JP6658092B2 - Non-woven fabric for reinforcing foam molded products - Google Patents
Non-woven fabric for reinforcing foam molded products Download PDFInfo
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- JP6658092B2 JP6658092B2 JP2016037038A JP2016037038A JP6658092B2 JP 6658092 B2 JP6658092 B2 JP 6658092B2 JP 2016037038 A JP2016037038 A JP 2016037038A JP 2016037038 A JP2016037038 A JP 2016037038A JP 6658092 B2 JP6658092 B2 JP 6658092B2
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- 239000004745 nonwoven fabric Substances 0.000 title claims description 79
- 230000003014 reinforcing effect Effects 0.000 title claims description 48
- 239000006260 foam Substances 0.000 title claims description 13
- 229920005989 resin Polymers 0.000 claims description 59
- 239000011347 resin Substances 0.000 claims description 59
- 238000002844 melting Methods 0.000 claims description 16
- 230000008018 melting Effects 0.000 claims description 16
- 230000035699 permeability Effects 0.000 claims description 10
- 239000010410 layer Substances 0.000 description 29
- 238000000034 method Methods 0.000 description 29
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 17
- 238000004090 dissolution Methods 0.000 description 13
- 238000005187 foaming Methods 0.000 description 13
- 239000002184 metal Substances 0.000 description 12
- 229910052751 metal Inorganic materials 0.000 description 12
- 239000005038 ethylene vinyl acetate Substances 0.000 description 7
- 239000000835 fiber Substances 0.000 description 7
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 7
- -1 polybutylene terephthalate Polymers 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 6
- 238000010030 laminating Methods 0.000 description 6
- 239000007789 gas Substances 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 238000005259 measurement Methods 0.000 description 5
- 230000002787 reinforcement Effects 0.000 description 5
- 238000000465 moulding Methods 0.000 description 4
- 229920000728 polyester Polymers 0.000 description 4
- 239000002131 composite material Substances 0.000 description 3
- 229920000098 polyolefin Polymers 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 230000002159 abnormal effect Effects 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 229920001707 polybutylene terephthalate Polymers 0.000 description 2
- 229920000139 polyethylene terephthalate Polymers 0.000 description 2
- 239000005020 polyethylene terephthalate Substances 0.000 description 2
- 229920002215 polytrimethylene terephthalate Polymers 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000004925 Acrylic resin Substances 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 241000700647 Variola virus Species 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 238000000113 differential scanning calorimetry Methods 0.000 description 1
- 238000009820 dry lamination Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 229920006244 ethylene-ethyl acrylate Polymers 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 238000010097 foam moulding Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 229920000554 ionomer Polymers 0.000 description 1
- 230000005389 magnetism Effects 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 239000012299 nitrogen atmosphere Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 239000011112 polyethylene naphthalate Substances 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 238000007650 screen-printing Methods 0.000 description 1
- 238000009958 sewing Methods 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 238000009864 tensile test Methods 0.000 description 1
- KKEYFWRCBNTPAC-UHFFFAOYSA-L terephthalate(2-) Chemical compound [O-]C(=O)C1=CC=C(C([O-])=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-L 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
Landscapes
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Molding Of Porous Articles (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Laminated Bodies (AREA)
Description
本発明は、発泡成形品補強用不織布に関する。より詳しくは、発泡時の金型セット性に優れた発泡成形品補強用に最適な不織布に関する。 The present invention relates to a nonwoven fabric for reinforcing a foamed molded product. More specifically, the present invention relates to a nonwoven fabric which is excellent in setting a mold during foaming and is most suitable for reinforcing a foamed molded product.
近年、座席等のクッション材として、発泡ウレタン成形体が広く用いられている。一般的に、発泡ウレタン成形体としては成形時に補強用不織布が一体化されたものが用いられている。かかる補強用不織布は、発泡ウレタン成形体と自動車シートの金属スプリングの間に位置して、金属スプリングのクッション作用を均等に分散すると共に、金属スプリングから受ける摩擦から発泡ウレタン成形体を保護するという役割を担うものである。この補強用不織布を使用し、クッション材を生産するには、まず生産するクッション形状に合わせ補強用不織布を打ち抜きまたはカットし縫製する。さらには金型にセットするための穴を開ける。その後、金型に取り付けた突起やピン等のセット治具に前記穴を突き刺して金型にセットした後、ウレタンを発泡させ、発泡ウレタン成形体を生産する。 In recent years, urethane foam molded articles have been widely used as cushioning materials for seats and the like. Generally, a molded non-woven fabric for reinforcement is used as the urethane foam molded article at the time of molding. The reinforcing non-woven fabric is located between the urethane foam and the metal spring of the automobile seat, and functions to evenly disperse the cushioning action of the metal spring and to protect the urethane foam from friction received from the metal spring. It is responsible for. In order to produce a cushion material using this reinforcing nonwoven fabric, first, the reinforcing nonwoven fabric is punched or cut and sewn according to the cushion shape to be produced. Further, a hole for setting in a mold is made. Then, the hole is pierced into a set jig such as a projection or a pin attached to the mold and set in the mold, and then urethane is foamed to produce a urethane foam molded article.
近年、自動車シートにはいろいろなセンサーや機能を付与するため、形状が複雑となり、補強用不織布の縫製等の負担が大きくなり、工数やコストアップとなっている。上記の通り、金型への補強用不織布のセットも負荷となっており、さまざまな工夫がなされている。例えば、補強用不織布にホッチキスやメタル等を取り付け、金型に取り付けた磁石等の磁力を活用する方法や、補強用不織布または金型に接着剤などを塗布する方法である。 In recent years, since various sensors and functions are imparted to an automobile seat, the shape thereof is complicated, and the burden of sewing a nonwoven fabric for reinforcement and the like is increased, resulting in an increase in man-hours and costs. As described above, the setting of the reinforcing nonwoven fabric in the mold is also a load, and various measures have been taken. For example, a method of attaching a stapler, metal, or the like to the reinforcing nonwoven fabric and utilizing the magnetic force of a magnet or the like attached to the mold, or a method of applying an adhesive or the like to the reinforcing nonwoven fabric or the mold.
ホッチキスやメタル等を取り付ける方法では、あらかじめ金型に磁石等の磁力を取り付ける必要があり、設計が変わるたびに、磁石等の取り付け場所を変更するなど手間とコストが高くなる問題がある。接着剤を活用する方法は金型を汚す問題がある。 In the method of attaching a stapler, metal, or the like, it is necessary to attach a magnetic force such as a magnet to a mold in advance, and there is a problem in that the location for attaching the magnet or the like is changed every time the design is changed, which increases labor and cost. The method of using the adhesive has a problem of soiling the mold.
特許文献１には、発泡金型内部に装着ピンをあらかじめ備えることで補強用不織布をセットする方法が提案されている。しかし、この方法では、発泡形状が変わる都度製作する金型に装着ピンを設置する必要があるだけでなく、発泡後の取り外し時に補強用不織布へダメージを与える可能性がある。 Patent Literature 1 proposes a method of setting a reinforcing nonwoven fabric by previously providing a mounting pin inside a foaming mold. However, in this method, it is necessary not only to install the mounting pins in the mold to be manufactured each time the foam shape changes, but also there is a possibility that the reinforcing nonwoven fabric may be damaged at the time of removal after foaming.
特許文献２には、あらかじめ補強用不織布に使用するバインダー中に鉄粉または砂鉄を混入して補強用不織布に磁性を付与する方法が提案されている。しかし、この方法では金属スプリングとの接触による鉄粉または砂鉄の脱落で車内を汚す恐れや異音の可能性がある。さらに、補強用不織布への金属混入、例えば補強用不織布製造工程で使用するニードルパンチの針混入などの検知がし難い問題がある。 Patent Literature 2 proposes a method in which iron powder or iron sand is mixed in advance into a binder used for a reinforcing nonwoven fabric to impart magnetism to the reinforcing nonwoven fabric. However, in this method, there is a possibility that the inside of the vehicle may be stained due to the dropping of iron powder or iron sand due to contact with the metal spring, and there is a possibility of abnormal noise. Furthermore, there is a problem that it is difficult to detect metal contamination in the reinforcing nonwoven fabric, for example, needle mixing of a needle punch used in the manufacturing process of the reinforcing nonwoven fabric.
特許文献３には、補強用不織布に金属製のワイヤを取り付け、発泡成形型に設けられた永久磁石に吸着させることで、型内に装着する方法が提案されている。しかし、この方法も補強用不織布へのワイヤ取り付けの工程が増えるだけでなく、発泡成形型に永久磁石を設ける必要がある。 Patent Literature 3 proposes a method in which a metal wire is attached to a reinforcing nonwoven fabric, and the metal wire is attached to a permanent magnet provided in a foaming mold so as to be mounted in the mold. However, this method not only increases the number of steps for attaching wires to the reinforcing nonwoven fabric, but also requires the provision of permanent magnets in the foaming mold.
従来は、金型に改良を加えず、従来の金型を使用し、汚すこともなく簡単に補強用不織布をセットする方法は提案はなされていなかった。本発明は従来技術を背景になされたもので、補強用不織布の金型セット性をより向上させて、効率良くクッション材を発泡成形させことが可能な発泡成形品用補強用不織布を提供することを課題とする。 Heretofore, there has been no proposal for a method of simply setting a reinforcing non-woven fabric without using a conventional mold without adding any improvement to the mold. The present invention has been made based on the background of the prior art, and provides a reinforcing nonwoven fabric for a foam molded article capable of efficiently foaming and molding a cushion material by further improving the mold setability of the reinforcing nonwoven fabric. As an issue.
本発明者らは上記課題を解決するため、鋭意研究した結果、ウレタンを発泡させウレタン発泡成形体を生産するため、金型は通常６０℃以上の温度に昇温されており、この温度で補強用不織布と金型が接着する樹脂を補強用不織布にあらかじめ塗布しておくことにより、簡単にセットできることを見出し、本発明に到達した。 The inventors of the present invention have conducted intensive studies to solve the above-described problems. As a result, the mold is usually heated to a temperature of 60 ° C. or more to produce urethane foam by molding urethane. The present inventors have found that the resin can be easily set by previously applying a resin to which the nonwoven fabric and the mold adhere to the reinforcing nonwoven fabric, and have reached the present invention.
すなわち、本発明は、以下の通りである。
（１）補強用不織布層と樹脂層を積層した発泡成形品補強用不織布であって、樹脂層に使用する樹脂の融点が３０℃以上６０℃以下であり、樹脂層に使用する樹脂の溶解エネルギーが２０Ｊ／ｇ以上１００Ｊ／ｇ以下である発泡成形品補強用不織布。
（２）通気度が３０ｃｃ／ｃｍ２／秒以上３００ｃｃ／ｃｍ２／秒以下である（１）に記載の発泡成形品補強用不織布。
That is, the present invention is as follows.
(1) A nonwoven fabric for reinforcing a foamed molded product obtained by laminating a nonwoven fabric layer for reinforcement and a resin layer, wherein the melting point of the resin used for the resin layer is 30 ° C. or more and 60 ° C. or less, and the dissolving energy of the resin used for the resin layer Is 20 J / g or more and 100 J / g or less.
(2) The nonwoven fabric for reinforcing a foamed molded product according to (1), wherein the air permeability is 30 cc / cm 2 / sec or more and 300 cc / cm 2 / sec or less.
本発明の発泡成形品補強用不織布は、補強用不織布層と樹脂層を積層し、その樹脂層に発泡時の金型の温度で軟化する樹脂を選定する。さらに発泡成形品補強用不織布の通気度を一定以上に保つことにより、発泡時に発生するガスを抜くことができ、見栄えの良いクッション材を得ることができる。
その結果、従来の金型を使用し、縫製のみ施された発泡成形品補強用不織布を効率良く金型にセットでき、作業性を向上できる。
この発泡成形品補強用不織布は、発泡成型後の金型への汚れもなく、発泡成形品補強用不織布の成型性にも影響を与えないため、従来と全く同じ方法で使用することができるという利点がある。
In the nonwoven fabric for reinforcing a foam molded article of the present invention, a reinforcing nonwoven fabric layer and a resin layer are laminated, and a resin that softens at the temperature of a mold during foaming is selected for the resin layer. Further, by maintaining the air permeability of the non-woven fabric for reinforcing a foamed molded product at a certain level or more, gas generated at the time of foaming can be released, and a cushion material having a good appearance can be obtained.
As a result, it is possible to efficiently set the nonwoven fabric for reinforcing the foamed molded product, which is sewn only, using a conventional mold in the mold, thereby improving workability.
Since this non-woven fabric for reinforcing a foamed molded product does not stain the mold after foaming and does not affect the moldability of the non-woven fabric for reinforcing a foamed molded product, it can be used in exactly the same manner as before. There are advantages.
本発明の発泡成形品補強用不織布の補強用不織布層には、従来知られている不織布全てに適用することができるが、不織布の引き裂き強力が２０Ｎ以上、発泡後の強力（発泡後の不織布層を切り出し、ＪＩＳ Ｌ １９１３（２０１０）に準拠して強力を測定する）が１０Ｎ／ｃｍ以上、ウレタンの染み出しを少なくさせる密度が高い部位を持つ不織布が好ましい。 As the reinforcing nonwoven fabric layer of the foamed molded product reinforcing nonwoven fabric of the present invention, any conventionally known nonwoven fabric can be applied. However, the nonwoven fabric has a tear strength of 20 N or more and a post-foaming strength (foamed nonwoven fabric layer). Is cut out, and the strength is measured in accordance with JIS L 1913 (2010)). A nonwoven fabric having a high density portion of 10 N / cm or more and less urethane exudation is preferable.
補強用不織布層に使用する不織布を構成する樹脂としては、ポリエステル、ポリオレフィンやポリアミドが好ましく、汎用熱可塑性樹脂で安価なポリエステルやポリオレフィンが特に好ましい。ポリエステルとしては、ポリブチレンテレフタレート（ＰＢＴ）、ポリエチレンテレフタレート（ＰＥＴ）、ポリブチレンナフタレート（ＰＢＮ）、ポリエチレンナフタレート（ＰＥＮ）、ポリシクロヘキサンジメチルテレフタレート（ＰＣＨＴ）、ポリトリメチオレンテレフタレート（ＰＴＴ）などのホモポリエステル及びそれらの共重合ポリエステルなどが例示できる。また、ポリオレフィンではポリエチレンやポリプロピレンなどが例示できる。 As a resin constituting the nonwoven fabric used for the reinforcing nonwoven fabric layer, polyester, polyolefin or polyamide is preferable, and polyester and polyolefin which are inexpensive general-purpose thermoplastic resins are particularly preferable. Examples of the polyester include polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polybutylene naphthalate (PBN), polyethylene naphthalate (PEN), polycyclohexanedimethyl terephthalate (PCHT), and polytrimethylene terephthalate (PTT). Examples thereof include homopolyesters and copolymerized polyesters thereof. Examples of the polyolefin include polyethylene and polypropylene.
補強用不織布層に使用する不織布の製造方法は、長繊維不織布としてはスパンボンド法、メルトブロー法など、短繊維不織布としてはニードルパンチ法、スパンレース法などによる機械交絡によるものや、ケミカルボンド法、サーマルボンド法などが例示できる。さらにこれらを複合したものも使用することができる。
スパンボンド法により得られる不織布を使用する補強用不織布層としては、目付が３０〜２００ｇ／ｍ２で、空隙率が９０〜９４％のかさ高な不織布層と目付が２０〜１００ｇ／ｍ２で、空隙率８７〜９１％の緻密な不織布を積層し、ニードルパンチ法で積層一体化させたものや、一層であるが厚み方向に密度差を付け、ウレタン補強層とウレタン発泡時の染み出し防止層を兼ね備えたニードルパンチスパンボンド不織布を使用したもの、さらには捲縮数が２〜４０個／２５ｍｍ、繊維径が１〜３０μｍである捲縮長繊維不織布で構成され、目付が５０〜２００ｇ／ｍ２、厚さが０．５〜２．０ｍｍのスパンボンド不織布を使用したものが好ましい。
また、短繊維不織布とスパンボンド不織布との複合不織布層であれば、繊維径が１〜２３デシテックスの繊維で形成され、目付が２０〜１００ｇ／ｍ２であるスパンボンド不織布に短繊維のカードウェッブを片面もしくは両面に積層し、ニードルパンチ法で積層一体化させた複合不織布層が好ましい。
The manufacturing method of the nonwoven fabric used for the reinforcing nonwoven fabric layer includes a spunbond method and a melt blow method for a long-fiber nonwoven fabric, a mechanical punching method such as a needle punch method and a spunlace method for a short-fiber nonwoven fabric, and a chemical bond method. A thermal bond method and the like can be exemplified. Further, a composite of these can also be used.
The reinforcing nonwoven fabric layer using the nonwoven fabric obtained by the spun bond method has a basis weight of 30 to 200 g / m 2 , a porosity of 90 to 94%, and a bulky nonwoven layer of 20 to 100 g / m 2 . , A nonwoven fabric having a porosity of 87 to 91% is laminated and laminated and integrated by the needle punch method, or a single layer is provided with a density difference in the thickness direction to prevent exudation at the time of urethane foaming with the urethane reinforcing layer. A needle-punched spunbonded nonwoven fabric having a double layer, a crimped long-fiber nonwoven fabric having a number of crimps of 2 to 40/25 mm and a fiber diameter of 1 to 30 μm, and a basis weight of 50 to 200 g / It is preferable to use a spunbond nonwoven fabric having a m 2 and a thickness of 0.5 to 2.0 mm.
In the case of a composite nonwoven fabric layer of a short fiber nonwoven fabric and a spunbonded nonwoven fabric, a card web of short fibers is formed from a spunbonded nonwoven fabric having a fiber diameter of 1 to 23 dtex and a basis weight of 20 to 100 g / m 2. Are laminated on one side or both sides, and the composite nonwoven fabric layer is laminated and integrated by a needle punch method.
樹脂層に使用する樹脂は、示差走査熱量測定による融点が３０℃以上６０℃以下、好ましくは３０℃以上５５℃未満、より好ましくは３５℃以上５０℃未満の樹脂を用いることで金型セット性が良好となる。融点が３０℃未満となると通常保管状態で粘着性が上がり、重ねて保管した場合、取り扱い性が悪くなり、場合によっては完全に接着してしまう場合がある。融点が６０℃より高くなると、金型温度での接着性が不十分となり、セット性が悪くなり、作業中に剥がれるなどの問題が発生する。 The resin used for the resin layer has a melting point of 30 ° C. or more and 60 ° C. or less, preferably 30 ° C. or more and less than 55 ° C., and more preferably 35 ° C. or more and less than 50 ° C., which is a property of mold setting. Is good. When the melting point is lower than 30 ° C., the tackiness is increased in a normal storage state, and when stored in a stacked state, the handleability is deteriorated, and in some cases, complete adhesion may occur. If the melting point is higher than 60 ° C., the adhesion at the mold temperature becomes insufficient, the setting property is deteriorated, and problems such as peeling during operation occur.
さらに、樹脂層に使用する樹脂は、示差走査熱量測定による溶解エネルギーが２０Ｊ／ｇ以上１００Ｊ／ｇ以下、好ましくは２５Ｊ／ｇ以上７０Ｊ／ｇ以下、より好ましくは３０Ｊ／ｇ以上４０Ｊ／ｇ未満の樹脂を用いることで金型セット性が良好となる。溶解エネルギーが２０Ｊ／ｇ未満となると通常保管状態での環境変化により粘着性が上がり、重ねて保管した場合、取り扱い性が悪くなり、場合によっては完全に接着してしまう場合がある。溶解エネルギーが１００Ｊ／ｇより高くなると、金型への接着に時間がかかり、作業性が悪くなる問題が発生する。 Further, the resin used for the resin layer has a dissolution energy by differential scanning calorimetry of 20 J / g or more and 100 J / g or less, preferably 25 J / g or more and 70 J / g or less, more preferably 30 J / g or more and less than 40 J / g. By using a resin, the mold setting property is improved. If the dissolution energy is less than 20 J / g, the tackiness will increase due to environmental changes in the normal storage state, and when stored in a stack, the handleability will deteriorate, and in some cases, complete adhesion may occur. If the dissolution energy is higher than 100 J / g, it takes a long time to adhere to the mold, and a problem occurs that workability is deteriorated.
融点および溶解エネルギーが上記の範囲であれば、樹脂の種類は特に限定されないが、エチレン−酢酸ビニルコポリマー、エチレン−エチルアクリレートコポリマー、アイオノマー樹脂、ウレタン樹脂、またはこれらの誘導体が好適に使用できる。 The type of the resin is not particularly limited as long as the melting point and the dissolution energy are in the above ranges, but ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, ionomer resin, urethane resin, or derivatives thereof can be suitably used.
補強用不織布層と樹脂層を積層した発泡成形品補強用不織布の通気度は好ましくは３０ｃｃ／ｃｍ２／秒以上、より好ましくは４０ｃｃ／ｃｍ２／秒以上３００ｃｃ／ｃｍ２／秒以下、さらに好ましくは５０ｃｃ／ｃｍ２／秒以上２５０ｃｃ／ｃｍ２／秒以下である。通気度が３０ｃｃ／ｃｍ２／秒未満となるとウレタン発泡時に発生するガスが抜け難くなり、発泡ウレタン成形体に欠点が発生する場合がある。また、３００ｃｃ／ｃｍ２／秒より高くなると発泡成形品補強用不織布からウレタンが染み出し、金属スプリングとの接触による異音の問題が発生する場合がある。 The air permeability of the non-woven fabric for reinforcing a foam molded product obtained by laminating a non-woven fabric layer for reinforcement and a resin layer is preferably 30 cc / cm 2 / sec or more, more preferably 40 cc / cm 2 / sec or more and 300 cc / cm 2 / sec or less. Is 50 cc / cm 2 / sec or more and 250 cc / cm 2 / sec or less. If the air permeability is less than 30 cc / cm 2 / sec, gas generated during urethane foaming becomes difficult to escape, and a defect may occur in the urethane foam molded article. On the other hand, when the pressure is higher than 300 cc / cm 2 / sec, urethane may seep out from the nonwoven fabric for reinforcing the foamed molded product, which may cause a problem of abnormal noise due to contact with the metal spring.
樹脂を積層する量としては特に限定されないが、１０ｇ／ｍ２以上６０ｇ／ｍ２以下、好ましくは１０ｇ／ｍ２以上５０ｇ／ｍ２以下、より好ましくは１５ｇ／ｍ２以上４０ｇ／ｍ２以下である。樹脂の積層量が１０ｇ／ｍ２未満であれば、発泡成形品補強用不織布の十分な金型へのセット性を得ることができない場合があり、６０ｇ／ｍ２より多くなると通気度の確保が困難となる場合がある。 The amount of the resin to be laminated is not particularly limited, but is 10 g / m 2 or more and 60 g / m 2 or less, preferably 10 g / m 2 or more and 50 g / m 2 or less, more preferably 15 g / m 2 or more and 40 g / m 2 or less. is there. If the amount of the resin laminated is less than 10 g / m 2 , it may not be possible to obtain sufficient setability of the non-woven fabric for reinforcing a foamed molded product in a mold, and if it is more than 60 g / m 2 , air permeability may be secured. It can be difficult.
樹脂層を積層し、最適な通気度を得るための方法としては、樹脂押し出しラミネート法、タンデム押し出しラミネート法、ドライラミネート法、カーテンスプレー法などの公知の方法を用いることができる。さらに、プリント法等によるドット加工などを用いることができる。これらの方法を用い、積層する樹脂の面積率は、補強用不織布の面積に対し好ましくは１０％以上９０％以下、より好ましくは２０％以上８０％以下、さらに好ましくは３０％以上７０％以下である。積層する樹脂面積率が１０％未満となると、金型へのセット性が不十分となり、９０％以上となると通気度を確保が難しくなる場合がある。 Known methods such as resin extrusion lamination, tandem extrusion lamination, dry lamination, and curtain spraying can be used as a method for laminating the resin layers and obtaining an optimum air permeability. Further, dot processing by a printing method or the like can be used. Using these methods, the area ratio of the resin to be laminated is preferably from 10% to 90%, more preferably from 20% to 80%, even more preferably from 30% to 70%, based on the area of the reinforcing nonwoven fabric. is there. When the area ratio of the resin to be laminated is less than 10%, the setting property to the mold becomes insufficient, and when it exceeds 90%, it may be difficult to secure the air permeability.
金型セット性への付与と通気度をより最適にするための樹脂層としては、樹脂を線状またはランダム状に間隔を開けて積層する方法あるいはドット状に積層することが好ましい。線状に積層する場合、樹脂の幅は好ましくは０．３〜１０ｍｍであり、樹脂間の間隔は好ましくは１〜１０ｍｍである。ランダム状に積層する場合、樹脂が非連続的に存在することが好ましく、樹脂量を５０ｇ／ｍ２以下にすることがより好ましい。ドット状に積層する場合は、ドット形状に特に指定はなく、丸型や菱型等を用いることができる。サイズも特に指定はないが、円換算での直径で好ましくは１ｍｍ以上１０ｍｍ以下である。配置については格子状や千鳥配列等を用いることができる。 As the resin layer for imparting the mold setting property and optimizing the air permeability, it is preferable to laminate the resin linearly or randomly at intervals or to laminate the resin in a dot shape. When laminating linearly, the width of the resin is preferably 0.3 to 10 mm, and the interval between the resins is preferably 1 to 10 mm. When laminating in a random shape, it is preferable that the resin is present discontinuously, and it is more preferable that the amount of the resin is 50 g / m 2 or less. When laminating in a dot shape, there is no particular designation for the dot shape, and a round shape, a diamond shape, or the like can be used. Although the size is not particularly specified, it is preferably 1 mm or more and 10 mm or less in diameter in terms of a circle. For the arrangement, a lattice shape, a staggered arrangement, or the like can be used.
本発明の発泡成形品補強用不織布は、クッション用途に限定されるものではなく、金型を用い、成型する発泡成形品の補強用不織布として、車両用の各種内装材や、建築資材、電化製品の表面発泡成形品などの用途にも有用である。 The non-woven fabric for reinforcing a foamed molded product of the present invention is not limited to cushioning applications, but is used as a reinforcing non-woven fabric for a foamed molded product to be molded using a mold, as various interior materials for vehicles, building materials, and electric appliances. It is also useful for applications such as surface foam moldings.
以下、実施例および比較例によって本発明をさらに具体的に説明するが、本発明はこれらに何ら限定されるものではない。
なお、本発明の実施例および比較例で用いた評価方法は下記の方法でおこなった。
Hereinafter, the present invention will be described more specifically with reference to Examples and Comparative Examples, but the present invention is not limited thereto.
The evaluation methods used in the examples and comparative examples of the present invention were performed by the following methods.
（１）樹脂の融点（℃）
発泡成形品補強用不織布から樹脂部のみを４〜５ｍｇ採取した。この際、不織布が一緒に採取された場合、そのまま測定した。装置はＴＡ ｉｎｓｔｒｕｍｅｎｔｓ社製Ｑ１００を用い、−７０℃から１２０℃まで２０℃／ｍｉｎの速度で昇温させた。測定は窒素雰囲気下で行った。チャートより、図１に示したベースライン（２０℃−９５℃）と接線との交点を融点とした。図１の場合、４８．６２℃が融点となる。
(1) Melting point of resin (℃)
Only 4 to 5 mg of the resin part was collected from the nonwoven fabric for reinforcing the foamed molded product. At this time, when the nonwoven fabric was collected together, the measurement was performed as it was. The apparatus used was Q100 manufactured by TA Instruments, and was heated from -70 ° C to 120 ° C at a rate of 20 ° C / min. The measurement was performed under a nitrogen atmosphere. From the chart, the intersection between the baseline (20 ° C.-95 ° C.) and the tangent shown in FIG. 1 was taken as the melting point. In the case of FIG. 1, 48.62 ° C. is the melting point.
（２）樹脂の溶解エネルギー（Ｊ／ｇ）
上記（１）記載の測定により得られたチャートより、溶解エネルギーを求めた。図１の場合、３５．８８Ｊ／ｇとなる。
(2) Dissolution energy of resin (J / g)
From the chart obtained by the measurement described in (1) above, the dissolution energy was determined. In the case of FIG. 1, it is 35.88 J / g.
（３）通気度（ｃｃ／ｃｍ２／秒）
ＪＩＳ Ｌ １０９６（２０１０）「織物及び編物の生地試験方法」８．２６．１ Ａ法（フラジール形法）」に準拠して測定した。
(3) Air permeability (cc / cm 2 / sec)
The measurement was carried out in accordance with JIS L 1096 (2010) "Dough test method for woven and knitted fabrics" 8.26.1 A method (Fragile method).
（４）樹脂層の面積率（％）
ＳＥＭにて樹脂層側から撮影し、単位当りの樹脂層の面積を求め、百分率で示した。
(4) Area ratio of resin layer (%)
Photographs were taken with the SEM from the resin layer side, and the area of the resin layer per unit was determined and expressed as a percentage.
（５）金型への接着性（Ｎ／φ２２ｍｍ）
試験片を幅２５ｍｍ、長さ１００ｍｍにカットし、１端を金属板（ＳＳ４００フラットバー幅３０ｍｍ、長さ１００ｍｍ）の１端に５１．６ｋＰａ Ｋｙｏｗａ製「ゲージメイト」を使用し、２ｋｇｆ／φ２２ｍｍ端子の荷重で３０℃±３℃および７０℃±３℃で１０秒間圧縮する。その後、島津製引張試験機のチャック上部に金属板を、チャック下部に試験片の反対の１端をチャック間距離が１０ｍｍとなるようセットする。引張速度１００ｍｍ／分で引っ張り試験を行い、最大強度を求める。
(5) Adhesion to mold (N / φ22mm)
A test piece was cut into a width of 25 mm and a length of 100 mm. One end of a metal plate (SS400 flat bar width: 30 mm, length: 100 mm) was used at one end with a 51.6 kPa Kyowa “gauge mate” using a 2 kgf / φ22 mm terminal. Compress at 30 ° C. ± 3 ° C. and 70 ° C. ± 3 ° C. for 10 seconds under a load of Thereafter, a metal plate is set on the upper part of the chuck of the tensile tester manufactured by Shimadzu, and one end of the test piece is set on the lower part of the chuck so that the distance between the chucks is 10 mm. A tensile test is performed at a tensile speed of 100 mm / min to determine the maximum strength.
（６）室温３０℃での補強用不織布の取り扱い性
２０ｃｍ×２０ｃｍにカットした試験片を１０枚重ね、１０ｋｇ／４００ｃｍ２となるよう荷重を掛け、室温３０℃の部屋で２４時間放置する。その後、重りを除き、１枚１枚取り出すときの状況を以下の通り評価した。
○：各層で接着がなく取り出すことができた。
×：各層で接着が起こり、取り出すことが難しかった。
(6) Handling property of reinforcing nonwoven fabric at room temperature of 30 ° C. Ten test pieces cut to 20 cm × 20 cm are piled up, a load is applied so as to be 10 kg / 400 cm 2, and left in a room at room temperature of 30 ° C. for 24 hours. After that, the conditions when removing the weights one by one were evaluated as follows.
：: Each layer could be taken out without adhesion.
×: Adhesion occurred in each layer, and it was difficult to take out.
（７）発泡成形加工性
○：ウレタンの表面にガスの後がなく、きれいに発泡されていた。
△：ウレタンの表面にガス後が部分的に発生する。
×：ウレタン表面にガスの後があり、痘痕状などの欠点があった。
(7) Foaming processability ：: The urethane surface was cleanly foamed with no gas behind.
Δ: Gas is partially generated on the surface of urethane.
×: There was a gas behind the urethane surface, and there were defects such as smallpox traces.
＜実施例１＞
東洋紡株式会社製不織布ボランス「ＣＲＥ３０８０」白色面側にヤスハラケミカル株式会社製エチレン酢酸ビニルコポリマー（融点４７℃、溶解エネルギー３６Ｊ／ｇ）をＴ−ダイから押し出し、上記不織布の長手方向と平行に樹脂幅１ｍｍ、樹脂間隔２ｍｍで線状に積層した。樹脂は２０ｇ／ｍ２であった。
<Example 1>
Extruded from a T-die an ethylene vinyl acetate copolymer (melting point 47 ° C., dissolution energy 36 J / g) manufactured by Yasuhara Chemical Co., Ltd. on the white side of the nonwoven fabric Borans “CRE 3080” manufactured by Toyobo Co., Ltd. , And laminated linearly at a resin interval of 2 mm. The resin was 20 g / m 2 .
＜実施例２＞
三井化学株式会社製不織布タフネル「ＥＳＥ４４４」の片面にヤスハラケミカル株式会社製エチレン酢酸ビニルコポリマー（融点３８℃、溶解エネルギー２４Ｊ／ｇ）をＴ−ダイから押し出し、上記不織布の長手方向と平行に樹脂幅１ｍｍ、樹脂間隔２ｍｍで線状に積層した。樹脂は３０ｇ／ｍ２であった。
<Example 2>
An extruded ethylene vinyl acetate copolymer (melting point: 38 ° C., dissolution energy: 24 J / g) extruded from a T-die on one side of a nonwoven fabric tufnel “ESE444” manufactured by Mitsui Chemicals, Inc., and a resin width of 1 mm parallel to the longitudinal direction of the nonwoven fabric. , And laminated linearly at a resin interval of 2 mm. The resin was 30 g / m 2 .
＜参考例１＞
東洋紡株式会社製不織布ボランス「ＣＲＥ３０８０」白色面側にヤスハラケミカル株式会社製エチレン酢酸ビニルコポリマー樹脂（融点３３℃、溶解エネルギー７０Ｊ／ｇ）をＴ−ダイから押し出し、上記不織布の長手方向と平行に樹脂幅２ｍｍ、樹脂間隔２ｍｍで線状に積層した。樹脂は２０ｇ／ｍ２であった。
< Reference Example 1 >
Extrude an ethylene vinyl acetate copolymer resin (melting point 33 ° C, dissolution energy 70 J / g) manufactured by Yashara Chemical Co., Ltd. from the T-die on the white side of the nonwoven fabric Borans “CRE 3080” manufactured by Toyobo Co., Ltd. They were laminated linearly at 2 mm and a resin interval of 2 mm. The resin was 20 g / m 2 .
＜参考例２＞
東洋紡株式会社製不織布ボランス「ＣＲＥ３０８０」白色面側にヤスハラケミカル株式会社製エチレン酢酸ビニルコポリマー（融点４８℃、溶解エネルギー５８Ｊ／ｇ）をスクリーン印刷にてドット状に積層した。樹脂は２０ｇ／ｍ２であった。
< Reference Example 2 >
On the white surface side of Toyobo Co., Ltd. non-woven fabric volans "CRE 3080", an ethylene vinyl acetate copolymer (melting point 48 ° C., dissolution energy 58 J / g) made by Yashara Chemical Co., Ltd. was laminated in a dot shape by screen printing. The resin was 20 g / m 2 .
＜比較例３＞
東洋紡株式会社製不織布ボランス「ＣＲＥ３０８０」白色面側にヤスハラケミカル株式会社製エチレン酢酸ビニルコポリマー（融点５５℃、溶解エネルギー８５Ｊ／ｇ）をＴ−ダイから押し出し、上記不織布の長手方向と平行に樹脂幅２ｍｍ、樹脂間隔０．１ｍｍで線状に積層した。樹脂は５０ｇ／ｍ２であった。
< Comparative Example 3 >
Extruded from a T-die an ethylene vinyl acetate copolymer (melting point 55 ° C., dissolution energy 85 J / g) manufactured by Yashara Chemical Co., Ltd. on the white side of non-woven fabric volans “CRE 3080” manufactured by Toyobo Co., Ltd. , And linearly laminated with a resin interval of 0.1 mm. The resin was 50 g / m 2 .
＜比較例１＞
東洋紡株式会社製不織布ボランス「ＣＲＥ３０８０」白色面側にヤスハラケミカル株式会社製エチレン酢酸ビニルコポリマー（融点８０℃、溶解エネルギー７５Ｊ／ｇ）をＴ−ダイから押し出し、上記不織布の長手方向と平行に樹脂幅１ｍｍ、樹脂間隔２ｍｍで線状に積層した。樹脂は２０ｇ／ｍ２であった。
<Comparative Example 1>
Extruded from a T-die an ethylene vinyl acetate copolymer (melting point: 80 ° C, dissolution energy: 75 J / g) manufactured by Yashara Chemical Co., Ltd. on the white side of the non-woven borans “CRE3080” manufactured by Toyobo Co., Ltd. , And laminated linearly at a resin interval of 2 mm. The resin was 20 g / m 2 .
＜比較例２＞
東洋紡株式会社製不織布ボランス「ＣＲＥ３０８０」白色面側にサイデン化学株式会社製アクリル系樹脂 ＡＴＲ−１上記不織布に樹脂量が２０ｇ／ｍ２となるよう塗布した。常温（２０℃）でも粘性が高く、樹脂層のサンプルを取ることができず、融点は測定できなかった。
<Comparative Example 2>
Acrylic resin ATR-1 manufactured by Saiden Chemical Co., Ltd. ATR-1 was coated on the white side of non-woven fabric volans “CRE3080” manufactured by Toyobo Co., Ltd. so that the resin amount was 20 g / m 2 . Even at normal temperature (20 ° C.), the viscosity was high, a sample of the resin layer could not be taken, and the melting point could not be measured.
実施例１〜５および比較例１〜２で得られた補強用不織布の測定した各物性を表１にまとめた。 Table 1 summarizes the measured physical properties of the reinforcing nonwoven fabrics obtained in Examples 1 to 5 and Comparative Examples 1 and 2.
本発明の発泡成形品補強用不織布は、金型に改良を加えず、従来の金型を使用し、金型を汚すこともなく簡単に補強用不織布を金型にセットできるため、縫製から発泡成形までの工程を簡略化でき生産性を大幅に改善することができ産業界への寄与大である。 The nonwoven fabric for reinforcing a foamed molded product of the present invention uses a conventional mold without any modification to the mold, and can easily set the nonwoven fabric for reinforcement on the mold without soiling the mold. The process up to molding can be simplified and productivity can be greatly improved, contributing greatly to the industry.
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|---|---|---|---|---|
| JPS59187844A (en) * | 1983-03-29 | 1984-10-25 | 株式会社ブリヂストン | Manufacture of laminate |
| JP2976394B2 (en) * | 1990-10-03 | 1999-11-10 | 三井化学株式会社 | Reinforcing material for foam molded products |
| JPH1118909A (en) * | 1997-07-07 | 1999-01-26 | San Five Kk | Antislipping sheet and grip tape |
| JP5695525B2 (en) * | 2011-08-18 | 2015-04-08 | 株式会社クラレ | Adhesive sheet |
| JP5678987B2 (en) * | 2012-06-04 | 2015-03-04 | 東洋紡株式会社 | Nonwoven fabric for reinforcing foam molded products and products using the same |
| JP6372269B2 (en) * | 2014-09-12 | 2018-08-15 | 東洋紡株式会社 | Nonwoven fabric for reinforcing foam molded products |
| JP6409506B2 (en) * | 2014-09-01 | 2018-10-24 | 東洋紡株式会社 | Nonwoven fabric for reinforcing foam molded products |
| JP6651732B2 (en) * | 2015-08-12 | 2020-02-19 | 東洋紡株式会社 | Foam molding method |
| JP6651904B2 (en) * | 2016-02-29 | 2020-02-19 | 東洋紡株式会社 | Non-woven fabric for reinforcing foam molded products |
| JP6623835B2 (en) * | 2016-02-29 | 2019-12-25 | 東洋紡株式会社 | Non-woven fabric for reinforcing foam molded products |
-
2016
- 2016-02-29 JP JP2016037038A patent/JP6658092B2/en active Active
Also Published As
| Publication number | Publication date |
|---|---|
| JP2017154279A (en) | 2017-09-07 |
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