JPH0160576B2 - - Google Patents

Description

[Detailed description of the invention]

[Industrial Application Field] The present invention relates to a method for manufacturing a fibrous laminate, and more particularly to a method for manufacturing a fibrous laminate that can be deep drawn as an interior material for vehicles such as automobiles and has good shape retention. It is something. [Prior Art] Automotive interior materials include, for example, moldable fiber mat made by coating or impregnating a needle-punched nonwoven fabric with an aqueous emulsion of a thermoplastic resin with a softening point of 100 to 130°C and drying it, polyethylene terephthalate, etc. Carpets are made by heating and press-molding a non-woven fabric made of a blend of fibers with a high melting point and a thermoplastic resin fiber binder with a melting point of 100 to 130 degrees Celsius to match the shape of an automobile floor. It is being However, these carpets lack luxury by themselves and are unsatisfactory in terms of rigidity, elasticity, formability, etc., so tufted carpet or needle punch carving is used as a covering material on the surface of the carpet. Attempts have been made to bond PET using an adhesive or hot melt agent, or to back it with a resin sheet or foam sheet. The present inventor previously proposed a method of lining a carpet without reducing its air permeability by adding a material with a melting point of 60 to 200°C to the back side of a tufted carpet.
A web produced by needling a felt layer made by mixing a thermoplastic resin fiber binder with a fiber having a melting point 40°C or more higher than the melting point of the fiber binder is heat-pressed and molded via a fiber binder nonwoven fabric. Unexamined 1986 lining method
- Proposed as No. 135614. [Problems to be Solved by the Invention] The carpet lining method proposed in JP-A-61-135614 is different from the conventional method in which the hot melt adhesive film is continuous, and the adhesive layer has voids. Since it is discontinuous, it is excellent in that it does not impair breathability and flexibility. However, with this method, there is a problem with uniformity when mixing the fiber binder with the fiber mat used for lining, and it is necessary to mix the fiber binder and other fibers sufficiently, which improves the formability and the fiber quality. Fixation is achieved as evenly as possible, resulting in stable moldability. In order to ensure more secure adhesion between the carpet and the fiber mat, a water permeable non-woven fabric made of thermoplastic fiber binder is sandwiched between the two and bonded under heat.
Hot melt adhesives (non-woven fabric binder, thermoplastic resin film,
thermoplastic resin powder, etc.) is required. In the case of molded materials used for floors, etc., in order to fill voids, absorb uneven surfaces, and provide cushioning properties, a method is used in which underfelt is simultaneously bonded to the molded product during hot molding. There are other problems. If only needling is used for bonding, the surface of the covering material will be rough and the adhesion will be insufficient, and even if hot melt adhesive and needling are used together, the surface of the carpet will be rough. [Means for Solving the Problems] The present invention further improves the carpet lining method proposed above, and provides a simple and inexpensive lining that is highly decorative, has excellent moldability, and has excellent shape retention. The present invention provides a method for manufacturing a fibrous laminate from which carpets can be manufactured. That is, the present invention applies a thermoplastic fiber binder nonwoven fabric A having a melting point of 60 to 200°C to both the front and back sides of a fiber mat B mainly composed of synthetic fibers or natural fibers having a melting point 40°C or more higher than the melting point of the fiber binder. This laminate is then subjected to needling to form fibers of fiber binder nonwoven fabric A and fiber mat B.
A laminate Mat C obtained by entangling the fibers of
After overlapping the facing material D, the fiber binder A
Heating and compressing at a temperature equal to or higher than the melting point of and at a temperature at which the facing material D does not melt and at which the fibers of the main component of the fiber mat B do not melt,
This method of manufacturing a fibrous laminate is characterized in that the facing material D is adhered to the laminate mat C. [Specific description of the invention] (1) Fibrous laminate The fibrous laminate obtained by the method for producing a fibrous laminate of the present invention, as shown in FIG. For example, a needle punch carpet is layered as a facing material D on one side of a laminate mat C obtained by needling a laminate with a three-layer structure in which nonwoven fabrics A and A' are stacked, and the fiber binder nonwoven fabric A is heated and compressed. It has a structure in which the facing material and fiber mat are welded together by melting them. (A) Fiber binder nonwoven fabric The fiber binders A and A' used in the method for producing a fibrous laminate of the present invention are nonwoven fabrics made of thermoplastic resin fibers, such as polyethylene, polypropylene, linear polyester,
The melting point of polyamide, these composite fibers, etc. is 60
~200°C, preferably 90~170°C, the resin fibers may be thin or thick depending on the purpose, but are usually 3 deniers or more, and the fiber length is preferably 8 mm or more from the entanglement surface, and the resin fibers are spunbonded. It can be obtained by intertwining with the needle punch method. Alternatively, it may be in the form of a fibrous web obtained by carding or the like, or this fibrous web may be fixed with a binder. The basis weight is 6~
600 g/m ² , preferably 10-500 g/m ² and is breathable. In addition, this fiber binder nonwoven fabric A,
A′ is made by melting pellets of resin such as polypropylene, low-melting polyester, and low-melting polyamide using an extruder, extruding the pellets through a die with many thin holes, and then blowing the pellets into individual fibers. It may also be produced by pulling out the film so that it does not swell, depositing it on a screen below the die, and taking it up with a winder. Such nonwoven fabrics made of fiber binders have many gaps through which water can pass.For example, they are manufactured by Diabond Industries Co., Ltd. under the trade name "Meltron W", and polyamide-based ones are available such as PAY-200,
PAS−200, polyester type is ES−
500, those based on ethylene/acetic acid copolymer are Y
It is commercially available under the grade name ``Syntex'' PK-103, PK-106, and polypropylene products from Mitsui Petrochemical Industries, Ltd.
The product name is PK-404, PK-408, etc., and the polyethylene product is called "Admel".
In addition, similar nonwoven fabrics are available from Kureha Sen'i Co., Ltd. under the product name DYNAC, LNS-0000 and LNS-
2000, ES-00, B-1000, B-2000, B-
It is commercially available with grade names such as 3000. The fiber binder nonwoven fabric A preferably has a melting point that is 40° C. or more lower than the melting point of the fibers that are the main component of the fiber mat B. This is because the temperature at which nonwoven fabric A is melted is usually 20 to 30°C higher than the melting point of the binder fibers of nonwoven fabric A. In addition, this nonwoven fabric A is 10~
It is used in a proportion of 100% by weight. The lower nonwoven fabric A' is used in a weight of 10 to 500 g/m ² . Moreover, this fiber binder nonwoven fabric does not need to be made of a single type of fiber. For example, mixed fibers of polypropylene and polyethylene may be used. Furthermore, there is no problem even if high melting point fiber is mixed as long as it is 30% or less. In the case of recovered fibers, fibers with a high melting point may be mixed in. (B) Fiber mat The fibers for forming the fiber mat B used in the method for producing a fibrous laminate of the present invention may be synthetic fibers or natural fibers, or may be a mixture of both. The synthetic fibers include thermoplastic resins having a melting point higher than the melting point of the fiber binder nonwoven fabric A by 40°C or higher, preferably 70°C or higher (specifically 200 to 280°C), such as polyethylene terephthalate, polyamide, and polyacrylonitrile. used. As natural fibers, cotton, hemp, wool, miscellaneous felt, waste polyester fibers, etc. are used. This fiber mat B may contain a fiber binder having a melting point of 60 to 200°C in a proportion of 5 to 50% by weight. In the fiber mat B of the present invention, the fibers of the fiber binder nonwoven fabric laminated on both sides are entangled and integrated by needling, so the fiber mat itself is It is not necessary to provide sufficient shape retention to the fibers, and even if the fibers are not necessarily of high quality, a web of waste fibers can be used to achieve the purpose. That is, various fibers having a melting point higher than the melting point of the fiber binder A by 40° C. or more, preferably 70° C. or more, such as wool, nylon,
Contains 50% by weight or more of polyacrylonitrile, polyacetate, polyethylene terephthalate, etc., and is used to make fiber mats and needle punch carpets made into carded webs, as well as phenol felt made by hardening fiber laminates with binders. . The basis weight of fiber matte B is 100 to 1000 g/m ² ,
Preferably it is 300-750g/ ^m2 . (C) Laminate mat By needling a laminate with a three-layer structure in which fiber binder nonwoven fabrics A and A' are superimposed on both sides of fiber mat B, a laminate in which the fibers of the fiber binder and fiber mat are entangled is created. A body mat C is obtained. for that purpose,
It is necessary to perform needling to penetrate through the fiber mat B. As a result, binder fibers of the fiber binder nonwoven fabric A or A' are present in an amount of 5 to 80% throughout the fiber mat B layer. However, when using fiber mat B in which the fiber mat B layer contains 5 to 50% by weight of fiber binder before being needled, it is not necessarily necessary to insert the needles until they completely penetrate fiber mat B. Needling may be performed from either side of the laminate, but when needling is performed from the fiber binder nonwoven fabric A side, the binder fibers of the fiber binder nonwoven fabric A are mixed into the fiber mat B by needling. 80% is inserted, but the remaining 95 to 20% remains as a fiber binder layer on the surface of the laminate mat C, and the layer structure of the fiber binder layer A and the fiber mat B is clear, and the fiber mat B has a clear layer structure. A binder fiber is present. In this case, a portion of the fibers of the fiber mat B are inserted into the fiber binder nonwoven fabric A' on the opposite side and entangled therewith. That is, in this laminate mat C, the fibers of the fiber binder nonwoven fabric A are vertically inserted into the fiber mat B by needling, and the fibers of the fiber mat B also enter the fiber binder nonwoven fabric A' on the opposite side, so that three The fibers of the layers intertwine and become a whole. Of course, needling may be performed from the fiber binder nonwoven fabric A' side. The needling performed after laminating the fiber mat B and the fiber binder nonwoven fabric A is as follows:
This is done by passing the needles vertically through the opposite side at a rate of 80 to 300 needles per square inch. Needling is 5-80% of A binder.
are entangled with the fibers of fiber mat B. (D) Facing material The facing material D to be superimposed on the needled laminate mat C is a fiber having a melting point higher than the melting point of the fiber binder nonwoven fabric A by 40° C. or more, preferably 70° C. or more, such as wool, Needle-punched carpets made of fibers such as nylon, polyacrylonitrile, polyacetate, and polyethylene terephthalate, and primary base fabrics knitted from polypropylene flat yarns (this is commonly used for carpets, woven fabrics, etc.). A tufted carpet fabric with piles made of polyamide or polyethylene terephthalate (which may have been subjected to backing treatment) or the above-mentioned needle punch carpet or spunbond nonwoven fabric is used as the primary base fabric, and then There are raw materials such as tufted carpet with erected piles. The covering material does not necessarily have to be carpet; decorative sheets such as woven fabric, synthetic leather, paper, synthetic paper, and plastics may be used depending on the purpose of use. (2) Production of a fibrous laminate In order to produce a fibrous laminate by the method of the present invention, the facing material D is stacked on the needle-punched and intertwined laminate mat C, and heated and compressed. It is necessary. The facing material is placed on the fiber binder nonwoven fabric A and is finally thermally bonded, but there is also a method in which the facing material is entangled by light needling and then thermally bonded with the fiber binder nonwoven fabric A during thermoforming. It can be taken. However, with this method, there is a loss due to roughness of the surface of the covering material and an additional step. It is particularly important that the heating is carried out at a temperature higher than the temperature at which the fiber binder nonwoven fabric A melts, but at a temperature at which the facing material D and the fiber mat B do not melt. Pressure is 1 if only thermal bonding is used.
A pressure roll of approximately Kg/cm ² is sufficient, and 5 to 50 Kg/cm ² is necessary when molding and mat density are controlled at the same time as thermal bonding. In the case of only thermal bonding, heating and compression can be performed continuously using a roll or the like. The fibrous laminate of the present invention can be thermoformed to match the shape of the floor on which it is installed.
At this time, it can also be thermally bonded to other materials. This molding can be performed at the same time as adhering the above-mentioned facing material, or it is also possible to mold what has been thermally bonded once into a required shape depending on the intended use. [Effect] In the fibrous laminate of the present invention, the fiber mat B is sandwiched between the fiber binder nonwoven fabrics A and A' on both sides, and by needle punching, the fiber binder nonwoven fabric A enters the fiber mat B and the other fibers are removed. Since the fiber mats B are intertwined, the fiber mat B itself is heat set by heating, giving it strength, hardness and shape retention as a base layer. Even after needling, the surface of the base layer laminate Mat C is mainly made of the binder fibers of the fiber binder nonwoven fabric A, so no special adhesive such as adhesive cloth, powder, or hot melt is required for adhesion to the facing material D. There are advantages. In addition, since there is a layer mainly composed of the fiber binder nonwoven fabric A' in the lower layer, it has excellent moldability by heat molding, is particularly suitable for deep drawing, and has good shape retention after molding. Furthermore, the lower layer fiber binder nonwoven fabric A' allows for adhesion to other materials. Further, since the fiber mat and the fiber binder are stacked and entangled with each other by needle punching, there is no need to uniformly mix both fibers as in the conventional method, which simplifies the process. [Example] Example 1 As the fiber binder nonwoven fabric A, 16 denier,
50mm length polypropylene (melting point 164℃) fiber,
A web of 250 g/m ² was used with a card.
Further, the same fiber binder nonwoven fabric A' was used at 50 g/m ² . These fiber binder nonwoven fabrics A and A' were combined with phenol felt (B) from Howa Seni Co., Ltd.
10t” (product name 100mm thick, soft type, basis weight 550
g/m ² ) and then needle punched at a rate of 150 needles per square inch to obtain a wall thickness of approximately 13 mm.
A laminate Mat C having an apparent density of 0.065 g/cm ³ was obtained. A plain type needle-punch carpet made of 300g/ ^m3 fiber mat made by randomly stacking colored polyethylene terephthalate (melting point 264℃) fiber cards of 16 denier and fiber length of 85 to 120 mm was used as the covering material D above. Laminated on top of the fiber binder of MATSUTO C, this laminate was heated to 190°C to melt the polypropylene fiber binder, and then a cooling press mold was used to melt the polypropylene fiber binder.
Pressure molding was performed for 60 seconds at a pressure of 10 kg/cm ² to obtain an integrated carpet with a thickness of 6 mm that was faithful to the mold. Also, during molding, there is a 6t felt top inside the mold.
(6 mm thickness) was placed and molded in the same manner. The resulting carpet was evaluated for the following various properties. The results are shown in Table 1. (1) Adhesion of surface material A sample piece of 150 mm x 50 mm was cut from this carpet, supported with a span of 100 mm, and the peel strength between sample D and B was measured using an Instron type tester. (2) Breaking strength of fiber mat B The breaking strength of the fiber mat between fiber binders A and A' was measured in the same manner as above. (3) Heat setting properties: Is it possible to control the thickness when the laminate Mat C is heated and compressed to a thickness of 5 cm at 180°C for 60 seconds? ○ indicates that the thickness can be controlled. (4) Formability Shape retention of the product by molding at 180℃ and 10Kg/ ^cm2 . Those in which the shape conforming to the mold was obtained were rated ◎. (5) Adhesiveness to other materials When molding, there is a 6t felt top inside the mold.
◎ indicates the case where the felt is bonded to the fiber binder A′ layer on the back side and the bonded “felt top” layer is broken and peeled off, and the felt fibers remain on the A′ side and are bonded. did. (6) Tape adhesion strength on the back side The degree of adhesion when cloth duct tape is attached to the A′ side of the back side of a molded item without “Felt Tip” placed, and how the fibers come off when the affixed duct tape is peeled off. were observed, and those in which the fibers did not peel off were marked as ○. Example 2, Comparative Example 1 In Example 1, there is a case in which fiber binder nonwoven fabrics A and A' are not used (Comparative Example 1), and a polyethylene nonwoven fabric with a melting point of 119°C (Mitsui Petrochemical Industries, Ltd.) is used as the fiber binder nonwoven fabric. ) manufactured by product name "Admel" with a basis weight of 100 g/m ² ) (Example 2)
A fibrous laminate was obtained in the same manner as above. Example 3 In Example 1, as the laminate Mat B, the product name "Fine Needle 650L" manufactured by Aoyama Sangyo Co., Ltd.
Felt containing 20% fiber binder, basis weight 650
A fibrous laminate was obtained in the same manner except that 2 g/m ² ) was used.

【table】

[Table] Example 4 The fibers were prepared in the same manner as in Example 1, except that polyester miscellaneous felt (needle felt, 8 mm thickness, basis weight, 650 g/m ² ) from Kansai Felt Co., Ltd. was used as fiber mat B. A laminate was obtained. Comparative Example 2 A fibrous laminate was obtained in the same manner as in Example 2, except that the needling operation was not performed. Table 1 shows the physical properties of these fibrous laminates.

[Brief explanation of drawings]

Figure 1 is a cross-sectional view of a fibrous laminate obtained by the method of the present invention, which is a laminate obtained by needling a three-layer structure in which fiber binder nonwoven fabrics A and A' are superimposed on both sides of a fiber mat B. The figure shows a state in which a laminate mat C is laminated with a cladding material D as a cladding material, heated and compressed, and the laminate mat C and the cladding material D are welded together by melting the fiber binder.

Claims (1)

[Scope of Claims] 1. A thermoplastic fiber binder nonwoven fabric A having a melting point of 60 to 200°C is used as the front and back sides of a fiber mat B mainly composed of synthetic fibers or natural fibers having a melting point 40°C or more higher than the melting point of the fiber binder. After laminating the facing material D on the laminate mat C obtained by laminating on both sides and subjecting this laminate to needling to entangle the fibers of the fiber binder nonwoven fabric A and the fibers of the fiber mat B, The said facing material D is heated and compressed at a temperature higher than the melting point of the fiber binder A and at a temperature at which the facing material D does not melt and the fibers of the main component of the fiber mat B do not melt. 1. A method for producing a fibrous laminate, which comprises adhering a fibrous laminate to a laminate Mat C. 2 The amount of fiber binder A used is
10. The method according to claim 1, wherein the amount is 10 to 100% by weight.