JPH04108152A - Leather-like nonwoven cloth and production thereof - Google Patents

Abstract

PURPOSE:To readily and surely obtain the subject product suitable for leather- like car interior having excellent wear resistance and processability in a low cost by three-dimensionally interlacing an inner layer part and an outer layer part comprising respectively preferably a web in one body and performing specific embossing on the surface of the outer layer. CONSTITUTION:At first, a web having >=20g/m<2> areal weight using for an outer layer part is formed with polyester fiber containing 20-70wt.% low-melting point fiber and a web for an inner layer part composed of polyester fiber containing lower content of the lower melting point fiber than said web for the outer layer part is formed. Next, said web for outer layer is superposed on said web for inner layer and made in one body by a three-dimensional interlacing treatment. Successively, the surface in a side of the outer layer part not attaching to the inner layer part is connected by pressure with heat at a temperature higher than melting point of said low-melting point fiber using an embossing roll having leather-like design of >=0.2mm depth of grain to afford the aimed product in which a part of the low-melting point fiber in the surface is molten and solidified and forms a line composed of continuous depressed parts.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a leather-like nonwoven fabric with excellent abrasion resistance, appearance, and feel, and a method for producing the same.

Akira;! ``3 pieces 1゛ completed, no change in internal placement) (prior technology) In recent years, PVC leather has been disliked and textile products have been increasingly used as interior materials for vehicles, especially passenger cars.The reason is that As a result, the plastic feel of PVC leather and the cool feeling when it comes in contact with it are exaggerated.

However, due to the leather-like appearance, low price, size (particularly wear resistance) and good moldability of PVC leather, it is used in the ceiling skins, door trims, instrument panels, etc. of passenger cars. On the other hand, textile products have a warm texture,
Although its natural appearance is preferred, apart from ceiling skins, it is only used in fabrics that are comparable in price and performance to the PVC leather, and in some door trim ornaments. In particular, conventional short fiber nonwoven fabrics have extremely poor abrasion resistance and are therefore hardly used in the above applications.

(Problem H to be Solved by the Invention) The present invention solves the conventional problems and provides a leather-like nonwoven fabric that is excellent in abrasion resistance, moldability, and is suitable for use as a low-cost leather-like vehicle interior material, and a method for producing the same. The purpose is to provide

(Means for Solving the Problem) The present invention takes the following means to solve the problem. That is, the present invention consists of a nonwoven fabric in which a surface layer part and an inner layer part are three-dimensionally intertwined and integrated, and the surface layer part is made of a web of polyester fibers containing 20 to 70% by weight of low melting point fibers, The web has a basis weight of 20 g/ze or more, and is a leather-like material in which at least a portion of the low melting point fibers on the surface of the surface layer not in contact with the inner layer are melted and solidified to form a line consisting of continuous recesses. The inner layer has a handle of 0, and the inner layer has a handle of 0
A leather-like nonwoven fabric containing ~70% by weight of low-melting point fibers, the blending rate of the low-melting point fibers being less than or equal to the blending rate of the low-melting point fibers in the surface layer, and polyester fibers together with 20-70% by weight of the low-melting point fibers. is used to form a web with a basis weight of 20 g/lF or more to form a part of the surface layer, and on the other hand, if the blending ratio of the low melting point fiber is below the blending ratio of the web in the surface layer, it is 0 to 7.
A web made of 0% by weight polyester fiber is formed as an inner layer, and then the surface layer and the light layer are
Changed to 1. ) The inner layer is overlapped and subjected to a three-dimensional entanglement treatment to integrate, and then the surface of the surface layer on the side not in contact with the inner layer is heated to a temperature lower than the melting point of the low melting point fiber and the grain depth is 0. .2 A method for producing an inter-leather nonwoven fabric, characterized in that the surface is formed by thermo-compression bonding with an embossing roll having a leather-like pattern having the following properties: A polyester short fiber web with a basis weight of Bog/I or higher containing 20 to 70% by weight of low melting point short fibers without using
This is a method for producing an interleather nonwoven fabric in which a surface layer portion is formed by processing with the hot embossing roll and melting and solidifying a portion of the low melting point fibers in contact with the roll surface.

The present invention will be explained below with reference to the drawings. The interleather nonwoven fabric of the present invention is different from conventional needle-punched short fiber nonwoven fabrics (hereinafter referred to as "kneepants"), and is a two-layer nonwoven fabric consisting of a surface layer that becomes a skin and an inner layer that becomes a cushion. FIG. 1 shows a schematic cross-sectional view of the interleather nonwoven fabric used in the vehicle interior material of the present invention, in which a surface layer 1 and an inner layer 2 are three-dimensionally intertwined and integrated. . The surface layer portion 1 contains 20 to 70% by weight of low melting point fibers. From the viewpoint of dyeability and light fastness, the low melting point fiber is a single polymer type made of 100% low melting point components of modified polyester, or a polyester type fiber with a low melting point component arranged in the sheath part of a core-sheath structure. Preferably used.

Such low melting point fibers are uniformly mixed with regular polyester (polyethylene terephthalate) fibers to form the surface web. The low melting point fibers and regular polyester fibers in the surface layer portion may be short fiber webs, long fiber webs made by the so-called spunbond method, or a combination thereof.

When the melting point of the low melting point fiber is 100° C. or less, it is practically susceptible to the influence of heat and is not suitable for the present invention. On the other hand, if the temperature exceeds 210°C, the melting point of regular polyester will be too close to that of regular polyester, and the texture will become too hard after hot embossing, which is not preferable. Moreover, the embossing temperature must be set high, which is not suitable for practical use.

The proportion of low melting point fibers in the surface web is 20% to 70% by weight, preferably 30% to 60% by weight. If it is less than 20% by weight, sufficient abrasion resistance cannot be obtained, and a leather-like pattern cannot be deeply embossed. If it exceeds 70% by weight, the texture becomes plastic-like and it is difficult to differentiate it from current PVC leather.

The surface weight of the web used is 20 g/I/ or more, but if it is less than 20 g/+/, the function of the surface layer of the present invention cannot be achieved. On the other hand, if it exceeds 300 g, it is not preferable because there is no improvement in functionality despite the increased cost. Other than the low melting point fibers in the surface layer, regular polyester fibers are preferably used in terms of light resistance, dyeability, etc. The denier of regular polyester fiber in the surface layer is
- 1 to 10 denier is used for boat fishing, and 2 to 5 denier is used practically.

The thinner the fiber, the softer it will be, but if molding is required, the molding pressure will lower the grain on the surface, which is undesirable.If it is too thick, the number of fibers will decrease for the same basis weight, making three-dimensional entanglement difficult.

The web of the inner layer is preferably composed of short fibers or long fibers of regular polyester. For applications that require strength and shallow molding or no molding, long fiber so-called spunbond nonwoven fabrics are suitable, but short fibers are preferable for those that require deep molding. In addition, the inner layer is
Basically, low melting point fibers are not required, but depending on the manufacturing method, it is not possible to separate the low melting point fibers, so the same sea urchin as the surface layer is used at the same blending ratio as the surface layer. When short fibers are used as the inner layer, mixing low melting point fibers and heat-treating them during or before embossing will increase the strength of peeling.
Moreover, it is possible to manufacture products with great strength.

The web weight of the inner layer is generally 20 to 200 g/f, but in the case of long fibers, it is 20 to 120 g/aF,
In the case of short fibers, 60 to 200 g/l is used, and when cushioning properties are required, 100 g/l or more is preferable.

If both the surface layer and the inner layer are made of short fibers and are manufactured on a single line, the web should not be made into two layers but a single web, and the low melting point fibers should weigh between 20 and 70%. % blended fiber (cotton). Therefore, at this stage of the web, it is difficult to distinguish between the surface layer and the interior, but due to hot embossing, some of the low melting point fibers that have come into contact with the hot embossing roll are fused, and the surface layer ( The result is a two-layer structure. In this case, the basis weight of the web is required to be at least 60 g/ll. If it is less than 60 g/m2, the strength is weak and it is not suitable for use. A large basis weight, for example, exceeding 300 g/l/l is undesirable because it increases the cost. Here, the basis weight of the surface layer and the inner layer cannot be clearly distinguished, but since the two layers can be separated, it is possible to measure this as the basis weight of each layer.

The ratio of both layers varies depending on the blending ratio of low melting point fibers and embossing conditions, but in principle, it is set in the same way as in the method of separately producing webs of both layers.

In either case, the inner layer and the surface layer are three-dimensionally intertwined and integrated, and this is because the fibers of both are three-dimensionally intertwined to improve moldability and prevent tearing. This not only prevents the occurrence of dryness, but also improves the flexibility of the fabric and the elasticity of the inner layer.

Next, the manufacturability of the present invention will be explained. Low melting point fiber 2
0 to 70% by weight and 80 to 30% by weight of ordinary polyester fibers are mixed to form a web having a basis weight of 20 g/r1 or more to form the surface layer. On the other hand, polyester long fibers or short fibers are generally used in the T-body, with a basis weight of 20 to 200 g/fl.
A web of It is formed, and then the surface layer and the inner layer are three-dimensionally entangled between each fiber using a needle punch machine or a water jet or spunlace type machine.

According to this method, the fibers in the surface layer and the fibers in the inner layer are mixed into each other's layers and are further integrated.

However, the bonding method using hot embossing pressure bonding is not suitable for use because the elongation is small and tears may occur during molding or the like.

A nonwoven fabric having such a two-layer structure or a nonwoven fabric mixed with low melting point fibers to produce a short fiber nonwoven fabric in one series is
The fibers are thermocompressed using a heat embossing roll having a leather-like pattern with H) of 0.2*1 or more at a temperature above the melting point of the low melting point fiber, preferably at a temperature 10° C. or more higher than the melting point.

The depth of the grain of the heat embossing roll is usually 0.1 to 0.15 cm, which is used for textiles, PVC leather, etc., but a sufficient grain depth cannot be obtained. In the present invention, H is 0.20■1
It is preferably used for 0.25 hours or more.

Furthermore, by sharpening the peak of the convex part of the embossing roll (P in Figure 2) and making the height uniform, pressure ~
is concentrated, giving the nonwoven fabric deep, sharp recesses (lines). Therefore, the concave portions of the nonwoven fabric are more likely to be fused by low melting point fibers than other portions due to heat and pressure. On the other hand, the concave portions of the embossing roll (V in Figure 2) correspond to the convex portions (peaks) of the nonwoven fabric, but compared to the convex portions of the roll, the pressure applied is slightly weaker, there is less fusion, and the fibers are less fused. Texture tends to remain.

The embossing roll and the opposite roll are flat steel rolls,
It is fine to use paper rolls, but it is better to make them into paper rolls and mate the male and female parts to get a deep and complex grain shape.

The temperature of the embossing roll is lower than the melting point of the low melting point fiber.
t, preferably 10° C. or more above the melting point. Below the melting point, sufficient wear resistance and grain depth cannot be obtained. The higher the mixing ratio of low melting point fibers and the higher the temperature, the better the abrasion resistance will be, but the texture will be more plastic-like.

These conditions are selected depending on the required characteristics of the part to be used.

Also, before embossing rolls, heat-treat the surface layer with a flat thermal calendar roll at a temperature higher than the melting point of the low-melting point fibers to uniformly melt and solidify the surface, and the appearance after embossing will be more leather-like. Become. However, in this case, the texture becomes more plastic-like.

As a vehicle interior material, it must be colored,
Although spun-dyed fibers and dyed fibers are used, they may also be made into non-woven fabrics and dyed before or after embossing. However, when dyeing it after making it into a non-woven fabric, care must be taken as some colors may appear shaded due to the difference in dyeing between low-melting point fibers and regular polyester.

Black dope dyeing or cotton dyeing is preferable in order to obtain a uniform color.

Cotton dyeing has the advantage of easy lot size and color matching, but if the melting point of the low-melting point fibers is not raised to 150°C or higher, parts of the fibers will stick together during dyeing, making it difficult to manufacture webs. At this time, neps occur due to poor fiber opening, which is undesirable. Therefore, the optimal coloring method is selected depending on the purpose, loft size, etc.

In addition, as a vehicle interior material, it may be treated to impart various properties such as flame retardancy, water repellency, and stain resistance.

(Example) Example 1 4 d x 51 m cut as low melting point fiber, melting point 1
The core-sheath type (core: regular polyester, sheath: modified polyester) was dyed at 80℃, and regular polyester fiber was dyed with 3dX51m+r cut (melting point 260℃) at a ratio of 40% of the former and 60% of the latter. Mix the cotton uniformly to make a 180g/+/ web.
Next, it was two-dimensionally entangled with a needle punch to give 150g/
-+'' nonwoven fabric was pressed at 195°C with a heat embossing roll having a pattern between the leathers and a depth of 0.3 mm paired with a paper roll to produce an interleather nonwoven fabric. The physical properties were as shown in Table 1, and not only were the physical properties excellent, but the texture and appearance were also good.

Margin below Table 1 The inner layer spunbond is integrated.

After this, embossing was performed under the same conditions as in Example 1,
The interleather nonwoven fabric was molded. The physical properties of this product are shown in Table 2. Since spunbond is used for the inner layer, it has much stronger strength than Example 1, making it suitable for applications where strong force is applied. .

Table 2 Example 2 A web of 100 g/♂ was made from the same constituent fibers as in Example 1, and then a spunbond web made of regular polyester with a basis weight of 110 g// made of undyed color of the same color as the web was made. The former was used as the surface layer (upper layer) and three-dimensionally entangled with a needle punch from above to create short fibers in the surface layer.Example 3 The mixing ratio of low melting point fibers, embossing temperature, and pattern depth were changed in Example 1. The results are shown in Table 3, and the blending rate of low melting point fibers is 20% to 70% by weight, the embossing temperature is above the melting point of the low melting point, and the depth of the pattern is 0.2 times or above, which is suitable as a leather-like nonwoven fabric. It was already half a day early.

extra space In addition, the characteristics in the table were determined in the following manner.

○Abrasion resistance: Taper abrasion tester C5-10,500g,
Based on 500 graded judgments.

○ Appearance 2. Visually compare and judge the leather-like appearance and grain depth. Grade 5: Good leather-like pattern with the deepest grain; Grade 4.
3rd grade with deep grain ° 〃 2nd grade with deep grain where the pattern easily crumbles ° 〃
Grade 1, where the handle easily collapses and the grain is shallow; The handle is unclear (Note) Handle collapse is when the handle breaks when pulled lightly by hand.

○Texture: Comparing and judging the softness by feel as follows: Grade 5: Softest Grade 4, Softest Grade 3 Hardest Grade 2, Hard and stiff Grade 1 Plastic-like, but appearance judged from the required characteristics of leather-like nonwoven fabric However, wear resistance is not an important factor, and it can be said that grade 2 is acceptable.

O Comprehensive evaluation: Comparative evaluation based on a slight weighting for the above three items A: Best (pass) B: Good (pass) C: Average (pass) D: Bad (fail) E: Worst (fail) ( Effects of the Invention) According to the present invention, a leather-like nonwoven fabric with excellent abrasion resistance, appearance, and feel can be obtained, and the remarkable effect that such a nonwoven fabric can be produced reliably and easily is achieved.

[Brief explanation of drawings]

FIG. 1 is a sectional view of the nonwoven fabric of the present invention, FIG. 2 is a sectional view of an embossing roller, and FIG. 3 is a perspective view of the leather-like nonwoven fabric of the present invention. 1... Surface layer part, 2... Inner layer part.

Claims (3)

[Claims] (1) It is made of a nonwoven fabric in which a surface layer part and an inner layer part are three-dimensionally entangled and integrated, and the surface layer part is made of a web of polyester fibers containing 20 to 70% by weight of low-melting fibers, A leather-like handle having a basis weight of 20 g/m^2 or more and having at least a part of the low melting point fibers on the surface of the surface layer not in contact with the inner layer formed by melting and solidifying and forming a line consisting of continuous recesses. The inner layer part contains 0 to 70% by weight of low melting point fibers based on the inner layer part, and the mixing ratio of the low melting point fibers is equal to or lower than the mixing ratio of the low melting point fibers in the surface layer part. Leather-like nonwoven fabric. (2) A web with a basis weight of 20 g/m^2 or more is formed by using polyester fibers together with 20 to 70% by weight of low melting point fibers to form a part of the surface layer part, and on the other hand, the mixing ratio of the low melting point fibers is in the surface layer part. A web made of polyester fibers of 0 to 70% by weight is formed at a web blending ratio of 0 to 70% by weight or less to form an inner layer portion, and then the surface layer portion and the inner layer portion are overlapped and subjected to a three-dimensional entanglement treatment to be integrated. The surface of the surface layer part on the side not in contact with the inner layer part is bonded by thermocompression with an embossing roll having a leather-like handle having a grain depth of 0.2 mm or more at a temperature higher than the melting point of the low melting point fiber to bond the surface. A method for producing a leather-like nonwoven fabric characterized by forming a leather-like nonwoven fabric. (3) In claim 2, 20 to 70% by weight of low-melting point short fibers are used without using a web of polyester fibers forming the inner layer
Polyester short fiber web weight 60g/m containing
A method for producing a leather-like nonwoven fabric, in which a surface layer is formed by treating at least ^2 with the hot embossing roll and melting and solidifying a portion of the low melting point fibers in contact with the roll surface.