinforcing nonwoven fabric can significantly improve the handleability during drawing out of the nonwoven fabric by suppressing the elongation by increasing the elongation stress in the low elongation range, as well as formability, sound damping and durability. Also excellent in properties.
本発明の補強用不織布の目付は、５０〜１１０ｇ／ｍ2であり、好ましくは、６０〜１００ｇ／ｍ2である。目付が５０ｇ／ｍ2未満では、力学特性が低くなり補強機能が不充分になる場合がある。また、発泡性樹脂の遮断機能が低下して滲み出しを発生する場合がある。目付が１１０ｇ／ｍ2を超えると、車両の軽量化を阻害する問題がある。 The basis weight of the reinforcing nonwoven fabric of the present invention is 50 to 110 g / m 2 , and preferably 60 to 100 g / m 2 . If the basis weight is less than 50 g / m 2 , the mechanical properties may be low and the reinforcing function may be insufficient. In addition, the blocking function of the foamable resin may be reduced and bleeding may occur. When the basis weight exceeds 110 g / m 2 , there is a problem that hinders weight reduction of the vehicle.
本発明の補強用不織布の厚みは、０．５〜１．２ｍｍであり、好ましくは、０．６〜１．０ｍｍである。厚みが０．５ｍｍ未満では、発泡性樹脂の遮断機能が低下して滲み出しが発生する場合がある。厚みが１．２ｍｍを超えると、発泡成形時の金型追随性が悪化し、成形不良となる場合がある。 The reinforcing nonwoven fabric of the present invention has a thickness of 0.5 to 1.2 mm, preferably 0.6 to 1.0 mm. If the thickness is less than 0.5 mm, the blocking function of the foamable resin may be reduced and bleeding may occur. If the thickness exceeds 1.2 mm, mold followability at the time of foam molding is deteriorated, which may result in molding failure.
本発明の補強用不織布は、縦方向の５％伸長時応力が２３〜５０Ｎ／５ｃｍ、横方向の５％伸長時応力が１５Ｎ／５ｃｍ以下である。 The reinforcing nonwoven fabric of the present invention has a longitudinal stress of 5% elongation of 23 to 50 N / 5 cm and a transverse stress of 5% elongation of 15 N / 5 cm or less.
裁断工程の引き出し張力による不織布の変形を防止して裁断性を向上させ、発泡成形時の金型追随性を向上させるため、補強用不織布の縦方向の５％伸長時応力は２３〜５０Ｎ／５ｃｍであり、好ましくは３０〜４５Ｎ／５ｃｍである。２３Ｎ／５ｃｍ未満では、裁断・縫製工程での不織布の引出し張力で不織布が変形してしまい、作業性が低下し、ひいては安定した裁断や金型へのセッティングができなくなる場合がある。５０Ｎ／５ｃｍを超えると、発泡成形加工時に金型追随性が低下し、仕上がり形状不良や破れ、皺などを生じる。 In order to prevent the deformation of the nonwoven fabric due to the pulling tension in the cutting process and improve the cutting property, and to improve the mold followability at the time of foam molding, the stress at the time of 5% elongation in the longitudinal direction of the reinforcing nonwoven fabric is 23 to 50 N / 5 cm. And preferably 30 to 45 N / 5 cm. If it is less than 23 N / 5 cm, the nonwoven fabric is deformed by the pulling tension of the nonwoven fabric in the cutting / sewing process, the workability is lowered, and as a result, stable cutting or setting to the mold may not be possible. If it exceeds 50 N / 5 cm, the mold followability is reduced during foam molding, resulting in a finished shape defect, tearing, wrinkles and the like.
本発明の補強用不織布は、長繊維不織布の繊維配列を縦方向に揃えると、縦方向の５％伸長時応力は高くなり、横方向の５％伸長時応力は低くなる。しかし、所望の縦方向の５％伸長時応力を付与する場合でも、補強用不織布の横方向の５％伸長時応力が少なくとも５Ｎ／５ｃｍ以上でないと加工性不良となる場合がある。よって、少なくとも見掛け密度が高い方の長繊維不織布を製造する際、繊維配列を引取りコンベアネットのエンドレス方向（以下、「エンドレス方向」という。）から５°〜６０°傾斜させることが好ましく、１０°〜３０°傾斜させることがより好ましい。なお、繊維配列角度の測定方法は、任意の５箇所で、繊維１００本の配列角度を測定して、その角度の平均値を繊維配列角度とする。不織布の縦方向（ＭＤ方向）に全ての繊維が配列した場合、繊維配列角度は０°となり、不織布の横方向（ＴＤ方向）に全ての繊維が配列した場合、繊維配列角度は９０°となる。 In the reinforcing nonwoven fabric of the present invention, when the fiber arrangement of the long-fiber nonwoven fabric is aligned in the longitudinal direction, the stress at 5% elongation in the longitudinal direction increases and the stress at 5% elongation in the transverse direction decreases. However, even when a desired stress in the 5% elongation in the longitudinal direction is applied, if the stress in the 5% elongation in the transverse direction of the reinforcing nonwoven fabric is not at least 5 N / 5 cm or more, workability may be deteriorated. Therefore, when producing a long-fiber nonwoven fabric having a higher apparent density, it is preferable to incline the fiber array by 5 ° to 60 ° from the endless direction of the take-up conveyor net (hereinafter referred to as “endless direction”). It is more preferable to incline by 30 °. In addition, the measuring method of a fiber arrangement | positioning angle measures the arrangement | sequence angle of 100 fibers in arbitrary 5 places, and makes the average value of the angle the fiber arrangement | positioning angle. When all the fibers are arranged in the longitudinal direction (MD direction) of the nonwoven fabric, the fiber arrangement angle is 0 °, and when all the fibers are arranged in the transverse direction (TD direction) of the nonwoven fabric, the fiber arrangement angle is 90 °. .
好ましい繊維配列角度を有する長繊維不織布は、以下の製造方法で得ることができる。長繊維不織布の製造過程において、牽引流体及び同伴流（以下、併せて「随伴流」という。）と共に流下して伸長固化された長繊維を、エンドレス方向から１０°〜３０°傾斜させて配列させるために、引き取りコンベアネット表面において、コンベアネットの幅方向への随伴流、及びコンベアネットを突き抜ける方向（以下、「垂直方向」という。）への随伴流を抑制して、エンドレス方向への随伴流をやや多く流れるようにする。その結果、繊維はエンドレス方向に多く配列されるようになる。随伴流の調整方法としては、コンベアネットの幅方向端部に随伴流規制板を設置すること、垂直方向は随伴流の吸引風速を小さくすることなどが挙げられる。これにより、繊維配列角度の調整が可能となる。例えば、コンベアネット端部に数ｃｍの随伴流規制板を設け、サクション吸引風速を３．０〜９．０ｍ／秒まで低減させると、繊維配列角度が２０〜２８°である長繊維不織布が得られる。なお、随伴流規制板として、パンチングメタルや金網等が使用できる。 A long fiber nonwoven fabric having a preferred fiber arrangement angle can be obtained by the following production method. In the production process of the long-fiber nonwoven fabric, the long fibers that have flowed down and solidified along with the traction fluid and the accompanying flow (hereinafter also referred to as “associated flow”) are aligned at an angle of 10 ° to 30 ° from the endless direction. Therefore, on the surface of the take-up conveyor net, the accompanying flow in the width direction of the conveyor net and the accompanying flow in the direction penetrating the conveyor net (hereinafter referred to as “vertical direction”) are suppressed, and the accompanying flow in the endless direction is suppressed. To make it flow a little. As a result, many fibers are arranged in the endless direction. Examples of the method for adjusting the accompanying flow include installing an accompanying flow regulating plate at the end of the conveyor net in the width direction, and reducing the suction wind speed of the accompanying flow in the vertical direction. This makes it possible to adjust the fiber arrangement angle. For example, when a concomitant flow regulating plate of several centimeters is provided at the end of the conveyor net and the suction suction air speed is reduced to 3.0 to 9.0 m / sec, a long fiber nonwoven fabric having a fiber arrangement angle of 20 to 28 ° is obtained. It is done. In addition, a punching metal, a wire mesh, etc. can be used as an accompanying flow control board.
本発明の補強用不織布の横方向の５％伸長時応力は１５Ｎ／５ｃｍ以下であり、好ましくは５〜１４Ｎ／５ｃｍであり、より好ましくは８〜１２Ｎ／５ｃｍである。１５Ｎ／５ｃｍを超えると、金型追随性が悪くなるため、仕上がり形状が悪くなる場合がある。５Ｎ／５ｃｍ未満となると、裁断・縫製工程で横方向に張力が掛かると伸びて変形したり、発泡成形時の金型追随性が縦横方向で大きく異なってしまうため、成形品の仕上がり形状が悪くなったり、不織布が破れたりする場合がある。 The 5% elongation stress in the transverse direction of the reinforcing nonwoven fabric of the present invention is 15 N / 5 cm or less, preferably 5 to 14 N / 5 cm, more preferably 8 to 12 N / 5 cm. If it exceeds 15 N / 5 cm, the mold followability will deteriorate, and the finished shape may deteriorate. If it is less than 5N / 5cm, it will stretch and deform when the tension is applied in the horizontal direction in the cutting and sewing process, and the mold following at the time of foaming will vary greatly in the vertical and horizontal directions, so the finished shape of the molded product will be poor. Or the nonwoven fabric may be torn.
本発明の補強用不織布を構成する緻密層及び嵩高層のうち、緻密層は繊維を縦方向により配列させた、すなわち繊維配列角度が小さい長繊維不織布であることが好ましい。一方、嵩高層は、補強用不織布が低目付である場合、繊維配列角度は特には限定されないが、補強用不織布が高目付である場合、補強用不織布の横方向の５％伸長時応力が大きくなりすぎないようにするためにも、嵩高層も緻密層と同様に繊維配列角度が小さい長繊維不織布であることが好ましい。補強用不織布が高目付である場合は、嵩高層も高目付である場合が多く、その場合には繊維を縦方向に近い方向に多く配列させた長繊維不織布を使用しないと、得られる補強用不織布の横方向の５％伸長時応力を１５Ｎ／５ｃｍ以下とすることが困難になるからである。 Of the dense layer and the bulky layer constituting the reinforcing nonwoven fabric of the present invention, the dense layer is preferably a long fiber nonwoven fabric in which fibers are arranged in the longitudinal direction, that is, the fiber arrangement angle is small. On the other hand, in the bulky layer, when the reinforcing nonwoven fabric has a low basis weight, the fiber arrangement angle is not particularly limited, but when the reinforcing nonwoven fabric has a high basis weight, the stress at the time of 5% elongation in the lateral direction of the reinforcing nonwoven fabric is large. In order not to become too much, the bulky layer is preferably a long-fiber non-woven fabric having a small fiber arrangement angle like the dense layer. When the reinforcing nonwoven fabric has a high basis weight, the bulky layer also often has a high basis weight, and in that case, if the long fiber nonwoven fabric in which many fibers are arranged in the direction close to the longitudinal direction is not used, the resulting reinforcing reinforcement This is because it becomes difficult to set the stress at 5% elongation in the transverse direction of the nonwoven fabric to 15 N / 5 cm or less.
本発明の補強用不織布は、縦方向の５％伸長時応力と横方向の５％伸長時応力との比（縦方向の５％伸長時応力÷横方向の５％伸長時応力）は、２．２以上が好ましく、３〜１４がより好ましく、４〜７が最も好ましい。縦方向の５％伸長時応力と横方向の５％伸長時応力の比が２．２未満では、繊維配列がランダム構造となり、縦方向の５％伸長時応力が低くなり、裁断・縫製工程での寸法安定性が劣る場合がある。縦方向の５％伸長時応力と横方向の５％伸長時応力の比が１４を超えると、繊維配列が直列化し過ぎて、横方向の５％伸長時応力が低くなり、低応力で横伸びし易くなり、金型追随性が縦横方向で大きく異なってしまうため、成形品の仕上がり形状が悪くなる場合がある。また、横方向の伸び変形による破れが生じる場合もある。 The reinforcing nonwoven fabric of the present invention has a ratio of 5% elongation stress in the longitudinal direction to 5% elongation stress in the transverse direction (5% elongation stress in the longitudinal direction ÷ 5% elongation stress in the transverse direction). .2 or more is preferable, 3 to 14 is more preferable, and 4 to 7 is most preferable. If the ratio of 5% elongation stress in the longitudinal direction to 5% elongation stress in the transverse direction is less than 2.2, the fiber arrangement becomes a random structure, and the 5% elongation stress in the longitudinal direction becomes low. The dimensional stability of may be inferior. If the ratio of the 5% elongation stress in the longitudinal direction to the stress in the 5% elongation in the transverse direction exceeds 14, the fiber arrangement becomes too serial, the stress at 5% elongation in the transverse direction becomes low, and the lateral elongation occurs at a low stress. Since the mold followability is greatly different in the vertical and horizontal directions, the finished shape of the molded product may be deteriorated. Moreover, the tear by lateral elongation deformation may arise.
本発明で緻密層と嵩高層との交絡処理方法は、特には限定されないが、緻密層の表面に好ましい突出繊維構造の形成を調整できるニードルパンチにて交絡処理を行うことが好ましい。ニードルパンチによる積層交絡処理において、突出繊維構造を形成するには、針密度が３０〜３００本／ｃｍ2であることが好ましい。また、ニードルパンチの突出繊維構造の形成程度は、針の貫入具合に依存する。針の貫入具合としてはニードルの第１バーブが不織布に貫入する深度を９〜１２ｍｍに設定することが好ましい。貫入する深度が９ｍｍ未満では、好ましい突出繊維構造を形成しにくくなり、貫入する深度が１２ｍｍを超えると開孔径が大きくなって、発泡成形工程で発泡性樹脂が滲み出すことがある。 In the present invention, the entanglement treatment method between the dense layer and the bulky layer is not particularly limited, but it is preferable to perform the entanglement treatment with a needle punch that can adjust the formation of a preferable protruding fiber structure on the surface of the dense layer. In the lamination entanglement process by the needle punch, the needle density is preferably 30 to 300 / cm 2 in order to form the protruding fiber structure. Further, the degree of formation of the protruding fiber structure of the needle punch depends on the penetration of the needle. As the penetration of the needle, it is preferable to set the depth at which the first barb of the needle penetrates the nonwoven fabric to 9 to 12 mm. When the depth of penetration is less than 9 mm, it is difficult to form a preferable protruding fiber structure. When the depth of penetration exceeds 12 mm, the pore diameter becomes large, and the foamable resin may ooze out in the foam molding step.
本発明の緻密層は、目付が２０〜８０ｇ／ｍ2、厚みが０．２〜０．８ｍｍの長繊維不織布であることが好ましく、目付が３０〜７０ｇ／ｍ2、厚みが０．３〜０．６ｍｍの長繊維不織布であることがより好ましい。目付が低くても引張強力や破裂強力が高ければ、発泡成形時の発泡性樹脂遮断機能が大きく向上する。
さらに、緻密層は、その発泡体面側に、嵩高層である長繊維不織布を構成する繊維を交絡接合させることで形成した突出繊維構造を有することが好ましい。この突出繊維構造によって、発泡性樹脂の遮蔽機能を維持しながら、交絡処理を行うことで長繊維不織布自体を柔軟化できるため、均一な変形が可能な金型追随性を補強用不織布に付与することが可能となる。また、突出繊維構造を発泡体中に埋没させることで補強用不織布と発泡体とが強固に一体化するアンカー効果が発揮される。
Dense layer of the present invention preferably has a basis weight of a long fiber nonwoven fabric of 20 to 80 g / m 2, thickness 0.2 to 0.8 mm, a basis weight of 30~70g / m 2, 0.3~ thickness A 0.6 mm long fiber nonwoven fabric is more preferable. Even if the basis weight is low, if the tensile strength or bursting strength is high, the foaming resin blocking function at the time of foam molding is greatly improved.
Furthermore, it is preferable that the dense layer has a protruding fiber structure formed by tangling and joining the fibers constituting the bulky nonwoven fabric that is a bulky layer on the foam surface side. With this protruding fiber structure, the long-fiber nonwoven fabric itself can be softened by performing the entanglement process while maintaining the shielding function of the foamable resin, so that a mold followability capable of uniform deformation is imparted to the reinforcing nonwoven fabric. It becomes possible. In addition, by embedding the protruding fiber structure in the foam, an anchor effect is achieved in which the reinforcing nonwoven fabric and the foam are firmly integrated.
緻密層が短繊維不織布層であれば、繊維の連続性が無いため、低目付での力学特性が劣り、成形時の金型追随性が局所的に異なるため、変形破れを生じやすく好ましくない。 If the dense layer is a short fiber nonwoven fabric layer, there is no fiber continuity, so that the mechanical properties at a low basis weight are inferior, and the mold followability at the time of molding is locally different.
緻密層の長繊維不織布は、発泡成形時に発泡性樹脂の補強用不織布表面への漏れを遮断する遮断層として機能させる必要性から、独立したドット状部分圧着部を有することが好ましい。緻密層と嵩高層との交絡処理後は、緻密層も柔軟化されている。これは、成形加工時の金型追随性の確保、発泡時のガス抜け性の維持、及び成形品の浮き上がりの防止にも役立つ。緻密層の長繊維不織布に独立したドット状部分圧着部を形成することで、独立した圧着繊維集合部が構成長繊維を強固に固定する接合点として働く構造固定効果が発現する。ドット状部分圧着部以外のフラット化された部分は、緻密層に遮断層効果を付与している。この結果、緻密層は、適度な通気性を有しており、発泡成形による変形に、容易に追随できる機能と脱気機能とを有している。 The long-fiber nonwoven fabric of the dense layer preferably has an independent dot-shaped partial crimping portion because it needs to function as a blocking layer that blocks leakage of the foamable resin to the reinforcing nonwoven fabric surface during foam molding. After the entanglement treatment of the dense layer and the bulky layer, the dense layer is also softened. This also helps to ensure mold followability at the time of molding, maintain gas release properties at the time of foaming, and prevent the lift of the molded product. By forming an independent dot-like partial crimping part on the long-fiber nonwoven fabric of the dense layer, a structure fixing effect is achieved in which the independent crimping fiber assembly part acts as a joining point for firmly fixing the constituent long fibers. The flattened portion other than the dot-shaped partial pressure-bonding portion imparts a blocking layer effect to the dense layer. As a result, the dense layer has appropriate air permeability and has a function that can easily follow deformation caused by foaming and a deaeration function.
緻密層の長繊維不織布に圧着処理を行わない場合は、不織布強度の低下により破裂強力が低下すると共に、発泡性樹脂の遮断機能が低下し、発泡性樹脂の滲み出しを生じることがある。 When the compression treatment is not performed on the long-fiber nonwoven fabric of the dense layer, the bursting strength is lowered due to the reduction in the strength of the nonwoven fabric, the blocking function of the foamable resin is lowered, and the foamable resin may ooze out.
また、圧着処理が長繊維不織布の表面全面に形成されている場合は、交絡処理により、緻密層を柔軟化しても、発泡成形時の変形性が劣り、通気性が低下して、発泡成形工程で発泡成形品が金型から浮き上がることがある。また、圧着部が連続してつながっている場合は、圧着部の厚みと幅により柔軟性が悪くなって、発泡成形時の変形性を損なうことがある。 In addition, when the crimping process is formed on the entire surface of the long-fiber nonwoven fabric, even if the dense layer is softened by the entanglement process, the deformability at the time of foam molding is inferior, the air permeability is lowered, and the foam molding process In some cases, foam molded products may be lifted from the mold. Moreover, when the crimping | compression-bonding part is connected continuously, a softness | flexibility worsens with the thickness and width | variety of a crimping | compression-bonding part, and the deformability at the time of foam molding may be impaired.
緻密層の長繊維不織布の部分圧着部面積率は、特には限定されないが、好ましくは５〜４０％、より好ましくは８〜２５％、最も好ましくは１０〜２０％である。５％未満では、力学特性が低下する場合がある。また、発泡性樹脂の遮断機能が不足して発泡性樹脂の滲みだしを生じる場合がある。また、４０％を超えると金型追随性が劣る場合がある。 Although the partial crimping | bonding part area ratio of the long fiber nonwoven fabric of a dense layer is not specifically limited, Preferably it is 5 to 40%, More preferably, it is 8 to 25%, Most preferably, it is 10 to 20%. If it is less than 5%, the mechanical properties may deteriorate. In addition, the foaming resin may have insufficient blocking function, and the foaming resin may ooze out. Moreover, when it exceeds 40%, mold followability may be inferior.
長繊維不織布に独立した部分圧着部を形成する方法は、特には限定されない。本発明では、公知の方法、例えば、エンボスローラー加工などが使用される。部分圧着部の形状についても、独立したドットであれば特には限定されないが、好ましくは織目柄、ダイヤ柄、四角柄、亀甲柄、楕円柄、格子柄、水玉柄、丸柄などが例示される。 The method for forming an independent partial crimping portion on the long fiber nonwoven fabric is not particularly limited. In the present invention, a known method such as embossing roller processing is used. The shape of the partial crimping part is not particularly limited as long as it is an independent dot, but preferably a texture pattern, a diamond pattern, a square pattern, a turtle shell pattern, an ellipse pattern, a lattice pattern, a polka dot pattern, a round pattern, etc. are exemplified. The
緻密層において、発泡体と接する面には、突出繊維構造が形成されていることが好ましい。この突出繊維構造を発泡体中に埋没させることにより、発泡体と緻密層とが強固に接合一体化するアンカー効果が発現する。突出繊維構造が形成されていない場合、発泡体と緻密層との接合力が不充分となり、発泡体と補強用不織布とが剥離しやすくなるので好ましくない。 In the dense layer, a protruding fiber structure is preferably formed on the surface in contact with the foam. By embedding this protruding fiber structure in the foam, an anchor effect is produced in which the foam and the dense layer are firmly joined and integrated. When the protruding fiber structure is not formed, the bonding force between the foam and the dense layer becomes insufficient, and the foam and the reinforcing nonwoven fabric are easily peeled off, which is not preferable.
本発明の嵩高層に用いる長繊維不織布の目付、厚みは特には限定されないが、目付が２０〜８０ｇ／ｍ2、厚みが０．３〜１．０ｍｍであることが好ましく、目付が３０〜７０ｇ／ｍ2、厚みが０．４〜０．９ｍｍであることがより好ましい。 The basis weight and thickness of the long-fiber nonwoven fabric used for the bulky layer of the present invention are not particularly limited, but the basis weight is preferably 20 to 80 g / m 2 and the thickness is preferably 0.3 to 1.0 mm, and the basis weight is 30 to 70 g. / M 2 and a thickness of 0.4 to 0.9 mm are more preferable.
前述のとおり、嵩高層の長繊維不織布の繊維配列角度は特には限定されないが、補強用不織布が高目付である場合は、緻密層と同様に嵩高層も繊維配列角度が小さい長繊維不織布であることが好ましい。 As described above, the fiber arrangement angle of the bulky long-fiber nonwoven fabric is not particularly limited. However, when the reinforcing nonwoven fabric has a high basis weight, the bulky layer is a long-fiber nonwoven fabric having a small fiber arrangement angle as in the case of the dense layer. It is preferable.
本発明の補強用不織布の通気度は、５０〜２５０ｃｍ3／ｃｍ2・ｓｅｃであり、７５〜２００ｃｍ3／ｃｍ2・ｓｅｃであることが好ましい。通気度が５０ｃｍ3／ｃｍ2・ｓｅｃ未満では、発泡成形時の膨張空気抜けが不均一となり、欠肉、樹脂抜け等が生じる場合がある。２５０ｃｍ3／ｃｍ2・ｓｅｃを超えると、発泡性樹脂の漏れによる滲み出しが生じる場合がある。 Air permeability of the reinforcing nonwoven fabric of the present invention is a 50~250cm 3 / cm 2 · sec, it is preferable that 75~200cm 3 / cm 2 · sec. When the air permeability is less than 50 cm 3 / cm 2 · sec, the expansion air escape at the time of foam molding becomes non-uniform, and there may be a lack of thickness or resin loss. If it exceeds 250 cm 3 / cm 2 · sec, bleeding may occur due to leakage of the foamable resin.
緻密層および嵩高層に用いる長繊維不織布を構成する繊維の繊度は、特には限定されないが、長繊維不織布の発泡性樹脂遮断機能、補強機能、及びクッション機能を発現させる点から、１．０〜６ｄｔｅｘであることが好ましく、１．５〜４ｄｔｅｘであることがより好ましい。繊維断面は必要に応じて、異形断面や中空断面、異繊度混繊などを選択できる。 The fineness of the fibers constituting the long-fiber nonwoven fabric used for the dense layer and the bulky layer is not particularly limited, but from the point of expressing the foamable resin blocking function, the reinforcing function, and the cushion function of the long-fiber nonwoven fabric. 6 dtex is preferable, and 1.5 to 4 dtex is more preferable. As the fiber cross section, an irregular cross section, a hollow cross section, a mixed fiber of different fineness, and the like can be selected as necessary.
本発明の補強用不織布は、緻密層と嵩高層との２層構造とすることが好ましいが、緻密層と嵩高層との間にさらに中間層を積層一体化することもでき、中間層に用いる不織布は、特には限定されない。中間層は遮断層として用いることが可能である。 The reinforcing nonwoven fabric of the present invention preferably has a two-layer structure of a dense layer and a bulky layer, but an intermediate layer can be further laminated and integrated between the dense layer and the bulky layer, and used for the intermediate layer. The nonwoven fabric is not particularly limited. The intermediate layer can be used as a blocking layer.
本発明の緻密層および嵩高層である長繊維不織布の素材は、特には限定されないが、高ガラス転移温度のポリエチレンナフタレートやポリカーボネートは、成形温度が低い場合、発泡成形時の金型追随性が劣る場合がある。発泡性樹脂にポリウレタンを用いた低温成形加工では、濡れ性がやや不良で漏れ難く遮断機能が高く、かつ金型追随性が良好なポリエステル系樹脂からなる長繊維不織布が好ましい。 The material of the long fiber nonwoven fabric that is a dense layer and a bulky layer of the present invention is not particularly limited, but polyethylene naphthalate or polycarbonate having a high glass transition temperature has a mold following property during foam molding when the molding temperature is low. May be inferior. In the low-temperature molding process using polyurethane as the foamable resin, a long-fiber nonwoven fabric made of a polyester resin having a slightly poor wettability, hardly leaking, having a high blocking function, and having good mold followability is preferable.
ポリエステル系樹脂としては、ポリブチレンテレフタレート（ＰＢＴ）、ポリエチレンテレフタレート（ＰＥＴ）、ポリブチレンナフタレート（ＰＢＮ）、ポリシクロヘキサンジメチルテレフタレート（ＰＣＨＴ）、ポリプロピレンテレフタレート（ＰＴＴ）などのホモポリエステル、またはそれらの共重合体や混合物が例示される。 Examples of polyester resins include homopolyesters such as polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polybutylene naphthalate (PBN), polycyclohexanedimethyl terephthalate (PCHT), and polypropylene terephthalate (PTT), or their co-polymers. Examples include coalescence and mixtures.
ポリエステル系樹脂としては、融点が２２０℃以上であって、ガラス転移温度が８０℃以下のポリエステル樹脂が好ましく、ガラス転移温度が７０℃以下のポリエステル樹脂がより好ましい。好ましいポリエステル樹脂としては、例えば、ポリエチレンテレフタレート（ＰＥＴ）、ポリブチレンテレフタレート（ＰＢＴ）、ポリプロピレンテレフタレート（ＰＴＴ）、またはそれらの共重合体や混合物などが例示される。最も好ましいポリエステル樹脂としては、ポリエチレンテレフタレート（ＰＥＴ）、またはエチレンテレフタレートを主たる構成ユニットとする共重合体が挙げられる。 As the polyester resin, a polyester resin having a melting point of 220 ° C. or higher and a glass transition temperature of 80 ° C. or lower is preferable, and a polyester resin having a glass transition temperature of 70 ° C. or lower is more preferable. Examples of preferable polyester resins include polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polypropylene terephthalate (PTT), and copolymers and mixtures thereof. The most preferable polyester resin includes polyethylene terephthalate (PET) or a copolymer having ethylene terephthalate as a main constituent unit.
補強用不織布の特性を低下させない範囲で、必要に応じて、抗酸化剤、耐光剤、着色剤、抗菌剤、難燃剤、親水化剤などの改質剤を添加してもよい。 A modifier such as an antioxidant, a light-resistant agent, a colorant, an antibacterial agent, a flame retardant, and a hydrophilizing agent may be added as necessary as long as the properties of the reinforcing nonwoven fabric are not deteriorated.
上述の本発明要件を満たした補強用不織布は、所定の形状に切断して発泡成形品用補強布としてクッション用金型に突出繊維構造形成面を発泡性樹脂側となる（緻密層を発泡成形品の発泡性樹脂側となる）ようにセットして発泡性ウレタン樹脂を注入した後、発泡させれば、ウレタン発泡フォームからなる発泡成形品が得られる。発泡成形法としては、コールド発泡法、またはホット発泡法が挙げられる。成形した発泡成形品は良好な形状に仕上り、発泡性樹脂の滲み出しもなく、スプリング受け材としては、擦過音、屈曲音、屈折音を制音し、保形耐久性、耐摩耗性にも優れた発泡成形品が得られる。また、所定形状への切断工程及び金型へのセッティングの操作性は、不織布の変形もなく、きわめて良好となる。 The reinforcing nonwoven fabric satisfying the above-mentioned requirements of the present invention is cut into a predetermined shape, and the protruding fiber structure-forming surface is formed on the foamable resin side as a reinforcing fabric for foam molded articles (the dense layer is foam molded) If the foamed urethane resin is set and infused and then foamed, a foamed molded product made of urethane foam can be obtained. Examples of the foam molding method include a cold foaming method and a hot foaming method. The molded foam molded product is finished in a good shape, there is no exudation of foaming resin, and the spring receiving material suppresses scratching sound, bending sound, refraction sound, shape retention durability and wear resistance An excellent foam molded product can be obtained. Further, the operability of the cutting process to the predetermined shape and the setting to the mold is very good without deformation of the nonwoven fabric.
本発明の補強用不織布は、車両用座席のクッション用途に限定されるものではなく、補強用不織布として、車両用の各種内装材や、建築資材、電化製品の表面発泡成形品などの用途にも有用である。 The reinforcing nonwoven fabric of the present invention is not limited to a vehicle seat cushion application, but as a reinforcing nonwoven fabric, it can also be used for various interior materials for vehicles, building materials, surface foam molded products of electrical appliances, etc. Useful.
以下、実施例及び比較例によって本発明をさらに具体的に説明するが、本発明はこれらに何ら限定されるものではない。
なお、本発明の実施例および比較例で用いた評価方法は下記の方法で行った。
EXAMPLES Hereinafter, although an Example and a comparative example demonstrate this invention further more concretely, this invention is not limited to these at all.
In addition, the evaluation method used by the Example and comparative example of this invention was performed by the following method.
（１）繊度［ｄｔｅｘ］
各層の一方の面及び他方の面の任意の場所を５点選び、光学顕微鏡を用いて、単繊維径をｎ＝２０で測定して、その平均値を平均単繊維径（Ｄ）とした。同場所５点の繊維を取り出し、密度勾配管を用いて、繊維の比重をｎ＝５で測定して、その平均値を平均比重（ρ）とした。ついで、平均単繊維径より平均単繊維断面積を求め、その値と平均比重から１万ｍあたりの繊維質量（ｇ）を求め、それを繊度（ｄｔｅｘ）とした。なお、繊維径測定時、中空繊維等の繊維径の判別が難しい場合はＳＥＭ写真の繊維断面から求めた。
(1) Fineness [dtex]
Five points were selected on one side and the other side of each layer, and the single fiber diameter was measured at n = 20 using an optical microscope, and the average value was defined as the average single fiber diameter (D). Five fibers at the same place were taken out, the specific gravity of the fiber was measured at n = 5 using a density gradient tube, and the average value was defined as the average specific gravity (ρ). Next, the average single fiber cross-sectional area was determined from the average single fiber diameter, and the fiber mass (g) per 10,000 m was determined from the value and the average specific gravity, which was defined as the fineness (dtex). When measuring the fiber diameter, it was determined from the fiber cross section of the SEM photograph if it was difficult to determine the fiber diameter of the hollow fiber or the like.
（２）目付［ｇ／ｍ2］
ＪＩＳ Ｌ １９１３：２０１０の『単位面積当たりの質量』に準拠して測定した。
(2) Weight per unit [g / m 2 ]
Measured according to “mass per unit area” of JIS L 1913: 2010.
（３）厚さ［ｍｍ］
ＪＩＳ Ｌ１９１３：２０１０の『厚さ』に準拠し、荷重２０ｇｆ／ｃｍ2での厚みを測定した。
(3) Thickness [mm]
In accordance with “Thickness” of JIS L1913: 2010, the thickness at a load of 20 gf / cm 2 was measured.
（４）見掛け密度［ｇ／ｃｍ3］
上記（３）での厚みと（２）で測定した目付から見掛け密度を算出した。但し、表記を簡便にするため、単位をｇ／ｃｍ3に換算した。
(4) Apparent density [g / cm 3 ]
The apparent density was calculated from the thickness in (3) above and the basis weight measured in (2). However, in order to simplify the notation, the unit was converted to g / cm 3 .
（５）不織布の力学特性
ＪＩＳ Ｌ１９１３ ６．３：２０１０の『引張強さ及び伸び率』に準拠して、標準雰囲気（２２℃）にて、任意の場所５点の試料を切り出し、破断までの伸長荷重曲線を各点ｎ＝５で測定し、各値の総平均で算出した。
（５−１）５％伸長時応力［Ｎ／５ｃｍ］
２２℃での５％伸長時応力［Ｎ／５ｃｍ］を求め、５％伸長時応力［Ｎ／５ｃｍ］の値とする。
(5) Mechanical properties of non-woven fabric In accordance with JIS L1913 6.3: 2010 “Tensile strength and elongation”, samples at 5 arbitrary locations were cut out in a standard atmosphere (22 ° C.), and until the fracture. The elongation load curve was measured at each point n = 5 and calculated by the total average of each value.
(5-1) Stress at 5% elongation [N / 5cm]
The stress at 5% elongation [N / 5 cm] at 22 ° C. is obtained and set as the value of stress at 5% elongation [N / 5 cm].
（６）通気度（ｃｍ3／ｃｍ2・ｓｅｃ）
ＪＩＳ Ｌ１９１３ ６．８．１：２０１０に準じたフラジール通気度測定機によって行った。
(6) Air permeability (cm 3 / cm 2 · sec)
It was carried out with a fragile air permeability measuring machine according to JIS L1913 6.8.1: 2010.
（７）不織布の判別
嵩高層が短繊維不織布か否かは、構成している繊維を引出して、短繊維形態であることを目視で確認する。緻密層が長繊維不織布か否かは、交絡している他の繊維不織布層（突出繊維構造部を含む）を剥離して、長繊維で構成されていることを目視で確認する。
(7) Discrimination of non-woven fabric Whether or not the bulky layer is a short fiber non-woven fabric is obtained by pulling out the constituting fiber and visually confirming that it is in a short fiber form. Whether or not the dense layer is a long-fiber non-woven fabric is confirmed by peeling off other entangled fiber non-woven fabric layers (including the protruding fiber structure) and visually confirming that it is composed of long fibers.
（８）長繊維不織布層の部分圧着部面積率
緻密層の長繊維不織布を嵩高層の長繊維不織布（突出繊維構造部を含む）と剥離して試料とし、任意の２０箇所で３０ｍｍ角に裁断し、ＳＥＭにて５０倍の写真を撮る。撮影写真をＡ３サイズに印刷して圧着単位面積を切り抜き、面積（Ｓ０）を求める。次いで圧着単位面積内において圧着部のみを切り抜き個々の部分圧着部の圧着ドット面積（Ｓｉ［ｍｍ2］）を求め、その平均値を部分圧着部の圧着ドット面積とする。圧着部面積積算値（ΣＳｉ＝Ｓｐ）より下式により部分圧着部面積率（Ｐ［％］）を算出する。
Ｐ＝Ｓｐ／Ｓ０ （ｎ＝２０）
(8) Area ratio of partial pressure-bonded portion of long-fiber non-woven fabric layer The long-fiber non-woven fabric of the dense layer is peeled off from the bulky long-fiber non-woven fabric (including the protruding fiber structure) and cut into 30 mm squares at any 20 locations. And take 50x pictures with SEM. The photographed photograph is printed in A3 size, the crimping unit area is cut out, and the area (S0) is obtained. Next, only the pressure-bonding part is cut out within the pressure-bonding unit area, and the pressure-bonding dot area (Si [mm 2 ]) of each partial pressure-bonding part is obtained, and the average value is taken as the pressure-bonding dot area of the partial pressure-bonding part. A partial pressure-bonding area ratio (P [%]) is calculated from the pressure-bonding area integrated value (ΣSi = Sp) by the following formula.
P = Sp / S0 (n = 20)
（９）不織布の引出し変形性
ＪＩＳ Ｌ１９１３ ６．３：２０１０の『引張強さ及び伸び率』に準拠した幅５ｃｍの不織布試料を用いて、縦方向に対して２０Ｎ／５ｃｍの伸長応力で伸長回復処理を１０回行い、試料を１時間放置した後、縦方向の不織布の伸び変形と目視による形態変化を求めた。
伸び変形５％未満（形態変化なし）：○、伸び変形５％以上１０％未満（形態変化微小）：△、伸び変形１０％以上（形態変化あり）：×として評価した。
(9) Draw-out deformability of nonwoven fabric Using a nonwoven fabric sample with a width of 5 cm in accordance with “Tensile strength and elongation” of JIS L1913 6.3: 2010, stretch recovery is achieved with an elongation stress of 20 N / 5 cm in the longitudinal direction. The treatment was performed 10 times and the sample was allowed to stand for 1 hour, and then the elongation deformation of the longitudinal nonwoven fabric and the visual form change were determined.
Elongation deformation was less than 5% (no change in shape): ◯, elongation deformation was 5% or more and less than 10% (fine change in shape): Δ, elongation deformation was 10% or more (with change in shape): x.
（１０）発泡成形への適用性評価
クッションパッド金型に所定の形状に切断した補強用不織布を、形状に馴染ませるようにセットして、セット状態を金型追随性として官能評価し、次いで、２液ウレタン樹脂（イソシアネート：三洋化成工業（株）社製サンフォーム（登録商標）ＲＣ−１０２６／ポリオール：三洋化成工業（株）社製サンフォーム（登録商標）ＩＣ−５０５Ｎを１／２．５（質量比））にて６５℃のコールド発泡（発泡容積：幅４６０ｍｍ×長さ３８０ｍｍ×深さ５０ｍｍ）を行い、成形品の評価を目視判定で行った。
（１０−１）金型追随性
金型に馴染み易くセット容易：○、馴染み易いがセットし難い：△、馴染み難くセットできない：×で官能評価した。
（１０−２）滲み出し
成形品の補強用不織布面にウレタンの滲み出しがなし：○、滲み出し微小：△、滲み出し明確にあり：×で目視判定した。
（１０−３）破れ
成形品の補強用不織布面に破れなし：○、破れ直前：△、破れあり：×で目視判定した。
（１０−４）型添い性
成形品の補強用不織布面が金型の形状と一致する：○、わずかに形状が一致しない：△、明確に形状が一致しない：×で目視評価した。
(10) Applicability evaluation to foam molding A reinforcing nonwoven fabric cut into a predetermined shape in a cushion pad mold is set so as to conform to the shape, and the set state is sensory-evaluated as mold followability, and then 2-pack urethane resin (isocyanate: Sanyo Chemical Industries, Ltd. Sunfoam (registered trademark) RC-1026 / polyol: Sanyo Chemical Industries, Ltd. Sunfoam (registered trademark) IC-505N 1/2. (Mass ratio)) was subjected to cold foaming at 65 ° C. (foaming volume: width 460 mm × length 380 mm × depth 50 mm), and the molded product was evaluated by visual judgment.
(10-1) Mold Followability Easy to set in mold and easy to set: ○, easy to set but difficult to set: Δ, difficult to set and cannot be set: ×.
(10-2) Exudation No urethane exudation on the reinforcing nonwoven fabric surface of the molded product: ○, exudation fine: Δ, exudation clearly present: x was visually judged.
(10-3) Breaking No tearing on the reinforcing non-woven fabric surface of the molded product: ○, Immediately before tearing: Δ, With tearing: x was visually judged.
(10-4) Mold-attaching property The reinforcing nonwoven fabric surface of the molded product matches the shape of the mold: ○, slightly mismatched shape: Δ, clearly unmatched shape: × evaluated visually.
（１１）成形品の制音性評価
実車に成形品（クッションパッド）をセットして、時速６０ｋｍでの平地走行試験１時間での振動音、擦れ音を聞き、補強用不織布のない成形品（クッションパッド）と比べ静か：○、同等の静かさ：×で官能評価した。
(11) Evaluation of noise suppression of molded products A molded product (cushion pad) is set on an actual vehicle, and a vibration product and a rubbing sound are heard in a flat ground running test at 60 km / h for 1 hour. Compared with cushion pad), the sensory evaluation was performed with a quiet: ○ and an equivalent quiet: x.
＜実施例１＞
固有粘度０．６５ｄｌ／ｇのポリエチレンテレフタレート（以下、「ＰＥＴ」と略す。）を用いて、紡糸温度２９０℃にて丸断面ノズルより単孔吐出量１．０ｇ／分にて溶融紡糸し、紡糸速度４５００ｍ／分にて牽引しつつ開繊して、下方にあるコンベアネット上に振り落とした。当該コンベアネットの幅方向端部に高さ２ｃｍのパンチングメタルからなる随伴流規制板を設置し、サクション吸引風速を８ｍ／秒として繊度２．２ｄｔｅｘの長繊維からなる目付が３０ｇ／ｍ2のウエッブを得た。ついで、連続して圧着面積率１８％の楕円文様エンボスローラーを用いて、エンボス温度２００℃、線圧４０ｋＮ／ｍにてエンボス加工して、２．２ｄｔｅｘの連続繊維からなる目付が３０ｇ／ｍ2、繊維配列角度が２２°、見掛け密度０．１８５ｇ／ｃｍ3の緻密層用長繊維不織布を得た。
<Example 1>
Using polyethylene terephthalate (hereinafter abbreviated as “PET”) having an intrinsic viscosity of 0.65 dl / g, melt spinning is performed at a spinning temperature of 290 ° C. at a single hole discharge rate of 1.0 g / min. The fiber was opened while being pulled at a speed of 4500 m / min, and was shaken down on a conveyor net below. An adjoining flow regulating plate made of punching metal with a height of 2 cm is installed at the width direction end of the conveyor net, and a web having a basis weight of 30 g / m 2 made of long fibers having a fineness of 2.2 dtex with a suction suction air speed of 8 m / sec. Got. Subsequently, it was embossed at an embossing temperature of 200 ° C. and a linear pressure of 40 kN / m using an elliptical pattern embossing roller having a crimping area ratio of 18%, and the basis weight made of continuous fibers of 2.2 dtex was 30 g / m 2. A long fiber nonwoven fabric for a dense layer having a fiber arrangement angle of 22 ° and an apparent density of 0.185 g / cm 3 was obtained.
固有粘度０．６５ｄｌ／ｇのＰＥＴを用いて、紡糸温度２９０℃にて丸断面ノズルより単孔吐出量１．０ｇ／分にて溶融紡糸し、紡糸速度４５００ｍ／分にて牽引しつつ開繊して、下方にあるコンベアネット上に振り落とした。その際のサクション吸引風速を１２ｍ／秒として繊度２．２ｄｔｅｘの長繊維からなる目付が３０ｇ／ｍ2のウエッブを得た。ついで、連続して圧着面積率１８％の楕円文様エンボスローラーを用いて、エンボス温度１５０℃、線圧３０ｋＮ／ｍにてエンボス加工して、２．２ｄｔｅｘの連続繊維からなる目付が３０ｇ／ｍ2、繊維配列角度が４５°、見掛け密度０．１４６ｇ／ｃｍ3の嵩高層用長繊維不織布を得た。 Using PET with an intrinsic viscosity of 0.65 dl / g, melt spinning with a single-hole discharge rate of 1.0 g / min from a round cross-section nozzle at a spinning temperature of 290 ° C., and opening while pulling at a spinning speed of 4500 m / min Then, it was shaken down on the conveyor net below. At that time, a suction suction wind speed of 12 m / second was used to obtain a web having a basis weight of 30 g / m 2 made of long fibers having a fineness of 2.2 dtex. Subsequently, it was embossed at an embossing temperature of 150 ° C. and a linear pressure of 30 kN / m using an elliptical pattern embossing roller having a crimping area ratio of 18%, and the basis weight made of continuous fibers of 2.2 dtex was 30 g / m 2. A long fiber nonwoven fabric for bulky layers having a fiber arrangement angle of 45 ° and an apparent density of 0.146 g / cm 3 was obtained.
前記で得られた緻密層用長繊維不織布と嵩高層用長繊維不織布とをペネ５０本／ｃｍ2、ニードル針深度１０ｍｍにて嵩高層用長繊維不織布、緻密層用長繊維不織布の順にニードルが貫入するようにニードルパンチによる交絡処理を行って、目付６０ｇ／ｍ2の積層交絡した補強用不織布を得た。得られた補強用不織布は、厚み０．６２ｍｍ、５％伸長時応力が、縦方向２５Ｎ／５ｃｍ、横方向１０Ｎ／５ｃｍで５％伸長時応力の縦横比（以下、縦／横比という）が２．５０、通気度が２００ｃｍ3／ｃｍ2・ｓｅｃであった。 The dense fiber long fiber nonwoven fabric and the bulky layer long fiber nonwoven fabric obtained in the above were used in the order of the bulky layer long fiber nonwoven fabric and the dense layer long fiber nonwoven fabric in a pene of 50 / cm 2 and a needle needle depth of 10 mm. The entanglement process by a needle punch was performed so that it might penetrate, and the reinforcement nonwoven fabric which carried out the lamination | stacking of the fabric weight of 60 g / m < 2 > was obtained. The obtained non-woven fabric for reinforcement has a thickness ratio of 0.62 mm, a stress at 5% elongation of 25 N / 5 cm in the longitudinal direction and a stress ratio of 5% elongation at 10 N / 5 cm in the lateral direction (hereinafter referred to as a longitudinal / aspect ratio). The air permeability was 2.50 and 200 cm 3 / cm 2 · sec.
得られた補強用不織布の評価結果を表１に示す。本発明要件を満たす実施例１は、引出し変形、金型追随性とも良好で、発泡成形での滲み出し、破れは無く、型添い性も良好であった。性能評価でも制音性は良好で、発泡成形品補強用としての優れた性能を持つ不織布であった。 The evaluation results of the obtained reinforcing nonwoven fabric are shown in Table 1. In Example 1 satisfying the requirements of the present invention, the drawer deformation and the mold followability were good, there was no oozing and tearing in foam molding, and the moldability was also good. Even in the performance evaluation, the sound-damping property was good, and the nonwoven fabric had excellent performance for reinforcing foamed products.
＜実施例２＞
固有粘度０．６５ｄｌ／ｇのＰＥＴを用いて、紡糸温度２９０℃にて丸断面ノズルより単孔吐出量１．０ｇ／分にて溶融紡糸し、紡糸速度４５００ｍ／分にて牽引しつつ開繊して、下方にあるコンベアネット上に振り落とした。当該コンベアネットの幅方向端部に高さ２ｃｍのパンチングメタルからなる随伴流規制板を設置し、サクション吸引風速を６ｍ／秒として繊度２．２ｄｔｅｘの長繊維からなる目付が４０ｇ／ｍ2のウエッブを得た。
ついで、連続して圧着面積率１８％の楕円文様エンボスローラーを用いて、エンボス温度２００℃、線圧４０ｋＮ／ｍにてエンボス加工して、２．２ｄｔｅｘの連続繊維からなる目付が４０ｇ／ｍ2、繊維配列角度が２６°、見掛け密度０．１８２ｇ／ｃｍ3の緻密層用長繊維不織布を得た。
<Example 2>
Using PET with an intrinsic viscosity of 0.65 dl / g, melt spinning with a single-hole discharge rate of 1.0 g / min from a round cross-section nozzle at a spinning temperature of 290 ° C., and opening while pulling at a spinning speed of 4500 m / min Then, it was shaken down on the conveyor net below. An adjoining flow regulating plate made of punched metal with a height of 2 cm is installed at the width direction end of the conveyor net, and a web having a basis weight of 40 g / m 2 made of long fibers having a fineness of 2.2 dtex with a suction suction air speed of 6 m / sec. Got.
Subsequently, it was embossed at an embossing temperature of 200 ° C. and a linear pressure of 40 kN / m using an elliptical pattern embossing roller having a crimping area ratio of 18%, and a basis weight of continuous fibers of 2.2 dtex was 40 g / m 2. A long fiber nonwoven fabric for a dense layer having a fiber arrangement angle of 26 ° and an apparent density of 0.182 g / cm 3 was obtained.
嵩高層用長繊維不織布の目付が４０ｇ／ｍ2となるようにコンベア速度を調整する以外は、実施例１と同様にして繊維配列角度が４８°、見掛け密度０．１４３ｇ／ｃｍ3の嵩高層用長繊維不織布を得た。 Bulky layer having a fiber arrangement angle of 48 ° and an apparent density of 0.143 g / cm 3 in the same manner as in Example 1 except that the conveyor speed is adjusted so that the basis weight of the bulky nonwoven fabric for bulky layer is 40 g / m 2. A long fiber nonwoven fabric was obtained.
その後、実施例１と同様にニードルパンチによる交絡処理を行って、目付８０ｇ／ｍ2の積層交絡した補強用不織布を得た。得られた補強用不織布は、厚み０．８５ｍｍ、５％伸長時応力が、縦方向３２Ｎ／５ｃｍ、横方向１３Ｎ／５ｃｍで縦／横比が２．４６、通気度が１６０ｃｍ3／ｃｍ2・ｓｅｃであった。 Then, the entanglement process by a needle punch was performed like Example 1, and the nonwoven fabric for reinforcement which carried out the lamination | stacking of the fabric weight of 80 g / m < 2 > was obtained. The obtained nonwoven fabric for reinforcement had a thickness of 0.85 mm, a 5% elongation stress of 32 N / 5 cm in the vertical direction, 13 N / 5 cm in the horizontal direction, an aspect ratio of 2.46, and an air permeability of 160 cm 3 / cm 2. sec.
得られた補強用不織布の評価結果を表１に示す。本発明要件を満たす実施例２は、引出し変形、金型追随性とも良好で、発泡成形での滲み出し、破れは無く、型添い性も良好であった。性能評価でも制音性は良好で、発泡成形品補強用としての優れた性能を持つ不織布であった。 The evaluation results of the obtained reinforcing nonwoven fabric are shown in Table 1. In Example 2 satisfying the requirements of the present invention, the drawer deformation and the mold followability were good, there was no oozing and tearing in foam molding, and the moldability was also good. Even in the performance evaluation, the sound-damping property was good, and the nonwoven fabric had excellent performance for reinforcing foamed products.
＜実施例３＞
固有粘度０．６５ｄｌ／ｇのＰＥＴを用いて、紡糸温度２９０℃にて丸断面ノズルより単孔吐出量１．０ｇ／分にて溶融紡糸し、紡糸速度４５００ｍ／分にて牽引しつつ開繊して、下方にあるコンベアネット上に振り落とした。当該コンベアネットの幅方向端部には高さ２ｃｍのパンチングメタルからなる随伴流規制板を設置し、サクション吸引風速を６ｍ／秒として繊度２．２ｄｔｅｘの長繊維からなる目付が６５ｇ／ｍ2のウエッブを得た
。ついで、連続して圧着面積率１８％の楕円文様エンボスローラーを用いて、エンボス温度１５０℃、線圧３０ｋＮ／ｍにてエンボス加工して、２．２ｄｔｅｘの連続繊維からなる目付が６５ｇ／ｍ2、繊維配列角度が２８°、見掛け密度０．１５１ｇ／ｃｍ3の嵩高層用長繊維不織布を得た。
<Example 3>
Using PET with an intrinsic viscosity of 0.65 dl / g, melt spinning with a single-hole discharge rate of 1.0 g / min from a round cross-section nozzle at a spinning temperature of 290 ° C., and opening while pulling at a spinning speed of 4500 m / min Then, it was shaken down on the conveyor net below. An adjoining flow regulating plate made of a punching metal having a height of 2 cm is installed at the width direction end of the conveyor net, and the basis weight made of long fibers having a fineness of 2.2 dtex with a suction suction wind speed of 6 m / second is 65 g / m 2 . I got a web. Subsequently, it was embossed continuously at an embossing temperature of 150 ° C. and a linear pressure of 30 kN / m using an oval pattern embossing roller with a crimping area ratio of 18%, and the basis weight made of continuous fibers of 2.2 dtex was 65 g / m 2. A long fiber nonwoven fabric for bulky layers having a fiber arrangement angle of 28 ° and an apparent density of 0.151 g / cm 3 was obtained.
その後、実施例２と同様にして得た緻密層用長繊維不織布４０ｇ／ｍ2と前記嵩高層用長繊維不織布とを実施例１と同様にニードルパンチによる交絡処理を行って、目付１０５ｇ／ｍ2の積層交絡した補強用不織布を得た。得られた補強用不織布は、厚み１．１０ｍｍ、５％伸長時応力が、縦方向４２Ｎ／５ｃｍ、横方向１４Ｎ／５ｃｍで縦／横比が３．００、通気度が１２０ｃｍ3／ｃｍ2・ｓｅｃであった。 Thereafter, 40 g / m 2 of the long fiber nonwoven fabric for dense layer obtained in the same manner as in Example 2 and the long fiber nonwoven fabric for bulky layer were entangled by needle punch in the same manner as in Example 1 to obtain a basis weight of 105 g / m. Two laminated entangled nonwoven fabrics for reinforcement were obtained. The resulting non-woven fabric for reinforcement has a thickness of 1.10 mm, a 5% elongation stress of 42 N / 5 cm in the vertical direction, 14 N / 5 cm in the horizontal direction, an aspect ratio of 3.00, and an air permeability of 120 cm 3 / cm 2. sec.
得られた補強用不織布の評価結果を表１に示す。本発明要件を満たす実施例３は、引出し変形、金型追随性とも良好で、発泡成形での滲み出し、破れは無く、型添い性も良好であった。性能評価でも制音性は良好で、発泡成形品補強用としての優れた性能を持つ不織布であった。 The evaluation results of the obtained reinforcing nonwoven fabric are shown in Table 1. In Example 3 satisfying the requirements of the present invention, the drawer deformation and the mold followability were good, there was no oozing and tearing in foam molding, and the moldability was also good. Even in the performance evaluation, the sound-damping property was good, and the nonwoven fabric had excellent performance for reinforcing foamed products.
＜実施例４＞
固有粘度０．６５ｄｌ／ｇのＰＥＴを用いて、紡糸温度２９０℃にて丸断面ノズルより単孔吐出量１．０ｇ／分にて溶融紡糸し、紡糸速度４５００ｍ／分にて牽引しつつ開繊して、下方にあるコンベアネット上に振り落とした。当該コンベアネットの幅方向端部に高さ２ｃｍのパンチングメタルからなる随伴流規制板を設置し、サクション吸引風速を４．５ｍ／秒として繊度２．２ｄｔｅｘの長繊維からなる目付が４０ｇ／ｍ2のウエッブを得た。ついで、連続して圧着面積率１８％の楕円文様エンボスローラーを用いて、エンボス温度２００℃、線圧４０ｋＮ／ｍにてエンボス加工して、２．２ｄｔｅｘの連続繊維からなる目付が４０ｇ／ｍ2、繊維配列角度が２０°、見掛け密度０．１８９ｇ／ｃｍ3の緻密層用長繊維不織布を得た。
<Example 4>
Using PET with an intrinsic viscosity of 0.65 dl / g, melt spinning with a single-hole discharge rate of 1.0 g / min from a round cross-section nozzle at a spinning temperature of 290 ° C., and opening while pulling at a spinning speed of 4500 m / min Then, it was shaken down on the conveyor net below. An adjoining flow regulating plate made of a punching metal having a height of 2 cm is installed at the width direction end of the conveyor net, and the basis weight made of long fibers having a fineness of 2.2 dtex is 40 g / m 2 with a suction suction air speed of 4.5 m / second. I got the web. Subsequently, it was embossed at an embossing temperature of 200 ° C. and a linear pressure of 40 kN / m using an elliptical pattern embossing roller having a crimping area ratio of 18%, and a basis weight of continuous fibers of 2.2 dtex was 40 g / m 2. A long fiber nonwoven fabric for a dense layer having a fiber arrangement angle of 20 ° and an apparent density of 0.189 g / cm 3 was obtained.
その後、実施例２と同様にして得た嵩高層用長繊維不織布４０ｇ／ｍ2と前記緻密層用長繊維不織布とを実施例１と同様にニードルパンチによる交絡処理を行って、目付８０ｇ／ｍ2の積層交絡した補強用不織布を得た得られた補強用不織布は、厚み０．８４ｍｍ、５％伸長時応力が、縦方向３７Ｎ／５ｃｍ、横方向８Ｎ／５ｃｍで縦／横比が４．６３、通気度が１６０ｃｍ3／ｃｍ2・ｓｅｃであった。 Then, 40 g / m 2 of the bulky fiber long-fiber nonwoven fabric obtained in the same manner as in Example 2 and the dense fiber long-fiber nonwoven fabric were entangled by needle punching in the same manner as in Example 1, and the basis weight was 80 g / m. The reinforcing nonwoven fabric obtained by obtaining the laminated entangled reinforcing nonwoven fabric of No. 2 has a thickness of 0.84 mm, a 5% elongation stress of 37 N / 5 cm in the vertical direction and 8 N / 5 cm in the horizontal direction and an aspect ratio of 4. 63. The air permeability was 160 cm 3 / cm 2 · sec.
得られた補強用不織布の評価結果を表１に示す。本発明要件を満たす実施例４は、引出し変形、金型追随性とも良好で、発泡成形での滲み出し、破れは無く、型添い性も良好であった。性能評価でも制音性は良好で、発泡成形品補強用としての優れた性能を持つ不織布であった。 The evaluation results of the obtained reinforcing nonwoven fabric are shown in Table 1. In Example 4 satisfying the requirements of the present invention, the drawer deformation and the mold followability were good, there was no oozing and tearing in foam molding, and the moldability was also good. Even in the performance evaluation, the sound-damping property was good, and the nonwoven fabric had excellent performance for reinforcing foamed products.
＜比較例１＞
固有粘度０．６５ｄｌ／ｇのＰＥＴを用いて、紡糸温度２９０℃にて丸断面ノズルより単孔吐出量１．０ｇ／分にて溶融紡糸し、紡糸速度４５００ｍ／分にて牽引しつつ開繊して、下方にあるコンベアネット上に振り落とした。その際のサクション吸引風速を１２ｍ／秒として繊度２．２ｄｔｅｘの長繊維からなる目付が４０ｇ／ｍ2のウエッブを得た。ついで、連続して圧着面積率１８％の楕円文様エンボスローラーを用いて、エンボス温度２００℃、線圧４０ｋＮ／ｍにてエンボス加工して、２．２ｄｔｅｘの連続繊維からなる目付が４０ｇ／ｍ2、繊維配列角度が４５°、見掛け密度０．１８２ｇ／ｃｍ3の緻密層用長繊維不織布を得た。
<Comparative Example 1>
Using PET with an intrinsic viscosity of 0.65 dl / g, melt spinning with a single-hole discharge rate of 1.0 g / min from a round cross-section nozzle at a spinning temperature of 290 ° C., and opening while pulling at a spinning speed of 4500 m / min Then, it was shaken down on the conveyor net below. At that time, a suction suction wind speed of 12 m / sec was used to obtain a web having a basis weight of 40 g / m 2 made of long fibers having a fineness of 2.2 dtex. Subsequently, it was embossed at an embossing temperature of 200 ° C. and a linear pressure of 40 kN / m using an elliptical pattern embossing roller having a crimping area ratio of 18%, and a basis weight of continuous fibers of 2.2 dtex was 40 g / m 2. A long fiber nonwoven fabric for a dense layer having a fiber arrangement angle of 45 ° and an apparent density of 0.182 g / cm 3 was obtained.
固有粘度０．６５ｄｌ／ｇのＰＥＴを用いて、紡糸温度２９０℃にて丸断面ノズルより単孔吐出量１．０ｇ／分にて溶融紡糸し、紡糸速度４５００ｍ／分にて牽引しつつ開繊して、下方にあるコンベアネット上に振り落とした。その際のサクション吸引風速を１２ｍ／秒として繊度２．２ｄｔｅｘの長繊維からなる目付が５５ｇ／ｍ2のウエッブを得た。ついで、連続して圧着面積率１８％の楕円文様エンボスローラーを用いて、エンボス温度１７０℃、線圧３０ｋＮ／ｍにてエンボス加工して、２．２ｄｔｅｘの連続繊維からなる目付が５５ｇ／ｍ2、繊維配列角度が４９°、見掛け密度０．１５２ｇ／ｃｍ3の嵩高層用長繊維不織布を得た。 Using PET with an intrinsic viscosity of 0.65 dl / g, melt spinning with a single-hole discharge rate of 1.0 g / min from a round cross-section nozzle at a spinning temperature of 290 ° C., and opening while pulling at a spinning speed of 4500 m / min Then, it was shaken down on the conveyor net below. At that time, a suction suction wind speed of 12 m / second was used to obtain a web having a basis weight of 55 g / m 2 made of long fibers having a fineness of 2.2 dtex. Next, it was embossed continuously at an embossing temperature of 170 ° C. and a linear pressure of 30 kN / m using an oval pattern embossing roller with a crimping area ratio of 18%, and the basis weight made of 2.2 dtex continuous fiber was 55 g / m 2. A long fiber nonwoven fabric for bulky layers having a fiber arrangement angle of 49 ° and an apparent density of 0.152 g / cm 3 was obtained.
その後、実施例１と同様にニードルパンチによる交絡処理を行って、目付９５ｇ／ｍ2の積層交絡した補強用不織布を得た。得られた補強用不織布は、厚み０．９７ｍｍ、５％伸長時応力が、縦方向２０Ｎ／５ｃｍ、横方向１３Ｎ／５ｃｍで縦／横比が１．５４、通気度が１３５ｃｍ3／ｃｍ2・ｓｅｃであった。
得られた補強用不織布の評価結果を表１に示す。５％伸長時応力の縦方向が２０Ｎ／５ｃｍである比較例１は、引出し時に幅入りが大きく、所定寸法が採取できない不織布であった。
Then, the entanglement process by a needle punch was performed like Example 1, and the nonwoven fabric for reinforcement which carried out lamination | stacking of the fabric weight of 95 g / m < 2 > was obtained. The obtained reinforcing nonwoven fabric has a thickness of 0.97 mm, a 5% elongation stress of 20 N / 5 cm in the vertical direction, 13 N / 5 cm in the horizontal direction, an aspect ratio of 1.54, and an air permeability of 135 cm 3 / cm 2. sec.
The evaluation results of the obtained reinforcing nonwoven fabric are shown in Table 1. Comparative Example 1 in which the longitudinal direction of the stress at 5% elongation was 20 N / 5 cm was a nonwoven fabric that had a large width at the time of drawing and could not collect a predetermined dimension.
＜比較例２＞
固有粘度０．６５ｄｌ／ｇのＰＥＴを用いて、紡糸温度２９０℃にて丸断面ノズルより単孔吐出量１．０ｇ／分にて溶融紡糸し、紡糸速度４５００ｍ／分にて牽引しつつ開繊して、下方にあるコンベアネット上に振り落とした。その際のサクション吸引風速を１２ｍ／秒として繊度２．２ｄｔｅｘの長繊維からなる目付が６５ｇ／ｍ2のウエッブを得た。ついで、連続して圧着面積率１８％の楕円文様エンボスローラーを用いて、エンボス温度１５０℃、線圧３０ｋＮ／ｍにてエンボス加工して、２．２ｄｔｅｘの連続繊維からなる目付が６５ｇ／ｍ2、繊維配列角度が５０°、見掛け密度０．１５１ｇ／ｃｍ3の嵩高層用長繊維不織布を得た。
<Comparative example 2>
Using PET with an intrinsic viscosity of 0.65 dl / g, melt spinning with a single-hole discharge rate of 1.0 g / min from a round cross-section nozzle at a spinning temperature of 290 ° C., and opening while pulling at a spinning speed of 4500 m / min Then, it was shaken down on the conveyor net below. At that time, a suction suction wind speed of 12 m / second was used to obtain a web having a basis weight of 65 g / m 2 made of long fibers having a fineness of 2.2 dtex. Subsequently, it was embossed continuously at an embossing temperature of 150 ° C. and a linear pressure of 30 kN / m using an oval pattern embossing roller with a crimping area ratio of 18%, and the basis weight made of continuous fibers of 2.2 dtex was 65 g / m 2. A bulky nonwoven fabric for bulky layers having a fiber arrangement angle of 50 ° and an apparent density of 0.151 g / cm 3 was obtained.
その後、比較例１と同様にして得た緻密層用長繊維不織布４０ｇ／ｍ2と前記嵩高層用長繊維不織布とを実施例１と同様にニードルパンチによる交絡処理を行って、目付１０５ｇ／ｍ2の積層交絡した補強用不織布を得た。得られた補強用不織布は、厚み１．１０ｍｍ、５％伸長時応力が、縦方向２５Ｎ／５ｃｍ、横方向１７Ｎ／５ｃｍで縦／横比が１．４７、通気度が１２２ｃｍ3／ｃｍ2・ｓｅｃであった。 Thereafter, the dense fiber long-fiber nonwoven fabric 40 g / m 2 obtained in the same manner as in Comparative Example 1 and the bulky fiber long-fiber nonwoven fabric were entangled with a needle punch in the same manner as in Example 1, and the basis weight was 105 g / m. Two laminated entangled nonwoven fabrics for reinforcement were obtained. The obtained reinforcing nonwoven fabric has a thickness of 1.10 mm, a 5% elongation stress of 25 N / 5 cm in the vertical direction, 17 N / 5 cm in the horizontal direction, an aspect ratio of 1.47, and an air permeability of 122 cm 3 / cm 2. sec.
得られた補強用不織布の評価結果を表１に示す。５％伸長時応力の横方向が１７Ｎ／５ｃｍである比較例２は、引出し変形、金型追随性とも良好であったが、横方向の応力が高く、型添い性がやや劣る問題のある不織布であった。 The evaluation results of the obtained reinforcing nonwoven fabric are shown in Table 1. Comparative Example 2 in which the lateral direction of the stress at 5% elongation is 17 N / 5 cm was good in both the drawing deformation and the mold following property, but the nonwoven fabric has a problem that the lateral stress is high and the moldability is slightly inferior. Met.
＜比較例３＞
固有粘度０．６５ｄｌ／ｇのＰＥＴを用いて、紡糸温度２９０℃にて丸断面ノズルより単孔吐出量１．０ｇ／分にて溶融紡糸し、紡糸速度４５００ｍ／分にて牽引しつつ開繊して、下方にあるコンベアネット上に振り落とした。その際のサクション吸引風速を１２ｍ／秒として繊度２．２ｄｔｅｘの長繊維からなる目付が３０ｇ／ｍ2のウエッブを得た。ついで、連続して圧着面積率１８％の楕円文様エンボスローラーを用いて、エンボス温度２００℃、線圧４０ｋＮ／ｍにてエンボス加工して、２．２ｄｔｅｘの連続繊維からなる目付が３０ｇ／ｍ2、繊維配列角度が４５°、見掛け密度０．１８５ｇ／ｃｍ3の緻密層用長繊維不織布を得た。
<Comparative Example 3>
Using PET with an intrinsic viscosity of 0.65 dl / g, melt spinning with a single-hole discharge rate of 1.0 g / min from a round cross-section nozzle at a spinning temperature of 290 ° C., and opening while pulling at a spinning speed of 4500 m / min Then, it was shaken down on the conveyor net below. At that time, a suction suction wind speed of 12 m / second was used to obtain a web having a basis weight of 30 g / m 2 made of long fibers having a fineness of 2.2 dtex. Subsequently, it was embossed at an embossing temperature of 200 ° C. and a linear pressure of 40 kN / m using an elliptical pattern embossing roller having a crimping area ratio of 18%, and the basis weight made of continuous fibers of 2.2 dtex was 30 g / m 2. A long-fiber nonwoven fabric for a dense layer having a fiber arrangement angle of 45 ° and an apparent density of 0.185 g / cm 3 was obtained.
その後、実施例１と同様にして得た嵩高層用長繊維不織布３０ｇ／ｍ2と前記緻密層用長繊維不織布を実施例１と同様にニードルパンチによる交絡処理を行って、目付６０ｇ／ｍ2の積層交絡した補強用不織布を得た。 Thereafter, the bulky layer long-fiber nonwoven fabric 30 g / m 2 obtained in the same manner as in Example 1 and the dense layer long-fiber nonwoven fabric were entangled by needle punch in the same manner as in Example 1 to obtain a basis weight of 60 g / m 2. A non-woven fabric for reinforcement entangled with each other was obtained.
得られた補強用不織布は、厚み０．６２ｍｍ、５％伸長時応力が、縦方向１８Ｎ／５ｃｍ、横方向１３Ｎ／５ｃｍで縦／横比が１．３８、通気度が２０４ｃｍ3／ｃｍ2・ｓｅｃであった。 The obtained reinforcing nonwoven fabric has a thickness of 0.62 mm, a 5% elongation stress of 18 N / 5 cm in the vertical direction, 13 N / 5 cm in the horizontal direction, an aspect ratio of 1.38, an air permeability of 204 cm 3 / cm 2. sec.
得られた補強用不織布の評価結果を表１に示す。縦方向の５％伸長時応力が１８Ｎ／５ｃｍである比較例３は、引出し時に幅入りが大きく、所定寸法が採取できない不織布であった。 The evaluation results of the obtained reinforcing nonwoven fabric are shown in Table 1. Comparative Example 3 in which the stress at the time of 5% elongation in the longitudinal direction was 18 N / 5 cm was a non-woven fabric that had a large width at the time of drawing and could not collect a predetermined dimension.
＜比較例４＞
固有粘度０．６５ｄｌ／ｇのＰＥＴを用いて、紡糸温度２９０℃にて丸断面ノズルより単孔吐出量２．０ｇ／分にて溶融紡糸し、紡糸速度４５００ｍ／分にて牽引しつつ開繊して、下方にあるコンベアネット上に振り落とした。当該コンベアネットの幅方向端部に高さ２ｃｍのパンチングメタルからなる随伴流用幅規制板を設置し、サクション吸引風速を８ｍ／秒として繊度４．４ｄｔｅｘの長繊維からなる目付が３０ｇ／ｍ2のウエッブを得た。ついで、連続して圧着面積率１８％の楕円文様エンボスローラーを用いて、エンボス温度２００℃、線圧４０ｋＮ／ｍにてエンボス加工して、４．４ｄｔｅｘの連続繊維からなる目付が３０ｇ／ｍ2、繊維配列角度が２０°、見掛け密度０．１７８ｇ／ｃｍ3の緻密層用長繊維不織布を得た。
<Comparative Example 4>
Using PET with an intrinsic viscosity of 0.65 dl / g, melt spinning with a single-hole discharge rate of 2.0 g / min from a round cross-section nozzle at a spinning temperature of 290 ° C., and opening while pulling at a spinning speed of 4500 m / min Then, it was shaken down on the conveyor net below. An adjoining width regulating plate made of punching metal having a height of 2 cm is installed at the width direction end of the conveyor net, the suction suction air speed is 8 m / sec, and the basis weight made of long fibers having a fineness of 4.4 dtex is 30 g / m 2 . I got a web. Subsequently, it was embossed at an embossing temperature of 200 ° C. and a linear pressure of 40 kN / m using an elliptical pattern embossing roller having a crimping area ratio of 18%, and a basis weight made of continuous fibers of 4.4 dtex was 30 g / m 2. A long-fiber nonwoven fabric for a dense layer having a fiber arrangement angle of 20 ° and an apparent density of 0.178 g / cm 3 was obtained.
固有粘度０．６５ｄｌ／ｇのＰＥＴを用いて、紡糸温度２９０℃にて丸断面ノズルより単孔吐出量２．０ｇ／分にて溶融紡糸し、紡糸速度４５００ｍ／分にて牽引しつつ開繊して、下方にあるコンベアネット上に振り落とした。その際のサクション吸引風速を１２ｍ／秒として繊度４．４ｄｔｅｘの長繊維からなる目付が３０ｇ／ｍ2のウエッブを得た。ついで、連続して圧着面積率１８％の楕円文様エンボスローラーを用いて、エンボス温度１５０℃、線圧３０ｋＮ／ｍにてエンボス加工して、４．４ｄｔｅｘの連続繊維からなる目付が３０ｇ／ｍ2、繊維配列角度が４２°、見掛け密度０．１３３ｇ／ｃｍ3の嵩高層用長繊維不織布を得た。 Using PET with an intrinsic viscosity of 0.65 dl / g, melt spinning with a single-hole discharge rate of 2.0 g / min from a round cross-section nozzle at a spinning temperature of 290 ° C., and opening while pulling at a spinning speed of 4500 m / min Then, it was shaken down on the conveyor net below. At that time, a suction suction wind speed of 12 m / second was used to obtain a web having a basis weight of 30 g / m 2 made of long fibers having a fineness of 4.4 dtex. Subsequently, it was embossed at an embossing temperature of 150 ° C. and a linear pressure of 30 kN / m using an oval pattern embossing roller having a crimping area ratio of 18%, and the basis weight made of continuous fibers of 4.4 dtex was 30 g / m 2. A bulky nonwoven fabric for bulky layers having a fiber arrangement angle of 42 ° and an apparent density of 0.133 g / cm 3 was obtained.
その後、実施例１と同様にニードルパンチによる交絡処理を行って、目付６０ｇ／ｍ2の積層交絡した補強用不織布を得た。得られた補強用不織布は、厚み０．６６ｍｍ，５％伸長時応力が、縦方向２５Ｎ／５ｃｍ、横方向９Ｎ／５ｃｍで縦／横比が２．７８、通気度が３１５ｃｍ3／ｃｍ2・ｓｅｃであった。 Then, the entanglement process by a needle punch was performed like Example 1, and the nonwoven fabric for reinforcement which carried out the lamination | stacking of the fabric weight of 60 g / m < 2 > was obtained. The obtained reinforcing nonwoven fabric has a thickness of 0.66 mm, a 5% elongation stress of 25 N / 5 cm in the vertical direction, 9 N / 5 cm in the horizontal direction, an aspect ratio of 2.78, an air permeability of 315 cm 3 / cm 2. sec.
得られた補強用不織布の評価結果を表１に示す。通気度が３１５ｃｍ3／ｃｍ2・ｓｅｃである比較例４は、引出し変形、金型追随性とも良好であったが、発泡成形でのウレタンの滲み出しが発生し、成形品の制音性を評価した結果、制音性が劣る不織布であった。 The evaluation results of the obtained reinforcing nonwoven fabric are shown in Table 1. Comparative Example 4 having an air permeability of 315 cm 3 / cm 2 · sec was good in both drawing deformation and mold followability, but urethane exudation occurred in foam molding, and the sound damping property of the molded product was improved. As a result of the evaluation, the nonwoven fabric was inferior in sound damping.
本発明の発泡成形品補強用不織布は、特に、柔軟でありながらも、裁断・縫製工程での寸法安定性に優れ、さらに発泡性樹脂の遮断機能が高い緻密層と制音性に優れる嵩高層とからなり、突出繊維構造によるアンカー効果で発泡成形部と補強用不織布との密着性に優れるため、発泡成形用補強布用途に最適な不織布である。そのため、発泡成形時の金型追随性に優れ、発泡性樹脂の滲み出しがなく、高品位な発泡成形品が得られる。そして、発泡成形品とスプリング材間の摩擦によって発生する擦過音の制音性に優れ、優れた補強効果と耐久性も得られるので、製造コストを低く抑えた高機能な発泡成形品を得るための補強布用途に適している。
また、本発明の発泡成形品補強用不織布は、比較的軽量なため、軽量で高品位な発泡成形品を安価に製造でき、その発泡成形品を用いた車両用座席も安価に軽量化でき、車両運用上での省エネルギー化にも寄与できる。
The non-woven fabric for reinforcing foam-molded articles of the present invention is particularly a soft but high dimensional stability in cutting and sewing processes, and a dense layer having a high foaming resin blocking function and a bulky layer having excellent sound damping properties. Since the anchoring effect of the protruding fiber structure provides excellent adhesion between the foam molded part and the reinforcing nonwoven fabric, the nonwoven fabric is optimal for use as a foam molding reinforcing fabric. Therefore, the mold following property at the time of foam molding is excellent, the foaming resin does not ooze out, and a high-quality foam molded product can be obtained. In addition, it has excellent noise reduction of friction noise generated by the friction between the foam molded product and the spring material, and has excellent reinforcing effect and durability, so to obtain a highly functional foam molded product with low manufacturing cost. Suitable for use as a reinforcing fabric.
Moreover, since the nonwoven fabric for foam molded product reinforcement of the present invention is relatively lightweight, a lightweight and high-quality foam molded product can be manufactured at low cost, and a vehicle seat using the foam molded product can also be reduced in weight at low cost. It can also contribute to energy saving in vehicle operation.
Claims (4)
前記長繊維不織布はポリエチレンテレフタレートを含んでおり、少なくとも見掛け密度が高い方の長繊維不織布の繊維配列角度が５〜６０°であり、２２℃での縦方向の５％伸長時応力と２２℃での横方向の５％伸長時応力との比が２．２以上である
ことを特徴とする発泡成形品補強用不織布。 A nonwoven fabric in which two layers of long-fiber nonwoven fabrics with different apparent densities are laminated, having a basis weight of 50 to 110 g / m 2 , a thickness of 0.5 to 1.2 mm, and a longitudinal stress of 5% at 22 ° C. 23 to 50 N / 5 cm, the stress at 5% elongation in the transverse direction at 22 ° C. is 15 N / 5 cm or less, and the air permeability is 50 to 250 cm 3 / cm 2 · sec.
The long-fiber nonwoven fabric includes a polyethylene terephthalate, at least the apparent fiber alignment angle of the long-fiber nonwoven fabric towards denser is Ri 5 to 60 ° der, elongation of 5% stress and 22 ° C. in the longitudinal direction at 22 ° C. The non-woven fabric for reinforcing foam molded products , wherein the ratio of the stress at 5% elongation in the transverse direction at 2.2 is 2.2 or more .
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