JP5741270B2 - Nonwoven fabric for reinforcing foam molded products and products using the same - Google Patents

Description

  The present invention relates to a non-woven fabric for reinforcing foam molded products and a product using the same. Furthermore, the present invention relates to a non-woven fabric that is optimal for reinforcing a foam molded product having excellent functionality and a foam molded product using the same.

  In recent years, urethane foam molded bodies have been widely used as cushion materials for seats and the like, and generally, a material in which a reinforcing material is integrated at the time of molding a foamed urethane molded body is used. Such a reinforcing material is located between the foamed urethane molded body and the metal spring, and evenly disperses the cushioning action of the metal spring and protects the foamed urethane molded body from the friction received from the metal spring. is there. As the quality demanded by consumers becomes higher, there is an increasing demand for eliminating the noise generated by friction between urethane and metal springs that have oozed into the reinforcing material when a seat or the like is used. Therefore, as a reinforcing material that meets this requirement, a reinforcing material that has a bulky layer and a dense layer and prevents the urethane from seeping out in the dense layer has been proposed (see, for example, Patent Documents 1 to 5). However, such a reinforcing material has poor moldability during foamed urethane molding. Therefore, when deeply drawn foamed urethane, which has been highly demanded in recent years, is used for molded products, defects such as wrinkles and tearing occur, and the urethane oozes out from this, causing friction with the metal spring. However, there was a problem that the fraying noise increased and breakage occurred.

  Therefore, Patent Document 6 has been proposed as a reinforcing material that can be used for molding urethane foam with large irregularities by suppressing the 5% elongation stress at 65 ° C. and 100 ° C. of the dense layer that prevents the urethane from seeping out. However, such a reinforcing material is capable of preventing exudation of a foaming agent in a method of laminating and entangling a low-weight dense layer made of a long-fiber nonwoven fabric and a base material layer made of a long-fiber nonwoven fabric, but has a low elongation and a large elongation. Therefore, there is a problem that the mold attachment property at the time of molding deteriorates.

  As a punching improvement method, Patent Document 7 proposes a method of laminating and joining a long fiber nonwoven fabric composed of carbon black-containing fibers and a non-containing long fiber nonwoven fabric. However, such a method has improved punchability and handling properties, but in the deep-drawn foamed urethane molding having complicated and large irregularities, the followability to the mold becomes insufficient. For this reason, there remains a problem that the occurrence of lack of meat and wrinkles cannot be sufficiently prevented.

  Patent Document 8 proposes a method in which one surface of a high-weight single-layer nonwoven fabric is subjected to thermocompression bonding and the pressure-bonded surface is used as a spring receiving surface. In this method, since it is a single layer, it is necessary to make one side sufficiently thermocompression-bonded and rigidized, so in a deep-drawn foamed urethane molding with complicated and large irregularities, the followability to the mold becomes insufficient, and there is a lack of thickness and There remains a problem that the generation of wrinkles cannot be sufficiently prevented.

  Patent Document 9 proposes a method of obtaining a nonwoven fabric for molding with low air permeability by a method in which a single-layer spunbonded nonwoven fabric composed of fibers having medium orientation is temporarily embossed and then needle punched and densified by shrinkage treatment. . In such a method, only a low air permeability of 0 to 35 cc / cm 3 / sec can be obtained by being densified by shrink heat treatment. For this reason, in the case of a complex deep-drawn shape molding, there is a problem that the finished shape is deteriorated, for example, the moldability is inferior and the filling of the foaming agent is also inferior due to insufficient gas escape.

  Patent Document 10 proposes a reinforcing material for foam molding in which embossing is applied using a spunbond nonwoven fabric as a crimped polypropylene fiber nonwoven fabric as a low modulus material. This method is a method in which the crimped part is partially formed by embossing on a bulky bulky layer that has developed crimp, but the moldability is improved, but because of partial crimping by embossing on a single layer, bleeding from the non-crimped part Insufficient function to prevent ejection. Moreover, although it is described that the tear strength is improved by maintaining the amorphous state by low-temperature embossing, since the abrasion resistance is inferior, there is a problem that the nonwoven fabric tears due to rubbing with the S spring, which is practical. However, there remains a problem that it becomes a low-durability spring bearing reinforcement material.

  Patent Document 11 discloses a reinforcing material for a foam molded article that is bonded and bonded using a high-weight, long-fiber non-woven fabric as the bulky layer and a short-fiber non-woven fabric as the dense layer. However, with this method, the rigidity of the reinforcing material is increased, and in the molding of a complex deep-drawn shape, the moldability is inferior, and the filling of the foaming agent is inferior due to insufficient outgassing, resulting in a missing wall. There is a problem that the shape deteriorates.

Patent Document 12 proposes a foam molded article using a single layer foam reinforcing nonwoven fabric embossed by using a bulky long fiber nonwoven fabric to which a flame retardant is added to give three-dimensional crimps. However, in the method using a single layer of the nonwoven fabric for reinforcing a foam molded article having a large aspect ratio of 5% elongation stress, the shape following property is improved as a flexibility imparting effect by adding a flame retardant, but only by imparting bulkiness, Since it is a single layer, the function of the barrier layer is insufficient, and the problem of preventing the bleeding out remains insufficient. Moreover, because the tear strength (not disclosed) is low, there is a problem that the nonwoven fabric is torn by rubbing with the S spring, and the practicality is low.

Japanese Utility Model Publication No. 62-26193 JP-A-2-258332 Japanese Patent No. 2990207 Japanese Patent No. 2990208 Japanese Patent No. 3048435 Japanese Patent No. 3883008 JP 2007-33159 A Japanese Patent No. 2611422 Japanese Patent No. 2514193 JP 2009-167570 A Japanese Patent No. 2976394 JP 2011-511137 A

As a prior art, no proposal has been made to satisfy both the reinforcing material function and the handling property.
The present invention has been made against the background of the prior art, and it is an object of the present invention to provide a non-woven fabric that is particularly suitable for reinforcing a foam molded article with improved moldability and further improved handleability. Furthermore, in the obtained foamed molded product, there is a problem of obtaining a foamed molded product that has no bleeding, has a good finished shape, and has excellent sound-damping functions such as scratching, bending, and refraction, and shape retention durability. And

As a result of intensive studies in order to solve the above problems, the present inventors have obtained the following knowledge and arrived at the present invention.
The coating layer serving as the spring receiving surface was a bulky short fiber nonwoven fabric layer having an excellent sound damping function. The base material layer in contact with the foam was composed of a long-fiber non-woven fabric layer having a dense pressure-bonding portion having a foaming agent blocking function, which was imparted by improving the fiber arrangement with mechanical properties that improve handling properties. Then, these coating layers and the base material layer are entangled to form a protruding fiber structure on the surface of the base material layer, so that the entire structure is softened and structured with excellent mold followability and an anchor effect of the protruding fiber structure. A non-woven fabric for reinforcing foam molded articles with improved durability of the whole body can be obtained. A foam molded product using this nonwoven fabric is excellent in process moldability and sound damping.

That is, the present invention is as follows.
(1) A laminated nonwoven fabric obtained by laminating a short fiber nonwoven fabric layer and a long fiber nonwoven fabric layer having a dense pressure-bonded portion, wherein the short fiber nonwoven fabric layer and the long fiber nonwoven fabric layer are partially entangled and short fibers The fibers forming the non-woven fabric layer penetrate the long-fiber non-woven fabric layer to form a protruding fiber structure. The laminated nonwoven fabric has a stress of 10% to 50N / 5cm in the longitudinal direction and a stress of 5% in the transverse direction. Is a nonwoven fabric for reinforcing foamed molded products, wherein the ratio of the stress at 5% elongation in the longitudinal direction to the stress at 5% elongation in the transverse direction is 1.66 or more.
(2) Longitudinal 5% stretching stress is 15 to 45 N / 5 cm, lateral 5% stretching stress is 8 to 15 N / 5 cm, longitudinal 5% stretching stress and lateral 5% stretching. The nonwoven fabric for reinforcing foam molded articles according to (1), wherein the ratio of time stress is 2 to 10, and the basis weight is 50 to 200 g / m ² .
(3) The partial pressure-bonding treatment of the long-fiber nonwoven fabric layer is such that the pressure-bonded fiber assembly is independent, the partial pressure-bonding area ratio is 8 to 25%, and the pressure-bonding dot area is 0.01 to 2.5 mm ² (1 ) Or a non-woven fabric for reinforcing a foam molded product according to (2).
(4) The nonwoven fabric for reinforcing foam molded products according to any one of (1) to (3), wherein the short fiber nonwoven fabric layer is mainly composed of polyester fibers, and the long fiber nonwoven fabric layer is composed of polyolefin fibers.
(5) The nonwoven fabric for reinforcing a foam molded article according to any one of (1) to (4), wherein the air permeability is 50 to 350 cc / cm ² / sec.
(6) A foam molded article using the nonwoven fabric for reinforcing a foam molded article according to any one of (1) to (5) as a reinforcing cloth.

The nonwoven fabric for reinforcing foam molded products of the present invention has the following configuration. The coating layer serving as the spring receiving surface was a bulky short fiber nonwoven fabric layer having an excellent sound damping function. The base material layer in contact with the foam can suppress the elongation in the product flow direction under low stress when stretched in the processing process, and has a specific mechanical property with an aspect ratio that satisfies deformation followability during molding. Thus, the fiber was arranged in such a manner, and it was composed of a long fiber nonwoven fabric layer having a dense part having a foaming agent blocking function. And these laminated | coated layers and base material layers were entangled and joined, and the laminated nonwoven fabric which formed the protruding fiber structure in the base material layer surface was obtained.
As a result, the entire laminated nonwoven fabric is also softened and has excellent mold followability. When a foamed molded product is obtained, the foamed molded product is improved in durability because the entire structure is integrated by the anchor effect of the protruding fiber structure. As a result, a nonwoven fabric for reinforcing foam-molded articles was obtained.
This non-woven fabric for reinforcing foam molded products has a foam molding function that can obtain foam molded products with excellent moldability, sound-damping properties, and durability, and suppresses elongation by increasing the stress in the low elongation region of the nonwoven fabric drawing direction. By doing so, there is an advantage that a nonwoven fabric for reinforcing a foamed molded article having remarkably improved handling in the processing step can be obtained.

The nonwoven fabric for reinforcing foam-molded articles of the present invention is formed by laminating a short fiber nonwoven fabric layer having a coating layer function and a long fiber nonwoven fabric layer having a dense crimping portion having a base material layer function. The fiber nonwoven fabric layer is a laminated nonwoven fabric in which the fibers forming the short fiber nonwoven fabric layer are partially entangled and penetrated through the long fiber nonwoven fabric layer to form a protruding fiber structure. The laminated nonwoven fabric has a 5% elongation stress in the longitudinal direction of 10 to 50 N / 5 cm, a transverse stress of 5% in stretching of 15 N / 5 cm or less, a longitudinal stress of 5% and a lateral stress of 5%. This is a non-woven fabric for reinforcing foam molded products having a ratio of stress at elongation of 1.66 or more.
In the present invention, the MD direction of the long-fiber nonwoven fabric is the vertical direction, and the CD direction is the horizontal direction. In the present invention, in the long-fiber nonwoven fabric, since the fibers are arranged in the vertical direction, the arrangement direction of the fibers is the vertical direction. The direction orthogonal to the fiber arrangement direction is the lateral direction.

  Assuming that the nonwoven fabric for reinforcing foam molded products of the present invention is used as a reinforcing material for foam molded products for seats, the coating layer has a sound damping and abrasion resistance function as a spring receiving layer in contact with the spring material. In order to hold | maintain, it is comprised with the bulky short fiber nonwoven fabric layer. This is because the protruding layer made of the fibers constituting the base fiber layer and the short fiber non-woven layer formed through the base material layer is integrated with the foam and the entire laminated non-woven fabric with the anchor effect. It is also for providing an integrated function.

  When long-fiber non-woven fabric is used for the coating layer, the bulkiness is reduced, the sound damping effect is reduced, and the formation of protruding fiber structures due to the entanglement treatment is remarkably reduced, resulting in insufficient integration with the foam and durability. May decrease and cause peeling.

  The short fiber nonwoven fabric layer that is the coating layer of the present invention is partially entangled and integrated with at least the long fiber nonwoven fabric layer that is the base material layer to form a protruding fiber structure that penetrates the long fiber nonwoven fabric layer. When it is not entangled and integrated with the long fiber nonwoven fabric layer, it is easy to peel off and the durability of the coating layer function is inferior, which is not preferable. Moreover, when the short fiber nonwoven fabric layer is not entangled, the short fiber nonwoven fabric layer collapses, which is not preferable. In the case where the long fiber nonwoven fabric layer is a material having poor bonding properties with the foaming agent, integration with the foam becomes difficult, which is not preferable.

  The partial entanglement treatment of the short fiber nonwoven fabric layer and the long fiber nonwoven fabric layer in the present invention is not particularly limited, but the entanglement treatment is performed with a needle punch that can adjust the formation of a preferable protruding fiber structure on the surface of the long fiber nonwoven fabric layer. Is preferred.

The conditions for needle punching are not particularly limited, but as a manufacturing method, when a spread web is laminated on a long-fiber nonwoven fabric layer and entangled, adjustment is necessary depending on the type and conditions of the barb, but 50 to 300 pene / cm ² Is preferably selected.
If the pene is less than 50 / cm ² , the structure of the short fiber nonwoven fabric may not be maintained. If the pene exceeds 300 / cm ² , the function of blocking the foaming agent of the long fiber nonwoven fabric layer is lowered as described later. Blowing agent leakage may occur.
More preferable pene numbers are 80 to 150 / cm ² , most preferably 100 to 130 / cm ² .

  In the present invention, the base material layer that imparts the function of maintaining the shape of the foam molded product, the function of the foaming agent blocking layer at the time of foam molding, and the handleability of the processing step is a long length composed of long fibers that can retain mechanical properties even with a low basis weight. It is made of fiber nonwoven fabric. Even if the long fiber nonwoven fabric forms a partial pressure-bonding portion and has a low basis weight, it has good strength and bursting strength, and thus greatly contributes to the function of blocking the foaming agent during foam molding. Further, as described above, this long fiber nonwoven fabric is provided with a protruding fiber structure formed by penetrating short fibers on the foam surface side, and softening of the long fiber nonwoven fabric itself by entanglement treatment, thereby blocking the foaming agent. The anchor effect is firmly integrated with the foam by embedding the protruding fiber structure in the foam by providing the mold followability that allows uniform deformation while maintaining the function to the nonwoven fabric for reinforcing foamed products. It is given to the nonwoven fabric for reinforcing foamed products.

  If the base material layer is a short fiber nonwoven fabric layer, there is no continuity of fibers, so that the mechanical properties at a low basis weight are inferior, and deformation breakage due to follow-up spots is liable to occur due to follow-up deformation at the time of molding.

Since the long fiber nonwoven fabric layer needs to function as a blocking layer for blocking the leakage of the foaming agent to the foamed molded article reinforcing nonwoven fabric surface during foam molding, an independent dot-shaped partial crimping part is formed, It is made flexible by the entanglement process for laminating and integrating with the fiber nonwoven fabric layer. This also helps to ensure mold followability at the time of molding and maintain gas release properties at the time of foaming to prevent the molded product from floating.
By forming an independent partial crimping portion on the long-fiber nonwoven fabric layer, the independent crimping fiber assembly portion serves as a joining point for firmly fixing the constituent long fibers, thereby providing a structure fixing effect. A portion where only the other surface is flattened imparts a blocking layer effect. As a result, it has moderate air permeability and is provided with a function that can easily follow deformation caused by foam molding and a deaeration function.
If the long-fiber nonwoven fabric layer is not pressure-bonded, the strength and bursting strength are lowered due to a decrease in the strength of the nonwoven fabric, and the function of the blocking layer of the foaming agent is inferior, and the foaming agent oozes out.

  Moreover, when the crimping | compression-bonding process is formed in the whole surface of the long-fiber nonwoven fabric layer, even if entanglement softening is carried out, the deformation | transformation followability at the time of shaping | molding is inferior, air permeability may fall and a float may be produced. Moreover, when the crimping | compression-bonding part is connected continuously, the deformation followability at the time of shaping | molding may be impaired by the thickness and width | variety of a crimping | compression-bonding part.

  Although the partial crimping | bonding part area ratio of the long-fiber nonwoven fabric layer of this invention 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 as the base material layer are deteriorated. In addition, the foaming agent may have a blocking function and the foaming agent may ooze out. If it exceeds 40%, the mold followability may be inferior.

The area of the independent crimping dot of the partial crimping part of the long-fiber nonwoven fabric layer of the present invention (hereinafter sometimes referred to as “crimping dot area”) is preferably 0.01 to 2.5 mm ² , more preferably 0.00. If it is .0.01mm less than ² is 02～1.0Mm ^2, inferior mechanical properties by decreased strength of the junction, shape retention is deteriorated, may further cause bleeding in lowering of the blowing agent shut-off function If the thickness exceeds 2.5 mm ² , the followability due to deformation is deteriorated, and generation of wrinkles, cracks, pulling, and the like may occur, resulting in poor shape quality.

The method of forming the partial crimping | bonding part independent in the long-fiber nonwoven fabric layer of this invention is not specifically limited. In the present invention, known methods such as embossing roller processing can be 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. can be exemplified. .

A protruding fiber structure is formed on the surface of the long-fiber nonwoven fabric layer that is a base material layer in the nonwoven fabric for reinforcing foam-molded article of the present invention in contact with the foam. By embedding this protruding fiber structure in the foam, an anchor effect is obtained that is firmly joined and integrated with the foam.
When the protruding fiber structure is not formed, the bonding force between the foam for reinforcing the foam molded product and the foam of the foam molded product is insufficient, and the foam layer and the nonwoven fabric for reinforcing the foam molded product are easily peeled off.

In the non-woven fabric for reinforcing foam molded article of the present invention, the protruding fiber structure is not particularly limited as long as the protruding fiber structure is formed on the surface of the long-fiber non-woven fabric layer in contact with the foam. 300 / cm ² , more preferably 80-200 / cm ² , most preferably 90-150 / cm ² . If it is less than 50 pieces / cm ² , the softening effect due to the entanglement treatment effect and the anchor effect in the foamed material such as polyurethane are insufficient, and peeling may occur due to poor bonding. If it exceeds 300 pieces / cm ² , it is preferable from the bonding property to a foam such as polyurethane, but the long fiber nonwoven fabric layer becomes too porous and softened, and the foaming agent shielding layer effect may be lowered.
In addition, the number of protrusions of the protruding fiber structure in the present invention is also counted as one in which a plurality of fibers protrude from one hole generated by one entanglement process.

  The length of the fiber loop formed by the protruding fiber structure in the present invention is preferably 1 to 10 mm, more preferably 1.5 to 7 mm, and most preferably 2 to 5 mm. If the fiber loop length is less than 1 mm, the anchor effect may be insufficient. If it exceeds 10 mm, there may be a problem in workability of setting the nonwoven fabric for reinforcing foamed articles on the mold due to the catch.

In the laminating / entanglement process using the needle punch in the present invention, the number of punches is preferably 50 to 300 pens / cm ^{2 in} order to form the above-described preferable protruding fiber structure. Further, the effect of forming the protruding fiber structure of the needle punch depends on the needle depth, and it is preferable to make the needle elongation as shallow as possible under the condition that a necessary protruding fiber length can be formed. When the needle depth is deep, the aperture diameter becomes large and the foaming agent may ooze out, so it is preferable to set the optimum conditions. For example, in order to set the protruding fiber loop length to 3 to 10 mm, the needle depth is preferably set to 12 to 15 mm when the nonwoven fabric thickness is about 2 mm when measured with a load of 20 g / cm ² in a laminated web state.

  The non-woven fabric for reinforcing foamed articles of the present invention prevents deformation due to drawing of the non-woven fabric at the time of processing, and for convenience of cutting and setting to the mold. It is 10-50N / 5cm, Preferably it is 15-45N / 5cm, More preferably, it is 25-45N / 5cm. If it is less than 10 N / 5 cm, the nonwoven fabric is easily deformed by the drawing tension of the nonwoven fabric in the processing step, and stable cutting and setting may not be possible. If it exceeds 50 N / 5 cm, the deformation following property to the mold in the vertical direction is lowered during the molding process, resulting in a defective finished shape, tearing, wrinkles and the like, which is not preferable.

  As a method for increasing the stress at the time of 5% elongation in the longitudinal direction of the nonwoven fabric for reinforcing a foam molded article, it is necessary to increase the stress at the time of 5% elongation in the longitudinal direction of the long-fiber nonwoven fabric layer as the base material layer. Therefore, the stress at 5% elongation in the longitudinal direction of the long fiber nonwoven fabric layer in the present invention is preferably 15 to 150 N / 5 cm, more preferably 25 to 100 N / 5 cm, and most preferably 40 to 80 N / 5 cm. When the stress at 5% elongation in the longitudinal direction of the long fiber nonwoven fabric layer is less than 15 N / 5 cm, the stress at 5% elongation as the nonwoven fabric for reinforcing foamed articles after the entanglement treatment with the short fiber nonwoven fabric layer is preferably less than 10 N / 5 cm. Absent. If it exceeds 150 N / 5 cm, the stress at the time of 5% elongation as the nonwoven fabric for reinforcing a foam molded article after the entanglement treatment with the short fiber nonwoven fabric layer exceeds 50 N / 5 cm.

The stress at 5% elongation is affected by the weight per unit area, the density by embossing, the crimping area and the crimping dots. Therefore, when the foamed molded article reinforced nonwoven fabric for the present invention has a two-layer structure of the short fiber nonwoven fabric layer and the long-fiber nonwoven fabric layer, basis weight of the long-fiber nonwoven fabric layer is preferably 30 to 80 g / ^{m 2,} 40 to 60 g / ^{m 2} Is more preferable. The preferable conditions for the embossing of the long fiber nonwoven fabric layer in the present invention are as described above, in which the area ratio of the partial crimped portion of the long fiber nonwoven fabric layer is 8 to 25% and the crimp dot area is 0.01 to 2.5 mm ² / cc. This is a range condition.

  When the fiber arrangement in the long-fiber nonwoven fabric layer, which is the base material layer, is arranged 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. Therefore, even when a desired stress in the 5% stretch direction in the longitudinal direction is applied, if the stress in the 5% stretch direction in the nonwoven fabric for reinforcing foamed articles is not maintained at least 8 N / 5 cm, there may be a problem in workability. is there. That is, the fiber arrangement of the long-fiber nonwoven fabric layer needs to be in an appropriate range, and the appropriate fiber arrangement in the present invention is preferably arranged at 5 ° to 60 ° from the perpendicular when the MD direction is a perpendicular. It is more preferable to arrange them at 10 ° to 30 °. In the fiber array measurement method, the array angle of 100 fibers was measured at five arbitrary points, and the total average value of the angles was defined as the fiber array. It is 0 ° when all the fibers are arranged in the MD direction, and 90 ° when all the fibers are arranged in the CD direction. In an arrangement exceeding 60 ° from the perpendicular, the aspect ratio of the stress at 5% elongation when laminated to form a nonwoven fabric for reinforcing foamed articles is not 1.66 or more. In an arrangement of less than 5 ° from the perpendicular, the aspect ratio of the stress at 5% elongation is 1.66 or more, however, the fiber entanglement in the transverse direction becomes insufficient, and the stress at 5% elongation in the transverse direction becomes extremely low. Therefore, the workability in the nonwoven fabric manufacturing process is deteriorated. In addition, the stress at 5% elongation in the longitudinal direction may be extremely high, and when a foamed molded article reinforcing nonwoven fabric is used, deformation followability deteriorates and the finished shape is inferior, which may be undesirable.

A long fiber nonwoven fabric layer having a preferable fiber arrangement can be obtained by a special production method.
In the production process of the long-fiber nonwoven fabric layer, the stretched and solidified long fibers that flow down together with the traction fluid and the accompanying flow (hereinafter referred to as “associated flow”) are perpendicular to the MD direction (traveling direction) of the take-off net. Sometimes, in order to arrange 10 ° to 30 ° from the perpendicular, the accompanying flow in the CD (net width) direction on the surface of the take-off net and the accompanying flow through the take-out net (hereinafter referred to as “vertical direction”) Suppress the flow, and make the accompanying flow slightly more in the MD direction. As a result, the fibers are manufactured so as to be arranged in the MD direction. As a method for suppressing the accompanying flow, a method of restricting the width in the CD direction and suppressing the suction air volume (suction) of the accompanying flow in the vertical direction is used in combination. As a result, the fiber arrangement can be controlled. For example, when a 5 cm accompanying flow restriction plate was provided at the end of the conveyor as the width restriction and the suction air volume of the suction was reduced to 2/3, a long fiber web having a fiber arrangement of 20 to 28 ° in the MD direction was obtained. The mechanical properties of the long fiber web after embossing are as follows. When a long fiber nonwoven fabric having a fineness of 2 dtex and a basis weight of 40 g / m ² is formed using polypropylene having a melt index of 40, the stress at 5% elongation is 40 to 40 in the machine direction. A long-fiber nonwoven fabric having 60 N / 5 cm, a lateral direction of 10-15 N / 5 cm, and an aspect ratio of 3.0-6.0 can be obtained.

The stress at 5% elongation of the nonwoven fabric for reinforcing foam molded products of the present invention depends on the basis weight. Basis weight although increases larger the elongation of 5% stress, in the present invention, the basis weight is preferably ^{50~200g / m 2, 80~120g / m} 2 is more preferable. If the basis weight is less than 50 g / m ² , the mechanical properties may be low and the reinforcing material function may be insufficient. In addition, the covering function of the foaming agent may be reduced, and bleeding may occur. When the weight per unit area exceeds 200 g / m ² , there is a problem that hinders weight reduction of the vehicle.

  The 5% stretch stress in the transverse direction of the nonwoven fabric for reinforcing foam molded article of the present invention is 15 N / 5 cm or less, preferably 4 to 14 N / 5 cm, more preferably 8 to 12 N / 5 cm. If it exceeds 15 N / 5 cm, the mold followability is slightly deteriorated, and the finished shape may be deteriorated. If it is less than 4N / 5cm, it will stretch and deform if tension is applied in the transverse direction during processing, or the mold following property at the time of molding will cause unevenness in the longitudinal and lateral directions, resulting in a poor molded shape or tearing. There is.

  The non-woven fabric for reinforcing foam-molded articles 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). 1.66 or more, preferably 2-14, more preferably 4-7. If the ratio of the 5% elongation stress in the longitudinal direction to the 5% elongation stress in the transverse direction is less than 1.66, the fiber arrangement becomes a random structure, the stress in the 5% elongation in the longitudinal direction becomes lower, and the elongation due to work elongation is reduced. In some cases, dimensional stability in the processing step, such as occurrence, may be inferior. If the ratio of the 5% elongation stress in the longitudinal direction and the 5% elongation stress in the transverse direction exceeds 14, the fiber arrangement becomes too serial, and the 5% elongation stress in the transverse direction becomes low, and the lateral elongation occurs at low stress. Therefore, there are cases where unevenness of the mold follows and the finished shape is deteriorated. In addition, handling may be deteriorated, for example, tearing may occur due to lateral elongation deformation.

  The elongation in the machine direction and the transverse direction of the nonwoven fabric for reinforcing foam molded products of the present invention is not particularly limited, but is preferably 30 to 200%, more preferably 40 to 150%, and most preferably 50 to 130%. is there. Although there is a balance with the stress at 5% elongation, if the elongation is less than 30% in both the vertical and horizontal directions, the deformation following capability in mold molding that requires partial bending and extension such as deep drawing mold becomes insufficient. , The finished shape may be poor or torn. When the stress at 5% elongation is low, deformation tends to occur when the elongation exceeds 200%, and there are cases where wrinkles and loosening due to partial elongation are caused by complications during setting and deep drawing.

The air permeability of the nonwoven fabric for reinforcing foam molded products of the present invention is not particularly limited, but is preferably 20 to 500 cc / cm ² / second, more preferably 50 to 350 cc / cm ² / second, most preferably 80 to 200 cc / cm ² / sec. When the air permeability is less than 20 cc / cm ² / sec, the expansion air escape during foam molding becomes non-uniform, and the occurrence of a lack of thickness or resin loss may occur. If it exceeds 500 cc / cm ² / sec, bleeding may occur due to leakage of the foaming agent.

Apparent density of the foamed molded article reinforced nonwoven fabric for the present invention is not particularly limited, preferably 0.05~0.15g / cm ^3, more preferably at 0.07~0.12g / cm ³ .
The nonwoven fabric for reinforcing foamed molded products of the present invention has a laminated structure as described above. The apparent density of the coating layer is lower than the apparent density of the base material layer, and the apparent density of the nonwoven fabric for reinforcing foam molded products is dominated by the bulky layer. If the apparent density is less than 0.05 g / cm ³ , the coating layer is too bulky and wear resistance may be deteriorated. When the apparent density exceeds 0.15 g / cm ³ , the bulkiness of the coating layer is lost, and the sound damping effect may be deteriorated.

The apparent density of the long-fiber nonwoven fabric layer serving as the base material layer of the nonwoven fabric for reinforcing foam molded products of the present invention is not particularly limited, but varies depending on the specific gravity of the material, but when polypropylene is used, it is 0.08 to 0.00. preferably ^{25g / cm 3, 0.10~0.20g / cm} 3 is more preferable.

The basis weight of the long-fiber nonwoven fabric layer, which is the base material layer of the nonwoven fabric for reinforcing foam molded products of the present invention, is not particularly limited as long as it satisfies the foaming agent shielding function and can grip the protruding fiber structure, but preferably 20 to 100 g / m ² , more preferably 30 to 80 g / m ² , most preferably 35 to 60 g / m ² . If it is less than 20 g / m ² , the shielding function of the foaming agent may not be satisfied. If it exceeds 100 g / m ² , the mold followability may deteriorate during molding.

  The material of the long-fiber nonwoven fabric layer, which is the base material layer of the nonwoven fabric for reinforcing foam molded products of the present invention, is not particularly limited. Sometimes the mold following ability is inferior. In the molding process at a low temperature using polyurethane as a foaming agent, a polyolefin material that has slightly poor wettability, is difficult to leak, has a high blocking function, and has good mold followability is preferable. Among general olefins, impact resistance at low temperatures is slightly inferior to polyethylene, but polypropylene is more preferable because it has high heat resistance, strength and rigidity and can easily follow a mold even at low temperature.

  The fineness of the fibers constituting the long-fiber nonwoven fabric layer, which is the base material layer of the nonwoven fabric for reinforcing foam molded products of the present invention, is not particularly limited, but is preferably 1.0 to 6 dtex capable of expressing a blocking function and a reinforcing function. More preferably, it is 5-4 dtex. If necessary, the fiber cross section can be selected from an irregular cross section, a hollow cross section, a mixed fiber with different fineness, and the like.

Although the fabric weight of the short fiber nonwoven fabric layer which is a coating layer of the nonwoven fabric for reinforcing foam molded products of the present invention is not particularly limited, 20 to 200 g / m ² is preferable, 40 to 120 g / m ² is more preferable, and most preferable. 60 to 100 g / m ² . If it is less than 20 g / m ² , the coating function may be insufficient. If it exceeds 200 g / m ² , mold followability at the time of molding is lowered, resulting in a poor finish, and weight reduction of the foam becomes a problem.
In addition, when the covering layer is laminated with the base material layer, in a range in which a sufficiently protruding fiber structure can be formed, the laminated layer is obtained after needle opening punching the opening web to provide handling properties and form retention, Since friction durability improves, it is more preferable.

The nonwoven fabric for reinforcing foam-molded articles of the present invention preferably has a two-layer structure of a coating layer and a base material layer, but an intermediate layer can be laminated and integrated between the coating layer and the base material layer. Is not particularly limited. The intermediate layer can be used as a blocking layer.
When the intermediate layer is laminated, the basis weight of the uppermost coating layer is particularly limited as long as the projected fiber structure can be formed on the lowermost substrate layer surface and the uppermost coating layer can satisfy the spring receiving function. Not. When the basis weight of the nonwoven fabric for reinforcing foam molded products is 200 g / m ² or less, it is preferable to set the coating layer to 50 g / m ² and 150 g / m ² or less including the base material layer and the intermediate layer.

The material of the fiber constituting the short fiber nonwoven fabric layer that is the covering layer of the nonwoven fabric for reinforcing foam molded product of the present invention is not particularly limited, but has abrasion resistance and creep resistance characteristics that can withstand compression wear with the spring material. The material which has is preferable. Polyesters and polyamides having good wear resistance and creep resistance are preferred, and general-purpose thermoplastic resins and cheap polyesters are particularly preferred.
Polyesters in the present invention include polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polybutylene naphthalate (PBN), polyethylene naphthalate (PEN), polycyclohexanedimethyl terephthalate (PCHT), polytrimethylene terephthalate ( Examples thereof include homopolyesters such as PTT) and copolyesters thereof.
As a more preferable polyester in the present invention, a polyester having a melting point of 220 ° C. or higher and a glass transition temperature of 80 ° C. or lower is preferable, and a polyester having a glass transition temperature of 70 ° C. or lower is more preferable. Examples of preferable polyesters include polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), and copolymers and mixtures thereof. As the most preferable polyester, polyethylene terephthalate ( PET) and their copolyesters.
It should be noted that modifiers such as antioxidants, light fasteners, colorants, antibacterial agents, flame retardants, hydrophilizing agents and the like may be added as necessary within the range not deteriorating the characteristics.

  Although the fineness of the fiber which comprises the short fiber nonwoven fabric layer used as the coating layer of the nonwoven fabric for foam molded article reinforcement of this invention is not specifically limited, Preferably it is 1-15 dtex, More preferably, it is 1.2-10 dtex. Most preferably, it is 1.4 to 6 dtex. If it is less than 1 dtex, the rigidity due to the improvement of the cross-sectional secondary moment may be insufficient and the beam function may be insufficient, or the wear resistance may be reduced and the durability may be deteriorated. If it exceeds 15 dtex, the mold followability may decrease.

  Although the fiber length of the fiber which comprises the short fiber nonwoven fabric layer used as the coating layer of the nonwoven fabric for reinforcing foam molded articles of this invention is not specifically limited, Preferably it is 30-150 mm, More preferably, it is 38-120 mm. When the fiber length is less than 20 mm, the beam function in forming the beam structure may not be exhibited. When the fiber length is more than 250 mm, migration at the time of opening the mixed cotton may be insufficient.

  The fiber which comprises the short fiber nonwoven fabric layer used as the coating layer of the nonwoven fabric for reinforcing foam molded articles of the present invention is not particularly limited. A single component fiber may be used, and a mixed fiber with an irregular cross section or a mixed fiber of different degrees may be employed. In the case of improving the rigidity, it is a preferred embodiment to mix the hollow cross section and the irregular cross section.

The non-woven fabric for foam molded article reinforcement suitable for the foam molding reinforcing material satisfying the above-mentioned requirements of the present invention is cut into a predetermined shape and foamed with a protruding fiber structure forming surface as a foam molded article reinforcing material. A foamed molded article made of urethane foam is obtained by setting the product to be on the agent side and injecting and foaming a foaming agent. As the foam molding method, foam molding is performed by a cold foaming method or a hot foaming method. The molded foam molded body is finished in a good shape, the foaming agent does not bleed out, and as a spring receiving material, it suppresses scratching, bending, and refraction sound, and has excellent shape retention durability and wear resistance. Goods were obtained.
Further, the operability of the cutting process to the predetermined shape and the setting to the mold was very good without deformation of the nonwoven fabric.

  The nonwoven fabric for reinforcing foamed molded products of the present invention is particularly excellent in handleability, and can contribute to cost reduction while minimizing the cost burden in the processing process.

  The nonwoven fabric for reinforcing foam molded products of the present invention is not limited to cushion applications, but as a reinforcing material for foam molded products, it can be used for various interior materials for vehicles, building materials, surface foam molded products of electrical appliances, etc. Also useful.

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 with the following method.

(1) Fineness [dtex]
Any five points on the uppermost layer and the lowermost layer of the sample of each layer were selected, 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 with a density gradient tube at n = 5, and the average value was obtained 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 weight per 10,000 m was determined from the value and the average specific gravity, which was defined as the fineness (dtex). In addition, at the time of fiber diameter measurement, when it was difficult to discriminate fiber diameters such as hollow fibers, it was determined from the fiber cross section of the following (7) SEM photograph.

(2) Weight per unit [g / m ² ]
Measured according to JIS L 1913 “Mass per unit area”.

(3) Thickness [mm]
Based on JIS L1913 “Thickness”, the thickness at a load of 20 gf / cm ² was measured.

(4) Apparent density [g / cm ³ ]
It calculated using the following formula from the thickness in the above (3) and the basis weight measured in (2).
Apparent density = basis weight ÷ (thickness × 1000)

(5) Mechanical properties of non-woven fabric In accordance with JIS L1913 6.3 “Tensile strength and elongation”, specimens at 5 arbitrary points were cut out in a standard atmosphere (22 ° C.), and an elongation load curve until breaking Was measured at each point n = 5 and calculated by the total average of the respective values.
(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].
(5-2) Elongation [%]
The elongation at break [%] in an atmosphere at 22 ° C. is defined as the elongation.
(5-3) Tensile strength [N / 5 cm / g / m ² ]
The maximum load until breakage in an atmosphere at 22 ° C. is defined as tensile strength [N / 5 cm / g / m ² ].

(6) Air permeability (cc / cm ² / sec)
It was carried out using a Frazier air permeability measuring machine according to JIS L1096 8.27.1.

(7) Discrimination of non-woven fabric Whether or not the coating layer is a short fiber non-woven fabric is obtained by drawing out the constituting fiber and visually confirming that it is in a short fiber form. Whether or not the base material 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) Pressure-bonding dot area and partial pressure-bonding area ratio of the partial pressure-bonded portion of the long-fiber non-woven fabric layer The bottom long-fiber non-woven fabric layer is peeled off from other fiber non-woven fabric layers (including protruding fiber structures) and used as a sample. Cut 20mm squares into 30mm squares 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, 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) Protruding fiber structure The presence or absence of fibers protruding on the surface opposite to the needle punch driving surface of the non-woven fabric is determined by visual inspection. If necessary, the protruding fiber length per 1 cm ² of the protruding fibers of the representative portion is expressed on a scale. = 20 (mm or less is rounded off), and is shown as an average value.

(10) Draw deformation evaluation JIS L1913 6.3 Using a nonwoven fabric sample with a width of 5 cm in accordance with “Tensile strength and elongation”, stretch recovery treatment was performed 10 times with a tensile stress of 10 N / 5 cm in the longitudinal direction. The sample was allowed to stand for 1 hour, and then the stretch deformation of the nonwoven fabric in the longitudinal direction and the visual change in shape were determined.
Elongation deformation was less than 5%, no change in shape: ○, elongation deformation was 5% or more and 20% or less, small change in shape: Δ, elongation deformation was 20% or more, and there was change in shape: x.

(11) Foaming evaluation A non-woven fabric cut into a predetermined shape in a cushion pad mold is set as a reinforcing material for a foamed molded product so as to conform to the shape. Cold foaming at 65 ° C. was performed with urethane resin, and the molded product was evaluated by visual judgment.
(11-1) Setability It was easy to adjust to the mold and easy to set: ○, easy to adjust but difficult to set: Δ, difficult to set and difficult to set: ×, sensory evaluation.
(11-2) Exudation No urethane exudation on the reinforcing material surface of the molded product: ○, exudation fine: Δ, exudation clearly present: x was visually judged.
(11-3) Wrinkles were not generated on the reinforcing material surface of the molded product: ○, fine wrinkles were generated: Δ, wrinkles were generated: x was visually determined.
(11-4) Floating No lift occurred on the reinforcing material surface of the molded product: ○, Micro-floating: Δ, Floating: X, and judged by visual and tactile sensation.
(11-5) Tearing No tearing on the reinforcing material surface of the molded product: ○, Immediately before tearing: Δ, There was tearing: x was visually judged.
(11-6) Peeling For ease of boundary peeling between the reinforcing material surface of the molded product and the foam, when the reinforcing material end of the molded product is peeled 1 cm and the reinforcing material is torn from the foam by hand. The boundary does not peel: ○, peeling close to the boundary peeling occurs: Δ, peeling at the boundary: x
(11-7) Molding property The reinforcing material surface of the molded product is molded according to the shape of the mold: ○, the shape does not match slightly: Δ, there is a part that does not match the shape: × evaluated visually .

(12) Performance evaluation of molded products (12-1) Sound control characteristics Set a pad on an actual vehicle, listen to vibration and rubbing sound in a flat-ground running test at 60 km / h for 1 hour, quieter than the seat on which it is mounted: ○ The quietness equivalent to that of the mounted seat: Δ, the same or less the same as that of the mounted seat, and anxious: ×.
(12-2) Abrasion resistance Using a sample obtained by slicing a reinforcing material surface side of a molded product to a thickness of 5 mm including foam, a friction tester type II (Gakushin) The reinforcing material surface was set as a friction surface using a mold, and was worn for 10 minutes, and the degree of damage was classified by visual judgment and evaluated. No damage: 5, Minor damage: 4, Little damage: Grade 3, Damage moderate: Grade 2, Damage large: Grade 1.
(12-3) Shape retention When the pad is placed on a 55cm square 10mm iron plate, and the same iron plate is bonded to the load cell with Tensilon (Baldwin's UCT25T) and the contact height is Hcm, it is compressed to half the height. Recovery (50% repetitive compression) was repeated 100 times, and the damage state of the reinforcing material surface was visually judged and evaluated as follows. ○: Damage, no peeling, Δ: Small peeling, no damage, ×: Peeling, damaged

<Example 1>
Using polypropylene with a melt index of 40 g / 10 min (hereinafter referred to as “PP”), spinning at a spinning temperature of 240 ° C. with a single hole discharge rate of 0.9 g / min. However, when the fiber arrangement of most fibers on the lower take-off net is perpendicular to the vertical direction, the end of the take-up net is 2 cm high so that the fibers are arranged within 30 ° from the vertical line. An adjoining width regulating plate made of punched metal is provided, long fiber webs are laminated with a suction suction air velocity of the take-up net surface of 320 m / min, and a web having a basis weight of 40 g / m ² made of long fibers having a fineness of 2 dtex. Obtained. Subsequently, using an oval pattern embossing roller with a crimp area ratio of 18%, the embossing is performed at an embossing temperature of 130 ° C. and a linear pressure of 20 kN / m, and the basis weight made of continuous fibers of ² dtex is 40 g / m ² . When the fiber arrangement is 27 °, the stress at 5% elongation is 64 N / 5 cm in the longitudinal direction, 11 N / 5 cm in the transverse direction, the aspect ratio is 5.8, the crimp dot area is 0.05 mm ² , and the area ratio of the partial crimped portion is 16%. A spunbond nonwoven fabric for the material layer was obtained.
Polyester short fibers having a mechanical crimp of 1.4 dtex round cross section and a fiber length of 51 mm are opened, and a spread web is laminated so as to have a basis weight of 80 g / m ^{2 in} a cross layer. this / cm ^2, subjected to needle punching at Subsequently penetrometer, 120 / cm ^2, to obtain a needle punched nonwoven fabric. Next, a needle punched nonwoven fabric with a basis weight of 80 g / m ² is laminated on the spunbond nonwoven fabric for the base material layer, and then continuously entangled by needle punch from the web side at a penet of 120 pieces / cm ² and a needle needle depth of 10 mm. Was performed to obtain a nonwoven fabric for reinforcing foam-molded articles that were entangled in layers.
The obtained non-woven fabric for reinforcing a molded foam is a non-woven fabric having a weight per unit area of 120 g / m ² and an apparent density of 0.09 g / cm ³ in which the short fiber non-woven layer and the long fiber non-woven layer are entangled, and the number of protruding fibers is 116. A protruding fiber structure having a protruding fiber length of 8 mm consisting mainly of short fibers at a piece / cm ² is formed, the stress at 5% elongation is 38 N / 5 cm in the vertical direction, 10 N / 5 cm in the horizontal direction, and the aspect ratio is 3. 8. The air permeability was 110 cc / cm ² / sec, and the elongation was 72% in length and 106% in width.
Table 1 shows the evaluation results of the obtained nonwoven fabric for reinforcing foam molded products. In Example 1 satisfying the requirements of the present invention, both the drawing deformation and the mold setting property were good, and there was no oozing, wrinkle, floating, tearing and peeling in foam molding, and the moldability was also good. Even in the performance evaluation, it was a non-woven fabric that had good sound-damping properties, wear resistance, and shape retention, and had excellent performance for reinforcing foam molded products.

<Example 2>
The non-woven fabric for reinforcing foam molded articles obtained in the same manner as in Example 1 except that the number of penetrating needles in the laminated nonwoven fabric is 80 / cm ² is entangled with the short fiber nonwoven fabric layer and the long fiber nonwoven fabric layer. A non-woven fabric with a weight per unit area of 120 g / m ² and an apparent density of 0.08 g / cm ³ , forming a protruding fiber structure with a protruding fiber length of 8 mm, the number of protruding fibers being 75 / cm ² and mostly consisting of short fibers The stress at 5% elongation is 42N / 5cm in the vertical direction, 12N / 5cm in the horizontal direction, 3.5 is the aspect ratio, the air permeability is 74cc / cm ² / sec, the elongation is 54% in length, 89% in width Met.
As a result of evaluation of the obtained nonwoven fabric for reinforcing foam molded articles, Example 2 which satisfies the requirements of the present invention has good draw deformation and mold setting properties, and exudation, flaws, floats, tears, and peeling in foam molding are also observed. There was no mold fitting property. Even in the performance evaluation, it was a non-woven fabric that had good sound-damping properties, wear resistance, and shape retention, and had excellent performance for reinforcing foam molded products.

<Example 3>
Using polyethylene terephthalate (hereinafter referred to as PET) with an intrinsic viscosity of 0.65, melt spinning at a spinning temperature of 285 ° C. and a single hole discharge rate of 0.6 g / min, opening the fiber while taking it out with an ejector, The width regulating plate for the accompanying flow made of punching metal having a height of 2 cm at the end of the take-off net so that the fiber arrangement of the majority of the fibers on the conveyor is perpendicular to the vertical direction within 30 ° from the perpendicular. And a long fiber web was laminated at a suction suction air speed of 360 m / min on the take-up net surface and shaken to obtain a web having a basis weight of 40 g / m ² made of long fibers having a single yarn fineness of 1.3 dtex. Next, embossing is performed at 250 ° C. and a linear pressure of 40 kN / m using an embossing roller with a convex lattice pattern with a crimp area ratio of 18%, the basis weight is 40 g / m ² , the fiber arrangement is 24 °, and the stress at 5% elongation. Obtained a polyester long fiber nonwoven fabric for a base material layer having a longitudinal direction of 135 N / 5 cm, a lateral direction of 21 N / 5 cm, an aspect ratio of 6.4, a crimping dot area of 0.34 mm ² and a partial crimping portion area ratio of 17%.
Subsequently, the nonwoven fabric for reinforcing foam molded articles obtained by entanglement treatment of the short fiber web in the same manner as in Example 1 and then laminating the nonwoven fabric on the long fiber nonwoven fabric and entanglement treatment has a basis weight of 120 g / m ² and an apparent density. A protruding fiber structure having a protruding fiber length of 8 mm consisting of 0.09 g / cm ³ , the number of protruding fibers of 104 / cm ² and mostly short fibers is formed, the stress at 5% elongation is 44 N / 5 cm in the longitudinal direction, and the horizontal The direction was 12 N / 5 cm, the aspect ratio was 3.7, the air permeability was 124 cc / cm ² / sec, the elongation was 61% length, and 89% width.
In the evaluation results of the obtained nonwoven fabric for reinforcing foam molded articles, Example 3 satisfying the requirements of the present invention has good drawer deformation and mold setability, and exudation, wrinkling, floating, tearing, and peeling in foam molding are also possible. There was no mold fitting property. Even in the performance evaluation, it was a non-woven fabric that had good sound-damping properties, wear resistance, and shape retention, and had excellent performance for reinforcing foam molded products.

<Comparative Example 1>
Using PP with a melt index of 40 g / 10 min, spinning at a spinning temperature of 230 ° C. using a nozzle orifice with a U-shaped cross section, spinning at a single hole discharge rate of 1.2 g / min, and cooling air just below the nozzle with a U shape Opening is performed while rapidly cooling from the opening side, and an adjoining width regulating plate made of a punching metal with a height of 2 cm is provided at the end of the take-up net, and the suction suction air speed of the take-up net surface is set to 320 m / min. The fibers were laminated to obtain a web having a fineness of 3 dtex. Subsequently, crimping was performed with hot air at 120 ° C. with 5% limited shrinkage to obtain a web having a basis weight of 100 g / m ² , a fineness of 3 dtex, and a number of crimps of 21 pieces / inch.
Next, using a convex pattern embossing roller with a pressure bonding area ratio of 8%, embossing is performed at an embossing temperature of 120 ° C. and a linear pressure of 15 kN / m, and the basis weight of 3 dtex continuous fibers is 100 g / m2, and the fiber arrangement is 32. °, 5% elongation during stress longitudinal 42N / 5 cm, lateral 8N / 5 cm, the aspect ratio of 5.2, crimped dot area 1.0 mm ^2, part crimp portion area ratio with 8% of the three-dimensional crimps A spunbond nonwoven fabric was obtained.
Table 1 shows the results of evaluating the obtained spunbonded nonwoven fabric as a nonwoven fabric for reinforcing foam moldings.
Although it is bulky and increases the aspect ratio of stress at 5% elongation, there is a problem in handling properties such as insufficient fiber entanglement in the CD direction and lateral elongation. In molding, the foaming agent leaks from cracks due to lateral elongation and the foaming agent oozes out, resulting in poor quality of the molded product. Even in the performance evaluation, the nonwoven fabric has a practically problematic problem for reinforcement of foamed molded articles, which is particularly poor in abrasion resistance, inferior in sound insulation and shape retention.

<Comparative Example 2>
Using polyethylene terephthalate (hereinafter referred to as “PET”) with an intrinsic viscosity of 0.65, melt spinning at a spinning temperature of 285 ° C. and a single-hole discharge rate of 1.0 g / min, and opening the fiber while taking it up with an ejector Then, the suction air velocity of suction was dropped onto a net conveyor at 600 m / min without any width restriction, and a web having a basis weight of 40 g / m ² made of long fibers having a single yarn fineness of 2.0 dtex was obtained. Next, embossing is performed at 230 ° C. and a linear pressure of 20 kN / m using a convex grid pattern embossing roller with a crimping area ratio of 18%, the crimping dot area is 0.31 mm ² , and the 5% elongation stress is 85 N in the vertical direction. / 5 cm, lateral direction 24 N / 5 cm, aspect ratio 3.4, partial crimped portion area ratio 16% of the crimped portion of the polyester continuous fiber nonwoven fabric for the coating layer was slightly weak.
It was obtained by laminating the PET nonwoven fabric for the coating layer on the PP nonwoven fabric for the base material layer obtained in Example 1, and performing the entanglement process by needle punching with the penet 120 and the needle depth of the needle of 10 mm from the PET nonwoven fabric side. The non-woven fabric for reinforcing foam molded articles is a non-woven fabric having a basis weight of 80 g / m ² and an apparent density of 0.14 g / cm ³ in which a PET long-fiber non-woven fabric layer and a PP long-fiber non-woven fabric layer are entangled with 78 protruding fibers. A protruding fiber structure having a protruding fiber length of 3 mm, most of which is made of polyester fiber at / cm ² , is formed. The stress at 5% elongation is 42 N / 5 cm in the vertical direction, 12 N / 5 cm in the horizontal direction, and the aspect ratio is 3.5. The air permeability was 74 cc / cm ² / sec, and the elongation was 54% length and 87% width.
Table 1 shows the evaluation results of the obtained nonwoven fabric for reinforcing foam molded products. Comparative Example 2 using a long-fiber non-woven fabric for the coating layer is free from the requirements of the present invention, and is good in both drawing deformation and mold setting properties. It was somewhat inferior. Even in the performance evaluation, it was a non-woven fabric having a problem as a reinforcement for a foam molded product having good wear resistance but slightly inferior sound insulation and inferior shape retention.

<Comparative Example 3>
Using PP with a melt index of 40 g / 10 min, spinning at a spinning temperature of 240 ° C. using a nozzle orifice with a round cross section, spinning at a single hole discharge rate of 1.2 g / min, opening while cooling and thinning, and accompanying A long fiber web having a fineness of 3 dtex and a basis weight of 30 g / m ² was obtained without providing a diversion width regulating plate and laminating long fibers with a suction suction air speed on the take-up net surface of 520 m / min. Next, it was embossed at an embossing temperature of 130 ° C. and a linear pressure of 15 kN / m using an oval pattern embossing roller with a crimping area ratio of 18%, and the basis weight made of continuous fibers of 3 dtex was 30 g / m 2 and the fiber arrangement was 54 °. A spunbonded nonwoven fabric having a 5% elongation stress of 25 N / 5 cm in the longitudinal direction, 12 N / 5 cm in the transverse direction, an aspect ratio of 2.1, a crimping dot area of 0.05 mm ² and a partial crimped portion area ratio of 16% was obtained. .
Next, the PET short fibers used in Example 1 were spread and laminated on the spunbonded nonwoven fabric so as to have a basis weight of 30 g / m ^2, and the web was continuously formed with a penet of 120 pieces / cm ² and a needle needle depth of 10 mm. The entanglement process by the needle punch was performed from the side, and the nonwoven fabric for reinforcement | strengthening the foaming molded article which carried out lamination | stacking was obtained.
The obtained non-woven fabric for reinforcing a molded foam is a non-woven fabric having a weight per unit area of 60 g / m ² and an apparent density of 0.08 g / cm ³ in which a short fiber non-woven layer and a long fiber non-woven layer are entangled, and has 96 protruding fibers. pieces / cm ² at most form a protruding fiber structure of the protruding fiber length 8mm consisting staple fibers, 5% elongation stress at longitudinal 9N / 5 cm, lateral 5N / 5 cm, length / width ratio of 1. 8. The air permeability was 260 cc / cm ² / sec, and the elongation was 81% in length and 75% in width.
Table 1 shows the results of evaluating the obtained nonwoven fabric for reinforcing foam molded products.
The comparative example 3 in which the aspect ratio of the stress at the time of 5% elongation is low and deviates from the requirement of the present invention has a problem in handleability such as stretching in both length and breadth. The finished quality of the molded product was inferior due to the occurrence of exudation of the foaming agent from cracks caused by following spots. Even in the performance evaluation, the sound-insulating property was inferior due to the exudation of the foaming agent, and the nonwoven fabric had a problem for reinforcing the foamed molded product.

<Comparative Example 4>
PP long fiber having a basis weight of 20 g / m ² obtained in the same manner as in Example 1, a fiber arrangement of 22 °, a stress at 5% elongation of 16 N / 5 cm in the longitudinal direction, 4 N / 5 cm in the transverse direction, and an aspect ratio of 4.0. The laminate weight of the nonwoven fabric and the short fiber nonwoven fabric was set to 20 g / m ² , and the basis weight prepared in the same manner as in Example 1 was 40 g / m ² , apparent density, except that needle punching was performed at 80 penetrations / cm ² . The non-woven fabric of 0.10 g / cm ³ forms a protruding fiber structure having a protruding fiber length of 6 mm, the number of protruding fibers being 69 / cm ² and mostly consisting of short fibers, and the stress at 5% elongation is 8N in the longitudinal direction. / 5 cm, lateral direction 4 N / 5 cm, aspect ratio: 2.0, and air permeability was 364 cc / cm ² / sec.
Table 1 shows the evaluation results of the obtained nonwoven fabric for reinforcing foam molded products. Comparative Example 4 which deviates from the requirements of the present invention because the basis weight of the coating layer and the base material layer was excessively lowered is inferior in handleability. In foam molding, the air permeability is high and the shielding function is lowered, so that bleeding occurs and it is easily deformed. Therefore, the tear also occurred. For this reason, it became a molded product with poor mold fitting properties. Even in the performance evaluation, it was a nonwoven fabric having a problem as reinforcement for foamed molded products, which is slightly inferior in sound-damping property, wear resistance and shape retention.

<Comparative Example 5>
A PP continuous fiber non-woven fabric having a basis weight of 80 g / m ² , a fiber arrangement of 27 °, a 5% elongation stress of 155 N / 5 cm in the longitudinal direction, 28 N / 5 cm in the transverse direction, and an aspect ratio of 5.6, and a basis weight of 140 g / m ^The nonwoven fabric for reinforcing foam-molded articles obtained in the same manner as in Example 1 except that the short fiber web 2 was laminated, the basis weight is 220 g / m ² , the apparent density is 0.12 g / cm ³ , and the number of protruding fibers is A protruding fiber structure having a protruding fiber length of 5 mm consisting mainly of short fibers at 118 pieces / cm ² is formed, and the stress at 5% elongation is 122 N / 5 cm in the longitudinal direction, 36 N / 5 cm in the lateral direction, and the aspect ratio is 3 4. The air permeability was 18 cc / cm ² / sec.
Table 1 shows the evaluation results of the obtained nonwoven fabric for reinforcing foam molded products. Comparative Example 5 which deviates from the requirements of the present invention because the basis weight is too high, the handleability is good, but in foam molding, wrinkles and floats occur, the moldability is poor, and the foaming agent bleeds due to protrusion. The finished shape of the molded product was inferior. Even in the performance evaluation, the non-woven fabric has a problem as a reinforcement for foamed molded products having excellent sound-damping properties and abrasion resistance but slightly inferior in shape retention.

<Comparative Example 6>
By spreading the polyester staple fibers having a mechanical crimping fiber length 51mm with 1.4dtex round cross-section, in cross-layer, the web was laminated on the weight per unit area 80 g / ^{m 2,} a penetratin 120 at needle needle depth 10mm The entanglement process by a needle punch was performed and the short fiber nonwoven fabric for coating layers was obtained. Next, the PP non-woven fabric for base material layer obtained in Example 1 is laminated on the short fiber entangled non-woven fabric of the coating layer, and needle punch entangled with the penet 50 from the base material layer non-woven fabric side to be integrated for foam molding. A reinforced nonwoven fabric was prepared.
The produced non-woven fabric is a fluffy protruding fiber having a basis weight of 120 g / m ² , an apparent density of 0.06 g / cm ³ , a number of protruding fibers of 14 pieces / cm ² , and a protruding fiber length of 2 to 8 mm mainly composed of short fibers. Thus, it was determined that the number of protruding fibers was small, and the 5% elongation stress was 26 N / 5 cm in length, 8 N / 5 cm in width, 3.3 in the length / width ratio, and the air permeability was 81 cc / cm ² / sec. .
Table 1 shows the evaluation results of the obtained nonwoven fabric for reinforcing foam molded products. Comparative Example 6 which did not form the protruding fiber structure on the surface of the base material layer and deviated from the requirements of the present invention had no problem in handling, but foaming caused wrinkles and floats and poor moldability. Partial delamination between the base material layer and the coating layer also occurred, and the foaming agent oozed out from the surface, and the finished shape of the molded product was inferior. Even in the performance evaluation, it was a nonwoven fabric having a problem as a reinforcement for foamed molded products, in which the sound-damping property was slightly inferior, the abrasion resistance (the base layer and the coating layer were peeled off), and the shape retention were inferior.

<Comparative Example 7>
Using polyethylene terephthalate (hereinafter referred to as PET) with an intrinsic viscosity of 0.65, melt spinning at a spinning temperature of 285 ° C. and a single-hole discharge rate of 1.0 g / min, opening the fiber while taking it out with an ejector, The speed was adjusted so that the fiber arrangement was random on the conveyor and shaken to obtain a web having a basis weight of 80 g / m ² made of long fibers having a single yarn fineness of 2.0 dtex. Next, embossing is performed at 250 ° C. and a linear pressure of 50 kN / m using an embossing roller with a convex lattice pattern with a crimping area ratio of 28%, the crimping dot area is 0.34 mm ² , the partial crimping part area ratio is 27%, Foam molding obtained in the same manner as in Example 1 except that a polyester long fiber nonwoven fabric for a base material layer having a stress at 5% elongation of 142 N / 5 cm in the longitudinal direction, 84 N / 5 cm in the transverse direction and an aspect ratio of 1.7 was obtained. Reinforcing nonwoven fabrics have a protruding fiber structure with a basis weight of 160 g / m ² , an apparent density of 0.14 g / cm ³ , a number of protruding fibers of 115 / cm ² , and a protruding fiber length of 6 mm consisting mostly of short fibers The stress at 5% elongation is 73N / 5cm in the vertical direction, 52N / 5cm in the horizontal direction, the aspect ratio is 1.4, the air permeability is 43 cc / cm ² / sec, the elongation is 28% in length, and 30% in width. Met.
Table 1 shows the evaluation results of the obtained nonwoven fabric for reinforcing foam molded products. Comparative Example 7, which deviates from the requirements of the present invention due to the enhancement of the mechanical properties of the base material layer, has good handleability, but foam molding causes wrinkles and floats and poor moldability. The finished shape of the molded product was inferior due to the bleeding of the foaming agent due to the protrusion. Even in the performance evaluation, the non-woven fabric has good sound-damping properties and abrasion resistance, but has poor shape retention and is problematic for reinforcing foam molded products.

The non-woven fabric for reinforcing foam-molded articles of the present invention is composed of a base layer having a high shielding function and a coating layer that is bulky and excellent in sound-damping property, in particular, while being flexible but having a tensile stress resistance in handling. Due to the anchor effect of the protruding fiber structure, the foam molded part and the reinforcing material are well integrated, and the nonwoven fabric is optimal for use as a foam molding reinforcing material, which suppresses elongation at low elongation and has excellent handleability. Therefore, the followability to the mold at the time of foam molding is excellent, and the foaming agent does not ooze out, and a high-quality foam molded article can be obtained. In addition, it has excellent resistance to scratching generated by friction between the foam molded body and the spring material, and also has excellent reinforcement effect and durability, so reinforcement for obtaining a highly functional foam molded product with low manufacturing cost A non-woven fabric for reinforcing foam molded articles suitable for material use can be provided at low cost.
Since the nonwoven fabric for foam molded article reinforcement of the present invention is relatively lightweight, a lightweight and high-quality foam molded article can be produced at low cost, and a vehicle using the foam molded article can also be reduced in weight at a low cost. It can also contribute to energy saving.

Claims (6)

A short-fiber nonwoven fabric layer and a long-fiber nonwoven fabric layer formed with a dense crimping portion are laminated to form a laminated nonwoven fabric. The short-fiber nonwoven fabric layer and the long-fiber nonwoven fabric layer are partially entangled to form a short-fiber nonwoven fabric layer. Fibers to penetrate through the long fiber nonwoven fabric layer to form a protruding fiber structure, the apparent density of the laminated nonwoven fabric is 0.05 to 0.15 g / cm ³ , and the stress at 5% elongation in the longitudinal direction is 10 Foam molded product having a stress of 5N in the horizontal direction of 15N or less and a ratio of the stress in the vertical direction of 5% to the stress of 5% in the horizontal direction of 1.66 or more. Non-woven fabric for reinforcement. The 5% elongation stress in the longitudinal direction is 15 to 45 N / 5 cm, the 5% elongation stress in the transverse direction is 8 to 15 N / 5 cm, and the 5% elongation stress in the longitudinal direction and the 5% elongation stress in the transverse direction are the ratio from 2 to 10, molded foam reinforcing nonwoven according to claim 1, wherein the basis weight is 50 to 200 g / ^{m 2.} Partial pressure bonding treatment of the long fiber nonwoven fabric layer is independent crimping fiber assembly unit, partial crimping portion area ratio 8 to 25% bonding dot area is 0.01～2.5Mm ² claim 1 or 2 A nonwoven fabric for reinforcing foamed articles as described in 1.   The nonwoven fabric for reinforcing foamed articles according to any one of claims 1 to 3, wherein the short fiber nonwoven fabric layer is mainly composed of polyester fibers, and the long fiber nonwoven fabric layer is composed of polyolefin fibers. The nonwoven fabric for reinforcing a foam molded article according to any one of claims 1 to 4, having an air permeability of 50 to 350 cc / cm ² / sec.   A foam molded article using the nonwoven fabric for reinforcing a foam molded article according to any one of claims 1 to 5 as a reinforcing cloth.