JP5722511B1 - 発泡成形用不織布積層体、発泡成形用不織布積層体の製造方法、不織布積層体を用いたウレタン発泡成形体複合物、車両用シート、及び椅子 - Google Patents
発泡成形用不織布積層体、発泡成形用不織布積層体の製造方法、不織布積層体を用いたウレタン発泡成形体複合物、車両用シート、及び椅子 Download PDFInfo
- Publication number
- JP5722511B1 JP5722511B1 JP2014557646A JP2014557646A JP5722511B1 JP 5722511 B1 JP5722511 B1 JP 5722511B1 JP 2014557646 A JP2014557646 A JP 2014557646A JP 2014557646 A JP2014557646 A JP 2014557646A JP 5722511 B1 JP5722511 B1 JP 5722511B1
- Authority
- JP
- Japan
- Prior art keywords
- nonwoven fabric
- layer
- foam molding
- laminate
- foam
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- A—HUMAN NECESSITIES
- A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
- A47C—CHAIRS; SOFAS; BEDS
- A47C27/00—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas
- A47C27/14—Spring, stuffed or fluid mattresses or cushions specially adapted for chairs, beds or sofas with foamed material inlays
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- A—HUMAN NECESSITIES
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- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
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- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
- B60N2/64—Back-rests or cushions
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- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
- D04H1/43825—Composite fibres
- D04H1/43828—Composite fibres sheath-core
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- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
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Abstract
Description
前記補強層が、(A)繊維径が20μmより大きい熱可塑性樹脂短繊維を5質量%〜50質量%及び(B)繊維径が20μm以下の熱可塑性樹脂短繊維を95質量%〜50質量%含有し、前記(A)の熱可塑性樹脂短繊維と前記(B)の熱可塑性樹脂短繊維の合計が100質量%である短繊維不織布であり、かつ前記(A)の熱可塑性樹脂短繊維又は前記(B)の熱可塑性樹脂短繊維には、(C)融点の異なる2種以上の樹脂を含んで形成される複合ポリエステル系短繊維が含まれ、前記補強層中の前記(C)の複合ポリエステル系短繊維の含有率が10質量%〜40質量%であり、
前記緻密層は、嵩密度が0.05g/cm3〜0.3g/cm3の範囲にある不織布であり、
前記緻密層と前記補強層とがニードルパンチにより交絡されている発泡成形用不織布積層体。
緻密層の少なくとも片面に補強層を積層した後、前記緻密層と前記補強層とをニードルパンチにより交絡する発泡成形用不織布積層体の製造方法。
以下、本発明について具体的に説明する。
本発明の発泡成形用不織布積層体は、緻密層の少なくとも片面に補強層を有する。本発明に係る補強層は、(A)繊維径が20μmより大きい熱可塑性樹脂短繊維を5質量%〜50質量%及び(B)繊維径が20μm以下の熱可塑性樹脂短繊維を95質量%〜50質量%含有し、前記(A)の熱可塑性樹脂短繊維と前記(B)の熱可塑性樹脂短繊維の合計が100質量%である短繊維不織布であり、かつ前記(A)の熱可塑性樹脂短繊維又は前記(B)の熱可塑性樹脂短繊維には、(C)融点の異なる2種以上の樹脂を含んで形成される複合ポリエステル系短繊維が含まれ、前記補強層中の前記(C)の複合ポリエステル系短繊維の含有率が10質量%〜40質量%である。また、本発明に係る緻密層は、嵩密度が0.05g/cm3〜0.3g/cm3の範囲にある不織布であり、長繊維で構成されることが好ましい。
得られた不織布から、10mm×10mmの試験片を10点採取し、Nikon社製ECLIPSE E400顕微鏡を用い、倍率20倍で、繊維の直径をμm単位で小数点第1位まで読み取る。1試験片毎に任意の30箇所の径を測定し、平均値を求める。繊維が細い場合(メルトブローン層など)については、得られた不織布から試料片を採取して、走査型電子顕微鏡を用いて、倍率500倍または1000倍で観察し、構成繊維の30本の繊維径(μm)を測定し、平均値を求める。
本発明の発泡成形用不織布積層体を構成する補強層は、(A)繊維径が20μmより大きい熱可塑性樹脂短繊維を5質量%〜50質量%及び(B)繊維径が20μm以下の熱可塑性樹脂短繊維を95質量%〜50質量%含有し、前記(A)の熱可塑性樹脂短繊維と前記(B)の熱可塑性樹脂短繊維の合計が100質量%である短繊維不織布であり、かつ前記(A)の熱可塑性樹脂短繊維又は前記(B)の熱可塑性樹脂短繊維には、(C)融点の異なる2種以上の樹脂を含んで形成される複合ポリエステル系短繊維が含まれ、前記補強層中の前記(C)の複合ポリエステル系短繊維の含有率が10質量%〜40質量%である。
尚、(C)の複合ポリエステル系短繊維が、繊維径20μm以下のものを含む場合、(C)の複合ポリエステル系短繊維の全てにおいて繊維径が20μm以下であってもよいし、繊維径20μmよりも大きい複合ポリエステル系短繊維を更に含む混合繊維の形態であってもよい。(C)の複合ポリエステル系短繊維の総質量に対する、繊維径20μm以下の複合ポリエステル系短繊維の占める割合は特に限定されず、(A)の熱可塑性樹脂短繊維と(B)の熱可塑性樹脂短繊維との含有比率が、本発明の範囲を満たす限りにおいて適宜調整することができる。
また、(A)の熱可塑性樹脂短繊維及び(B)の熱可塑性樹脂短繊維も、2種以上の異なる熱可塑性樹脂からなる繊維を混合してなる混合繊維、形状が異なる2種以上の繊維を混合してなる混合繊維など、2種以上の繊維を混合してなる混合繊維であってもよい。
本発明の発泡成形用不織布積層体を構成する緻密層は、嵩密度が0.05g/cm3〜0.3g/cm3の範囲にある不織布であり、長繊維で構成される不織布であることが好ましい。本発明において、加熱・延展・圧縮の成形加工時に180℃程度の熱を受ける場合には、耐熱性の観点から、緻密層を構成する繊維はプロピレン系重合体などから形成されるポリオレフィン系繊維、及びポリエステル系繊維であることが好ましい。耐熱安定性の観点からポリエステル系繊維であることがより好ましい。但し、成形加工時に受ける熱が110℃程度までであれば、柔軟性、生産性などの観点からプロピレン系重合体などから形成されるポリオレフィン系繊維であることがより好ましい。また、ポリオレフィン系繊維及びポリエステル系重合体以外の重合体から形成されていてもよい。
本発明の発泡成形用不織布積層体は、緻密層の少なくとも片面に補強層が積層されてなり、緻密層と補強層とがニードルパンチにより交絡されている。
本発明の発泡成形用不織布積層体の製造方法では、緻密層の少なくとも片面に補強層を積層した後、前記緻密層と前記補強層とをニードルパンチにより交絡する。発泡成形用不織布積層体は、種々公知の方法、具体的には、例えば、熱エンボス加工あるいは超音波融着等の熱融着法、ニードルパンチあるいはウォータージェット等の機械的交絡法、ホットメルト接着剤あるいはウレタン系接着剤等の接着剤による方法、押出しラミネート等で、緻密層と補強層とが積層されてなり、緻密層と補強層との接合は、ニードルパンチによる機械的に接合する交絡法または加熱処理で融着させる熱融着法を採り得る。中でも、本発明では、ニードルパンチによる交絡処理によって、緻密層と補強層とを一体化するよう接合した積層体とする。このような構成とすることにより、偏りのない機械的交絡で緻密層と補強層とが接合される。また、ニードルパンチにより積層体としての厚み、緻密性において最良のバランスを保つことができる。このため本発明の発泡成形用不織布積層体は、発泡成形体を製造するための鋳型に立体的に追従させる段階を妨げず、かつ、追従により延伸が伴う場合などには延伸による厚さむらが生じにくく、全面において良好な緻密性及び柔軟性を維持することができるとともに、得られる発泡成形用不織布積層体に適度な通気性を保持させ、ウレタンなどが発泡成形する際に発生するガスを通過させることができ、ウレタン等の液の含浸をコントロールし漏れを防ぐことができる。
本発明のウレタン発泡成形体複合物は、上述の本発明の発泡成形用不織布積層体の補強層の外面に、発泡ウレタン層が設けられてなる。本発明のウレタン発泡成形体複合物は、上述の本発明の発泡成形用不織布積層体の補強層と、発泡ウレタン層とが一体化して形成されてなることが好ましい。発泡ウレタン層は、通常、所望の形状の型内でポリウレタンを発泡成形して製造される。本発明のウレタン発泡成形体複合物は、例えば、金型等の鋳型内の上部または底部などに上述した本発明の発泡成形用不織布積層体を追従させて配設し、鋳型内に発泡剤を含むポリウレタン原料を注入し、発泡成形させて製造することができる。
不織布から、機械方向(MD)100mm×横方向(CD)100mmの大きさで10点採取し、平均値を算出した。
上記目付量測定用試料の中央、四隅5点の厚みを測定し、50点の平均値を算出した。荷重が2g/cm2(荷重面積:4cm2)の厚み計を使用した。
不織布の嵩密度は、上記(1)及び(2)で得られた目付量及び厚さを用い、次式により求めた。
嵩密度=目付量(g/m2)/(上記厚さ(mm)/10×100×100)
JIS L 1906(2010)に準拠して測定した。発泡成形用不織布積層体から300mm(MD)×50mm(CD)の試験片を採取し、引張試験機(島津製作所:オートグラフAGS−J)を用いてチャック間距離200mm、ヘッドスピード100mm/minでMD(不織布の長さ方向):5点、CD(長さに直行する方向):5点を測定し、平均値を算出して、引張強度及び伸びをそれぞれ求めた。
発泡成形用不織布積層体から200mm(MD)×50mm(CD)の試験片を採取し、JIS L 1096(2010)に準じたフラジール通気度測定機によって、圧力差125Paでの流量を測定して求めた。
20cm角、高さ10cmの簡易鋳型を、40cm角(400mm(MD)×400mm(CD))の発泡成形用不織布積層体で覆い、真空圧空成形機にて200℃にて成形加工を実施した。成形加工時の型取りのしやすさや、加工後の不織布の形状保持性、寸法安定性、風合い(柔軟性)などを下記基準に従い目視と触感(手触り)にて判断した。
A: 加工可能で補強材として使用可能
B: 加工可であるが補強材としての風合いに劣る
BB: 溶融等により加工することが不可
10cm角(100mm(MD)×100mm(CD))の不織布に5kg荷重を掛け、110℃のオーブンに5分間放置した後の厚みを測定した。
発泡釜へ40cm角(400mm(MD)×400mm(CD))の発泡成形用不織布積層体を取り付け、ウレタンの染み出しを以下の基準により目視にて評価した。
A: ほとんど認められない
B: やや認められる
BB: かなり認められる
<補強層の製造>
ポリエステル系短繊維混合体を、プレニードルパンチ機にて不織布シート状にして、補強層用のポリエステル系短繊維不織布を得た。尚、ポリエステル系短繊維混合体は、下記PET3を30質量%含み、下記PET1を25質量%含み、下記PET2を45質量%含む。
PET1:融点が250℃である高融点ポリエステル樹脂の単独繊維。平均繊維径27μm、平均繊維長64mm。
PET2:融点が250℃である高融点ポリエステル樹脂の単独繊維。平均繊維径14μm、平均繊維長51mm。
MFRが60g/10分のプロピレン単重合体を用い230℃にて溶融紡糸を行い、得られた繊維を補集面上に堆積させ、目付量が6.0g/m2のスパンボンド不織布層(S1)(繊維径15μm)を製造した。
前記方法で得られた緻密層と補強層とを積層し、ニードルパンチにより接合して、発泡成形用不織布積層体を得た。得られた発泡成形用不織布積層体の物性を上記記載の方法で測定した。結果を表1に示す。
補強層に用いるポリエステル系短繊維不織布の目付量、繊維径、及び緻密層に用いるメルトブローン不織布層と、スパンボンド不織布層の目付量等を表1に示すように変更したこと以外は、実施例1と同様にして、発泡成形用不織布積層体を得た。得られた発泡成形用不織布積層体の物性を上記記載の方法で測定した。結果を表1に示す。
補強層に用いるポリエステル系短繊維不織布の目付量、繊維径、及び緻密層に用いるメルトブローン不織布層と、スパンボンド不織布層の目付量等を表1に示すように変更したこと以外は、実施例1と同様にして、発泡成形用不織布積層体を得た。成形加工時に緻密層が溶融し、不織布がフィルム化した結果、ウレタン発泡テストを行うができなかった。結果を表1に示す。尚、表1中、「−」は配合又は配置していないことを表す。
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Claims (23)
- 緻密層の少なくとも片面に補強層が積層されてなり、
前記補強層が、(A)繊維径が20μmより大きい熱可塑性樹脂短繊維を5質量%〜50質量%及び(B)繊維径が20μm以下の熱可塑性樹脂短繊維を95質量%〜50質量%含有し、前記(A)の熱可塑性樹脂短繊維と前記(B)の熱可塑性樹脂短繊維の合計が100質量%である短繊維不織布であり、かつ前記(A)の熱可塑性樹脂短繊維又は前記(B)の熱可塑性樹脂短繊維には、(C)融点の異なる2種以上の樹脂を含んで形成される複合ポリエステル系短繊維が含まれ、前記補強層中の前記(C)の複合ポリエステル系短繊維の含有率が10質量%〜40質量%であり、
前記緻密層は、嵩密度が0.05g/cm3〜0.3g/cm3の範囲にある不織布であり、
前記緻密層と前記補強層とがニードルパンチにより交絡されている発泡成形用不織布積層体。 - 厚みが1.6mm〜5.0mmである請求項1に記載の発泡成形用不織布積層体。
- 110℃、4.9Paで5分放置した後の厚さが1.2mm以上である請求項1又は請求項2に記載の発泡成形用不織布積層体。
- 前記(C)の複合ポリエステル系短繊維の少なくとも一部は、繊維径が20μm以下である請求項1〜請求項3のいずれか1項に記載の発泡成形用不織布積層体。
- 前記(C)の複合ポリエステル系短繊維を形成する少なくとも一つの樹脂の融点が、110〜190℃の範囲である請求項1〜請求項4のいずれか1項に記載の発泡成形用不織布積層体。
- 前記緻密層が、部分的な熱圧着、エアスルー加工、レジンボンド加工又はカレンダー加工が施されてなる不織布を含む請求項1〜請求項5のいずれか1項に記載の発泡成形用不織布積層体。
- 前記緻密層が、長繊維で構成される不織布である請求項1〜請求項6のいずれか1項に記載の発泡成形用不織布積層体。
- 前記(A)の熱可塑性樹脂短繊維及び前記(B)の熱可塑性樹脂短繊維が、ポリエステル系短繊維及びポリオレフィン系短繊維からなる群より選択される少なくとも1種の短繊維である請求項1〜請求項7のいずれか1項に記載の発泡成形用不織布積層体。
- 前記(A)の熱可塑性樹脂短繊維及び前記(B)の熱可塑性樹脂短繊維が、ポリエステル系短繊維である請求項1〜請求項8のいずれか1項に記載の発泡成形用不織布積層体。
- 前記緻密層が、部分的に熱圧着されてなる長繊維不織布を含む請求項1〜請求項9のいずれか1項に記載の発泡成形用不織布積層体。
- 前記緻密層の目付量が、10g/m2〜35g/m2の範囲にある請求項1〜請求項10のいずれか1項に記載の発泡成形用不織布積層体。
- 前記緻密層の通気度が、70cm3/cm2/sec〜200cm3/cm2/secの範囲にある請求項1〜請求項11のいずれか1項に記載の発泡成形用不織布積層体。
- 前記緻密層が、長繊維で構成されるメルトブローン不織布層(M)の両面に、長繊維で構成されるスパンボンド不織布層(S)が積層されてなり、かつ、前記メルトブローン不織布層(M)と前記スパンボンド不織布層(S)とが部分的に熱圧着されてなる積層体を含む請求項1〜請求項12のいずれか1項に記載の発泡成形用不織布積層体。
- 圧力差125Paにおける通気度が25cm3/cm2/sec〜160cm3/cm2/secである請求項1〜請求項13のいずれか1項に記載の発泡成形用不織布積層体。
- 目付量が20g/m2〜160g/m2である請求項1〜請求項14のいずれか1項に記載の発泡成形用不織布積層体。
- 圧力差125Paにおける通気度が、25cm3/cm2/sec〜140cm3/cm2/secである請求項1〜請求項15のいずれか1項に記載の発泡成形用不織布積層体。
- 補強層の目付量が40g/m2〜150g/m2の範囲にある請求項1〜請求項16のいずれか1項に記載の発泡成形用不織布積層体。
- 請求項1〜請求項17のいずれか1項に記載の発泡成形用不織布積層体の製造方法であって、
緻密層の少なくとも片面に補強層を積層した後、前記緻密層と前記補強層とをニードルパンチにより交絡する発泡成形用不織布積層体の製造方法。 - メルトブローン不織布層(M)の両側に、スパンボンド不織布層(S)を積層した後、部分的な熱圧着、エアスルー加工、レジンボンド加工又はカレンダー加工を施して、前記緻密層を形成する請求項18に記載の発泡成形用不織布積層体の製造方法。
- 請求項1〜請求項17のいずれか1項に記載の発泡成形用不織布積層体の補強層の外面に、発泡ウレタン層が設けられてなるウレタン発泡成形体複合物。
- 前記補強層と前記発泡ウレタン層とが一体化して形成されてなる請求項20に記載のウレタン発泡成形体複合物。
- 請求項1〜請求項17のいずれか1項に記載の発泡成形用不織布積層体、又は請求項20若しくは請求項21に記載のウレタン発泡成形体複合物を含んでなる車両用シート。
- 請求項1〜請求項17のいずれか1項に記載の発泡成形用不織布積層体、又は請求項20若しくは請求項21に記載のウレタン発泡成形体複合物を含んでなる椅子。
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