JPH0476781B2 - - Google Patents

Description

[Detailed description of the invention]

[Industrial Application Field] The present invention relates to a fibrous laminate with excellent thermoformability and shape retention, and a method for producing the same, and in particular, a fibrous laminate that can be deep drawn and has excellent thermoformability as an interior material for vehicles such as automobiles. The present invention also relates to a fibrous laminate with good shape retention and a method for producing the same. [Prior Art] Conventionally, fiber mats with excellent moldability have been used as interior materials for automobiles 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. 100-130℃ with high melting point fibers such as polyethylene terephthalate
Heating a nonwoven fabric made of mixed fibers with a thermoplastic resin fiber binder having a melting point of
Carpets are used that are press-molded to match the shape of the car floor. However, these carpets lack luxury by themselves, and moreover, among the various performance requirements for carpets such as rigidity, elasticity, and moldability, one of the performance is unsatisfactory, so the surface of these carpets Covering materials such as tufted carpets and needle punch carpets are adhered using adhesives or hot melt agents, and carpets lined with resin sheets or foam sheets are also used. However, even these carpets have problems in terms of breathability and flexibility. On the other hand, the present inventors proposed a method of lining a carpet without first reducing its air permeability, by applying a material with a melting point of 60% to the back side of a tufted carpet.
A web produced by needling a felt layer made of a mixture of a thermoplastic resin fiber binder at ~200°C and fibers having a melting point 40°C or more higher than the melting point of the fiber binder is heat-pressed via a fiber binder nonwoven fabric. Method of forming (JP-A-61-
(Refer to Publication No. 135614). [Problems to be Solved by the Invention] However, 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 no voids. Since it is discontinuous, it is excellent in that it does not impair breathability and flexibility. However, this method causes problems with uniformity when the fiber binder is mixed into the fiber mat used for lining. Therefore, it is necessary to sufficiently mix the fiber binder and other fibers, and in order to obtain stable moldability, the moldability must be improved and the fibers must be fixed as evenly as possible. To ensure more reliable adhesion between the carpet and fiber mat, a water-permeable non-woven fabric with a thermoplastic fiber binder may be sandwiched between the two, and hot-melt adhesive (non-woven fabric) may be used to bond the carpet to other materials. (binder, thermoplastic resin film, thermoplastic resin powder, etc.) are required. In the case of molded materials used for floors and the like, an underfelt must be bonded to the molded product at the same time during hot molding in order to fill voids, absorb uneven surfaces, and provide cushioning properties. There are other problems. It should be noted that if only needling is used as a bonding method, the surface of the covering material will be rough and the adhesive strength will be insufficient, and if a hot melt adhesive and needling are used in combination, 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 and has excellent moldability and shape retention. The present invention provides a method for manufacturing a fibrous laminate from which carpets can be manufactured. That is, the present invention provides upper and lower nonwoven fabric layers A and B formed of a thermoplastic fiber binder nonwoven fabric having a melting point of 60 to 200°C, and a melting point of the thermoplastic fiber binder nonwoven fabric sandwiched between the upper and lower nonwoven fabric layers A and B. The fiber mat layer C is composed mainly of synthetic fibers or natural fibers having a melting point 40°C or more higher than that of the fiber mat layer C, and the fibers of the fiber binder nonwoven fabric of the upper and lower nonwoven fabric layers A and B are the synthetic fibers of the fiber mat layer C or In a fibrous laminate formed by laminating a facing material E on a laminate mat D intertwined and bonded with natural fibers, the fiber mat layer C mainly composed of synthetic fibers or natural fibers has a glass transition point of 50. Emulsion resin solid content of resin at ℃ or higher per 100 parts by weight of the fiber
A fibrous laminate characterized by containing 10 to 100 parts by weight, and a thermoplastic fiber binder whose main component is synthetic fiber or natural fiber having a melting point 40°C or more higher than the melting point of the nonwoven fabric layers A and B. The thermoplastic fiber binder nonwoven fabric layers A and B are laminated on the front and back surfaces of the fiber mat layer C, respectively, and a laminate mat D obtained by needle punching is immersed in an emulsion of a resin having a glass transition point of 50 ° C. or higher. After the emulsion is impregnated with the emulsion, the facing material E is further layered and heated and compressed to dry the emulsion and melt the fiber binders of the fiber binder nonwoven fabric layers A and B to form the facing material. This is a method for producing a fibrous laminate characterized by heat-sealing E and a fiber mat layer C. [Specific Description of the Invention] (1) Fibrous Laminate As shown in FIG. 1, the fibrous laminate of the present invention mainly includes an upper layer fiber binder nonwoven fabric on both sides of a fiber mat layer C containing emulsion resin solid content. A laminate having a three-layer structure in which layer A and a lower fiber binder nonwoven fabric layer B are superimposed is intertwined with the fibers of the upper and lower fiber binder base fabric layers A and B and the fibers of the fiber mat layer C by needling or the like. It has a structure in which a facing material E such as a needle punch carpet is laminated on one side of a laminate mat D which is joined together. Fiber binder nonwoven fabric layers A and B The fiber binder nonwoven fabric layers A and B constituting the fibrous laminate of the present invention are layers made of a nonwoven fabric formed from thermoplastic resin fibers, and include polyethylene, polypropylene, linear polyester, It is made of resin fibers such as polyamide or composite fibers thereof, and has a melting point of 60 to 200℃.
It is preferably 90 to 170°C, and may be thin or thick depending on the purpose, but is usually 3 deniers or more,
The length of the fibers is preferably 8 mm or more in terms of entanglement.
It is obtained by intertwining these resin fibers using a spunbond method or a needle punch method. Alternatively, a fiber web obtained by carding or the like, or a fiber web fixed with a binder may be used. These fiber binder nonwoven fabrics A and B are made by melting pellets of resin such as polypropylene, low melting point polyester, and low melting point polyamide using an extruder.
Manufactured by extruding the fibers in a continuous shape through a die with many thin holes, blowing them out on the wind so that the individual fibers do not converge, depositing them on the screen below the die, and taking them up with a winder. It's okay to be. 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 include PAY-200, PAS-200, and polyester-based ones. The ethylene/acetic acid copolymer type is commercially available under the grade name ES-500, the ethylene/acetic acid copolymer type Y-7, and the polypropylene type from Mitsui Petrochemical Industries, Ltd. is ``Syntex'' PK-103 and PK.
-106, 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-3000
It is commercially available with grade names such as The fiber binder in the fiber binder nonwoven fabric layer A preferably has a melting point lower than the melting point of the fibers that are the main component of the fibers in the fiber mat layer C by at least 40°C. This is because the temperature at which the nonwoven fabric layer A is melted is usually 20 to 30°C higher than the melting point of the binder fibers of the nonwoven fabric layer A. The basis weight of fiber binders A and B is usually 6~
It is preferably 600 g/m ² , preferably 10 to 500 g/m ² and is breathable. Furthermore, the fiber binder nonwoven fabric layers A and B
does not have to be a single fiber type. 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 within 30%. When recycled fibers are used, fibers with a high melting point may be mixed in. Further, A may be a polypropylene fiber binder nonwoven fabric, and B may be a polyethylene fiber binder nonwoven fabric. Fiber Mat Layer C Synthetic fibers or natural fibers are generally used as the fibers forming the fiber mat layer C constituting the fibrous laminate of the present invention, but a mixture of both may also be used. The synthetic fibers include polyethylene terephthalate, polyamide, polyacrylonitrile, etc., which have a melting point higher than the fiber binder nonwoven fabric layer A.
A thermoplastic resin fiber having a high melting point of 40°C or higher, preferably 70°C or higher (specifically 200 to 280°C) is used. Further, as the natural fiber, cotton, linen, wool, miscellaneous felt, waste polyester fiber, etc. are used. This fiber mat layer C may contain a fiber binder having a melting point of 60 to 200°C in a proportion of 5 to 50% by weight. The fiber mat layer C can be integrated with the fiber binder nonwoven fabric layers A and B laminated on both the front and back sides by needling, so it is not necessary to need only the layer C in advance. It is not necessary to provide sufficient shape retention to the fiber mat layer C itself by impregnation with a ring or emulsion adhesive. Further, the purpose is not necessarily used as the fibers, but a web of waste fibers may be used to achieve the purpose. That is, the temperature is 40°C or higher than the melting point of the fiber binder A, preferably 70°C.
Various fibers with a melting point higher than ℃, such as wool,
50% by weight of nylon, polyacrylonitrile, polyacetate, polyethylene terephthalate, etc.
Among the above materials, needle punch carpet made of a carded web, and phenol felt made of a fiber laminate solidified with a binder can also be used. In addition, the basis weight of the fiber mat layer C is generally 100~
1000g/ ^m2 , preferably in the range of 300-750g/ ^m2 . Laminate Mat D By needling a laminate consisting of a three-layer structure in which fiber binder nonwoven fabric layers A and B are superimposed on both sides of the fiber mat layer C, the fibers of the fiber mat layer C become fiber binder nonwoven fabric layer A. , B intertwined with the fibers of layer C, and impregnated with emulsion from the layer B side, or by immersing this laminate mat in an emulsion bath, the entire area of layer C is impregnated with emulsion D. is obtained. In addition, the fiber mat of the fiber mat layer C before lamination is impregnated with an emulsion, or the fiber mat is immersed in an emulsion bath, the emulsion is semi-dry to completely dried, and both sides of the fiber binder nonwoven fabric layers A and B are applied. C
A laminate mat D in which the layers were impregnated with emulsion was obtained. The stacking amount of the fiber binder nonwoven fabric layers A and B is 10 to 100% by weight of the fiber mat layer C, respectively. When performing needling, it is necessary to penetrate through the fiber binder nonwoven fabric layer and the fiber mat layer, preferably perpendicularly, so that the fiber binder nonwoven fabric layer The binder fibers of A are inserted into the fiber mat layer C. Needling is performed until 5 to 80% of the fiber binder in the fiber binder nonwoven fabric layer A becomes entangled with the fibers in the fiber mat layer C. However, if a fiber mat layer C containing 5 to 50% by weight of fiber binder is used before being needled, the needle must be inserted until it completely penetrates the fiber mat layer C. do not have to. Needling may be performed from either side of the laminate, but when needling is performed from the fiber binder nonwoven fabric layer A, the binder fibers of the fiber binder nonwoven fabric layer A are transferred to the fiber mat layer C by needling. The remaining 95-20% remains as the fiber binder nonwoven fabric layer A on the surface of the laminate mat D, and the fiber binder layer A
The layer structure of the fiber mat layer C and the fiber mat layer C is clear, and the binder fibers of the fiber binder layer A are present in the fiber mat layer C. In this case, as a matter of course, a portion of the fibers of the fiber mat layer C are inserted into the fiber binder nonwoven fabric B on the opposite side and intertwined with the nonwoven fabric fibers. That is, in the laminate mat D, the fiber binder in the fiber binder nonwoven fabric layer A is vertically inserted into the fiber mat layer C by needling, and the fibers of the fiber mat layer C are also inserted into the fiber binder nonwoven fabric layer B on the opposite side. As it penetrates inside, the three layers of fibers intertwine and become one. Of course, needling may be performed from the fiber binder nonwoven fabric layer B side. The needling performed after laminating the fiber mat layer C and the fiber binder nonwoven fabric layers A and B 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. Surface material E The surface material E to be superimposed on the needled laminate mat D is 40°C or higher, preferably 70°C higher than the melting point of the fiber binder nonwoven fabric A.
Needle-punch carpets made from fibers with melting points higher than or above, such as wool, nylon, polyacrylonitrile, polyacetate, and polyethylene terephthalate, and primary base fabrics knitted from polypropylene flat yarns (this includes carpets, Raw fabric for tufted carpets, which has piles made of polyamide or polyethylene terephthalate (which may have been subjected to backing treatment that is generally performed on woven fabrics, etc.), or the above-mentioned needle punch carpets or spunbond nonwoven fabrics. There are tufted carpet fabrics that have a primary base fabric with piles erected on top of it. Note that this covering material E does not necessarily have to be the carpet itself; decorative sheets such as woven fabric, synthetic leather, paper, synthetic paper, and plastics may be used depending on the purpose of use. Emulsion F The emulsion impregnated into the fiber mat layer C constituting the fibrous laminate of the present invention has a glass transition point of 50°C or higher, preferably 80°C or higher as a resin solid content.
Resin at 180℃ is dispersed in water or organic solvent, and the particle size is generally 0.01 to 5 μm, preferably 0.05 to 5 μm.
It is a 1.5 μm emulsion, and the resin solid content present in the fiber mat in the fibrous laminate of the present invention is a resin impregnated with the emulsion and dried. Specific examples of the resin having a glass transition point of 50°C or higher include styrene/acrylic acid lower ester copolymer (ester has 2 to 6 carbon atoms) copolymer, styrene/acrylic acid lower ester/acrylic acid copolymer. Polymer, lower ester of methacrylate/acrylic acid (ester has 2 to 6 carbon atoms) copolymer, vinylidene chloride copolymer (vinylidene chloride content is 85
% by weight or more) and thermoplastic resins such as styrene-diene copolymers. Optimally, (a) polyn-propyl methacrylate (Tg 81°C),
Polystyrene (Tg100℃), polyacrylonitrile (Tg100℃), polymethyl methacrylate (Tg105℃), polymethacrylic acid (Tg130℃),
Aqueous emulsion of homopolymers such as polyitaconic acid (Tg 130℃) and polyacrylamide (Tg 153℃), (b) vinyl monomer 50, which is the raw material for these polymers.
-100% by weight, preferably 65-95% by weight, and other vinyl monomers such as 2-ethylhexyl acrylate (Tg - 85°C), n-butyl acrylate (Tg - 54°C), ethyl acrylate (Tg - 22℃),
Isopropyl acrylate (Tg-5℃), 2-ethylhexyl methacrylate (Tg-5℃), n-propyl acrylate (Tg8℃), n-butyl methacrylate (Tg20℃), vinyl acetate (Tg30
), t-butyl acrylate (Tg45℃), 2-hydroxyethyl methacrylate (Tg55℃), ethyl methacrylate (Tg65℃), isobutyl methacrylate (Tg67℃), vinyl chloride (Tg79℃)
or an aqueous emulsion of a copolymer of these vinyl monomers and vinylidene chloride (Tg - 18°C) (50% by weight or less, preferably 35 to 5% by weight) [In this section (b), shown in
Tg is the glass transition point of these vinyl monomers or vinylidene chloride homopolymers],
and (c) resin aqueous emulsion 50 with a Tg of +50 to 155°C.
~97% by weight, preferably 55-95% by weight, Tg
Resin water-based emulsion 50 with a temperature of -85 to less than +50℃
-3% by weight, preferably 45-5% by weight, and the like. This emulsion contains calcium carbonate, iron oxide, and
Fillers such as ferrite and barium sulfate can be blended, and powders of low-melting point resins such as low-density polyethylene, polystyrene, and ethylene/vinyl acetate copolymers can also be blended to impart moldability. It is. Such an emulsion is generally made by immersing the laminate Mat D in the emulsion, squeezing it with a roll to impregnate it, and drying it if necessary to uniformly disperse the emulsion resin solid content in the laminate Mat D. be able to. The content of the impregnated emulsion resin solids is 10 to 100 parts by weight, preferably 20 parts by weight, per 100 parts by weight of synthetic fibers or natural fibers in the fiber mat layer C.
~80 parts by weight. If the solid content of the emulsion resin is less than the above range, no improvement in rigidity can be obtained, and no improvement in shape retention after molding can be expected.
Also, if there is too much, it will become too hard and will have the feel of resin felt. (2) Production of fibrous laminate In order to produce the fibrous laminate of the present invention, fiber binder nonwoven fabric layers A and B are laminated on the front and back surfaces of the fiber mat layer C and intertwined by needle punching. After immersing the laminate Mat D in the emulsion and squeezing it with a roll or the like to impregnate it, the facing material E is further layered and heated and compressed to dry the emulsion and remove the fiber binder nonwoven fabric layer. Covering material E is obtained by melting the fiber binders A and B.
and the fiber mat layer C are thermally fused. After stacking the laminate mat D and the facing material E, they are thermally welded, and then the emulsion is impregnated from the fiber binder nonwoven fabric B side to at least the entire area of the mat of layer C, followed by drying and heat shaping. These methods are suitable for tufted carpets, raised carpets, and woven fabrics. The facing material E is placed on the fiber binder nonwoven fabric layer A and is finally heat-sealed. However, the facing material E is intertwined with the fiber binder nonwoven fabric layer A by light needling, and then thermoformed. Sometimes, a method of heat-sealing using fiber binder nonwoven fabric A can also be used. However, method (2) has drawbacks such as roughening of the surface of the covering material E and the addition of one manufacturing step. This method is easy to apply to plain needle carpets. It is particularly important to heat the fiber at a temperature higher than the temperature at which the fiber binder nonwoven fabric layer A melts, and at a temperature at which the high melting point fibers in the facing material E and the fiber mat layer C do not melt (the The fiber binder may be melted). For compression, a pressure roll of about 1 kg/cm ² is sufficient when only heat fusing is performed, and when molding to match the shape of the floor or adjusting the density of the mat at the same time as heat fusing, a pressure roll of about 1 kg/cm 2 is sufficient. A pressure of ~50Kg/ ^cm2 is required. Heating and compression in the case of only thermal fusion can also 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, another material may be heat-sealed to the side of the fibrous laminate opposite to the facing material E. This heat-forming can be performed simultaneously with the heat-sealing of the surface desiccant material E, or the sheet-like material once heat-sealed can be molded into a required shape depending on the application. [Examples] In order to explain the fibrous laminate of the present invention in more detail, examples will be given below to specifically explain the fibrous laminate of the present invention. However, these Examples are not intended to limit the fibrous laminate of the present invention. Example 1 The fiber binder nonwoven fabric layer A was made of 16 denier, 50 mm long polypropylene fibers (melting point 164°C), 250 g/m ² webbed with a card to a thickness of 3 mm.
I used the one from Further, as the fiber binder nonwoven fabric layer B, the same material was used with a thickness of 50 g/m ² and 1 mm. These fiber binder nonwoven fabric layers A and B are made of phenol felt layer C "Felt Top" manufactured by Howa Seni Co., Ltd.
10t” (product name, 10mm thickness, soft type, basis weight
550g/m ² ) on the front and back sides, and needled in that state at a rate of 150 pieces per square inch, resulting in a wall thickness of approximately 13mm and an apparent density.
A laminate Mat D weighing 0.065 g/cm ³ was obtained. The obtained laminate Matsuto D was mixed with an aqueous emulsion of a terpolymer of styrene (85% by weight), methyl acrylate (12% by weight), and acrylic acid (3% by weight) (resin average particle size 0.1 μm, solid content). The emulsion resin solid content per 100 parts by weight of fiber in the laminate Mat D is immersed in a bathtub with a temperature of 50% by weight (softening point of the resin is approximately 120°C), then taken out from the bathtub and squeezed with a roll. It was contained in an amount of 30 parts by weight (resin solid amount 250 g/m ³ ). Then colored 16 denier, fiber length 85-120
mm polyethylene terephthalate (melting point 264℃)
A plain type needle-punch carpet made of 300 g/m ³ fiber mat made of randomly stacked fiber cards was used as the covering material E, and was superimposed on the upper surface of the fiber binder nonwoven fabric layer A of the laminate mat D. . And this laminate is 190
After drying the emulsion and melting the polypropylene fiber binder by heating to
Pressure molded for 60 seconds using a cooling press mold at a pressure of 10 kg/cm ² to form an integrated product with a thickness of 6 mm that is faithful to the mold.
obtained carpet for installation. Additionally, during molding, a "felt top 6t" (6 mm thick) was placed in the mold and molded in the same manner. The resulting carpet was evaluated for the following various properties. The results are shown in Table 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 the surface material E and the fiber mat layer C of the sample was measured using an Instron type tester. Heat-setting property When the laminate Mat D was heated and compressed to a thickness of 5 cm at 180° C. for 60 seconds, it was determined whether or not the thickness could be controlled. If the thickness could be controlled, it was marked as ○, and if it was not possible, it was marked as ×. Formability The shape retention of the product was measured by molding at 180° C. and 10 Kg/cm ² . Those in which the shape according to the mold was obtained were marked as ◎, and those in which the shape according to the mold was not obtained were marked as ×. Bending strength Fix one end of the test piece (length 120 mm, width 30 mm),
The bending resistance value was measured when a deformation load was applied perpendicularly to the test piece at a rate of 50 cm/min using an Instron type testing machine at a location 100 mm in the longitudinal direction from the fixed location. Rigidity A test piece (length 300 mm, width 300 mm) was placed at both ends on a table with external dimensions 300 mm long x 300 mm wide and width 250 mm x 250 mm ^. Pressure was applied, and those within the wall thickness of this sample piece at this time were judged to have good rigidity, and those exceeding the wall thickness were judged to have poor rigidity. Adhesiveness to other materials When molding, place the "Felt Top 6t" in the mold and mold it, peel off the felt adhered to the thermoplastic fiber binder nonwoven fabric layer B on the back side, and then remove the bonded "Felt Top". A case where the felt fibers remained and adhered to the B side of the thermoplastic fiber binder nonwoven fabric layer was rated ◎, and a case where no felt fibers remained was rated x. Tape adhesion strength on the back side Adhesive strength when cloth packing tape is attached to the thermoplastic fiber binder nonwoven fabric layer B side on the back side of a molded product without "Felt Top" placed and fiber removal when the stuck packing tape is peeled off The fibers were observed, and those in which the fibers did not peel off were marked as ○, and those in which the fibers peeled off were marked as x. Comparative Example 1 A fibrous laminate was obtained in the same manner as in Example 1 except that the thermoplastic fiber binder nonwoven fabric layers A and B were not used. Comparative Example 2 A fibrous laminate was produced in the same manner as in Example 1, except that in Example 1, the laminate Mat D was not impregnated into a bath of an aqueous emulsion of a styrene/methyl methacrylate/acrylic acid terpolymer. Obtained. Example 2 In Example 1, a polyethylene nonwoven fabric with a melting point of 119° C. (manufactured by Mitsui Petrochemical Industries, Ltd., trade name "Admel", basis weight 100 g/m ² ) was used as the thermoplastic fiber binder nonwoven fabric layers A and B. Except for using

【table】

[Table] A fibrous laminate was obtained in the same manner as in Example 1. Example 3 In Example 1, "Fine Needle 650L" manufactured by Aoyama Sangyo Co., Ltd. (trade name, felt containing 20% fiber binder, basis weight
A fibrous laminate was obtained in the same manner except that 650 g/m ² ) was used. Example 4 A fibrous laminate was obtained in the same manner as in Example 1 except that polyester miscellaneous felt (needle felt, 8 mm thickness, area weight 650 g/m ² ) from Kansai Felt Co., Ltd. was used as fiber mat C. Ta. Comparative Example 3 A fibrous laminate was obtained in the same manner as in Example 1, except that a polyester fiber nonwoven fabric was used instead of the polypropylene fiber binder nonwoven fabric. Table 1 shows the physical properties of these fibrous laminates. [Effects of the Invention] In the fibrous laminate of the present invention, the fibrous mat layer C contains emulsion resin solids, and both sides of the fibrous mat layer C are sandwiched between the fiber binder nonwoven fabric layers A and B. Due to the ring, the fiber binder of the fiber binder nonwoven fabric layers A and B enters into the fiber mat layer C and becomes intertwined with the mating fibers, so that the fiber mat layer C itself is easily heat set by heating, and can be used as a base layer. It provides strength, hardness, moldability, and shape retention. In addition, since the fiber mat layer C and the fiber binder nonwoven fabric layers A and B are overlapped and intertwined by needling, there is no need to uniformly mix both fibers as in the conventional method, which simplifies the process. It is extremely useful industrially.

[Brief explanation of drawings]

FIG. 1 is a sectional view of a fibrous laminate according to an example of the present invention. A... Fiber binder nonwoven fabric, B... Fiber binder nonwoven fabric, C... Fiber mat layer impregnated with resin emulsion, D... Laminate mat, E...
Surface material.

Claims (1)

[Scope of Claims] 1. Upper and lower nonwoven fabric layers A and B formed from a thermoplastic fiber binder nonwoven fabric having a melting point of 60 to 200°C, and the thermoplastic fiber binder nonwoven fabric sandwiched between the upper and lower nonwoven fabric layers A and B. The fiber mat layer C is composed mainly of synthetic fibers or natural fibers having a melting point higher than the melting point by 40°C or more, and the fibers of the fiber binder nonwoven fabric of the upper and lower nonwoven fabric layers A and B are the synthetic fibers of the fiber mat layer C. Or, in a fibrous laminate formed by laminating a facing material E on a laminate mat D intertwined and bonded with natural fibers, the fiber mat layer C mainly composed of synthetic fibers or natural fibers,
Glass transition temperature 50℃ impregnated as emulsion
A fibrous laminate characterized in that the above resin is contained in a solid content of 10 to 100 parts by weight per 100 parts by weight of the fibers. 2. Claim 1, wherein the amount of each of the fiber binders A and B is 10 to 100% by weight of the fiber mat layer C.
The fibrous laminate described in . 3. The above-mentioned plastic fiber binder non-woven fabric layers A and B are respectively applied to the front and back surfaces of the fiber mat layer C which is mainly composed of synthetic fibers or natural fibers having a melting point 40°C or more higher than the melting point of the thermoplastic fiber binder non-woven fabric layers A and B. After the laminate mat D, which is laminated and needled, is immersed in an emulsion of a resin having a glass transition point of 50° C. or higher to be impregnated with the emulsion, a facing material E is further layered and heated and compressed. Production of a fibrous laminate, characterized in that the emulsion is dried and the fiber binders of the fiber binder nonwoven fabric layers A and B are melted to heat-seal the facing material E and the fiber mat layer C. Method.