JPH0476782B2 - - Google Patents

Description

[Detailed description of the invention]

[Industrial Application Field] The present invention relates to a fibrous laminate with excellent thermoformability, shape retention, and cushioning properties, and a method for manufacturing the same, and particularly to a fibrous laminate with excellent thermoformability and shape retention as an interior material for vehicles such as automobiles. The present invention also relates to a fibrous laminate with good cushioning properties and a method for producing the same. [Prior art] Conventionally, fiber mats and 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. , high melting point fibers such as polyethylene terephthalate, and 100
Non-woven mats made of mixed fibers with a thermoplastic resin fiber binder having a melting point of ~130°C, etc.
Carpets are used that are heated and press-molded to match the shape of the car floor. [Problems to be Solved by the Invention] However, the fiber mat made by coating or impregnating the entire nonwoven fabric with an aqueous emulsion of thermoplastic resin and drying it has excellent rigidity and moldability, but has poor cushioning properties. In this respect, it was significantly inferior. In addition, carpets made from non-woven mats made of mixed fibers of high melting point fibers and thermoplastic resin fiber binders are heated and press-molded to match the shape of the car floor, and have excellent cushioning properties. However, the rigidity and formability were not satisfactory. In addition, these carpets lack luxury by themselves, and as mentioned above, they are unsatisfactory in any of the various performances of carpets such as rigidity, moldability, and cushioning properties. Used are tufted carpets, needle punch carpets, and other covering materials bonded together using adhesives or hot melt agents, as well as carpets lined with resin sheets or foam sheets. However, these carpets are still unsatisfactory in terms of cushioning properties, thermoformability and shape retention. [Means for Solving the Problems] The present invention has been made in view of the above problems, and is simple, inexpensive, highly decorative, and has excellent thermoformability, shape retention, and cushioning properties. The present invention provides a fibrous laminate and a method for manufacturing the same, which can be used to manufacture carpets. 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. A fibrous laminate formed by laminating a facing material E on a laminate mat D comprising a fibrous mat layer C mainly composed of synthetic fibers or natural fibers having a melting point higher than 40° C. The present invention provides a fibrous laminate characterized in that a portion of layer C contains an emulsion resin solid content of a resin having a glass transition point of 50° C. or higher, and a method for producing the same. (1) Fibrous laminate As shown in FIG. 1, the fibrous laminate of the present invention mainly includes a fibrous binder nonwoven fabric layer A on the front and back surfaces of a fibrous mat layer C partially containing emulsion resin solids. 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 having a three-layer structure in which a fiber binder nonwoven fabric layer B is laminated on the lower side. 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, and polyamide. It is made of resin fibers such as, or composite fibers of these, with a melting point of 60 to 200℃, preferably 90 to 170℃, and the thickness of the fibers can be arbitrary depending on the purpose, but usually The resin fibers are preferably 3 deniers or more, and the length of the fibers is preferably 8 mm or more in terms of entanglement, and can be obtained by intertwining these resin fibers by 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.
The basis weight is usually 6~600g/ ^m2 , preferably 10~
It should be 500g/m ² and breathable. This fiber binder nonwoven fabric is made by melting resin pellets such as polypropylene, low-melting point polyester, and low-melting point polyamide using an extruder and extruding them through a die with many thin holes, which is then carried by the wind so that the individual fibers do not converge. Pull it out like this,
It may also be produced by 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 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 of the fiber binder nonwoven fabric layers A and B 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 fibers in the fiber mat layer C. This is because the temperature at which the nonwoven fabric layers A and B are melted is usually 20 to 30°C higher than the melting point of the binder fibers of the nonwoven fabric layers A and B. Furthermore, the fiber binder nonwoven fabric layers A and B
does not have to be a single fiber type. For example, a mixed fiber 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. Fiber mat layer C The fiber mat layer C constituting the fibrous laminate of the present invention is composed of an upper layer, a resin solid content-containing fiber mat layer C ² containing an emulsion resin solid content of a resin having a glass transition point of 50° C. or higher, and a lower layer. and a fiber mat layer ^C1 which does not contain the above-mentioned resin. As the fibers forming the fiber mat layer C, synthetic fibers or natural fibers are generally used, but mixed fibers of both can 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 made of polyethylene, polypropylene, etc. having a melting point of 60 to 200° C. in a proportion of 5 to 50% by weight. The fiber mat layer C is needled together with the fiber binder nonwoven fabric layers A and B laminated on the front and back surfaces, or with the mounting material E described later, so that the fibers of both are entangled and integrated. Therefore, it is not necessarily necessary to give sufficient shape retention to the fiber mat layer C itself in advance by needling or using an adhesive. Moreover, the fibers do not necessarily have to be of high quality; even a web of waste fibers can be used to achieve the purpose. That is, the temperature is 40°C or higher than the melting point of fiber binder A, preferably
Contains 50% by weight or more of various fibers with a melting point higher than 70°C, such as wool, nylon, polyacrylonitrile, polyacetate, polyethylene terephthalate, etc., and can be used to make needle punch carpets made into card webs, as well as fibers. Phenol felt, which is a 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 . Emulsion The emulsion resin solid content that is impregnated into a part of the fiber mat layer C constituting the fibrous laminate of the present invention to form the resin-impregnated fiber mat layer ^C2 has a glass transition point of 50°C or higher, preferably 80°C. The particle size formed by dispersing ~180℃ resin in water or organic solvent is generally 0.01~5μm, preferably 0.05~
It is a 1.5 μm emulsion, and the emulsion is coated 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) 50 to 97% by weight, preferably 55 to 95% by weight of an aqueous resin emulsion having a Tg of +80 to 155°C;
Examples include a mixture with 50 to 3% by weight, preferably 45 to 5% by weight of an aqueous resin emulsion having a Tg of -85 to less than +80°C. Fillers such as calcium carbonate, iron oxide, ferrite, barium sulfate, etc. may be added to these emulsions to give the obtained nonwoven fabric a sense of weight, and fillers such as low-density polyethylene, polystyrene, etc. may be added to give moldability. It is also possible to blend powder of low melting point resin such as ethylene/vinyl acetate copolymer. Such an emulsion is generally applied to the lower surface of the fiber mat layer C before lamination or to the laminate mat D.
After forming, the lower part B of the laminate mat D is sprayed or coated with a foam coater, or the lower surface of the fiber mat layer C or the lower part B of the laminate mat D is immersed in the emulsion, Next, the fiber mat layer C or the lower layer of the laminate mat D is impregnated by squeezing with a roll, and then dried to form a resin-impregnated fiber mat layer ^C2 in the lower layer of the fiber mat layer C. The resin-impregnated fiber mat layer ^C2 is generally formed to have a thickness of 5 to 80%, preferably 30 to 65%, of the thickness of the fiber mat layer C. Resin-impregnated fiber mat layer formed on this lower layer
C ² imparts thermoformability and shape retention to the fibrous laminate, and the fibrous laminate layer C ¹ formed on the upper layer and not impregnated with resin imparts cushioning properties to the fibrous laminate. It will be done. Laminated body mat D 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 can be made by needling as necessary, so that the fibers of the fiber mat layer C are A laminate mat D can be obtained in which the fibers of the fiber binder and nonwoven fabric layers A and B are intertwined. Since such a laminate mat D does not easily lose its shape, it is preferable to perform needling. The amount of the fiber binder layers A and B used is 10 to 100% by weight of the fiber mat layer C. The upper and lower fiber binder nonwoven fabric layers A and B are each
Laminated in an amount of 10-500g/ ^m2 . In order to obtain the laminate mat D in which the fibers of the fiber binder are entangled, it is necessary to perform needling so as to penetrate through the fiber mat layer C. As a result, 5 to 80% of the binder fibers of the fiber binder nonwoven fabric A are inserted into the fiber mat layer C over the entire fiber mat layer C. However, if the fiber mat layer C before needling already contains 5 to 50% by weight of the fiber binder, it is not necessarily necessary to insert the needle until it completely penetrates the fiber mat layer C. 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 layer structure of the fiber binder layer A and the fiber mat layer C is clear. and,
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 of 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. Needling uses needles of 80 to 1 square inch.
This is done by piercing the fibers in the opposite direction in the vertical direction at a rate of 300 fibers until 5 to 80% of the fiber binder of the fiber binder nonwoven fabric layer A becomes intertwined with the fibers of the fiber mat layer C. Further, needling can also be performed after laminating the later-described mounting material E on the laminate mat D. Surface material E The surface material E constituting the fibrous laminate of the present invention, which is superimposed on the needled laminate mat D, has 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. Needle punch carpets made from fibers with a melting point, such as wool, nylon, polyacrylonitrile, polyacetate, polyethylene terephthalate, etc.; primary base fabrics knitted from polypropylene flat yarns (this includes carpets and woven fabrics) A raw fabric for tufted carpet with piles made of polyamide or polyethylene terephthalate erected on the surface (which may have been subjected to a backing treatment that is generally performed for There are raw materials such as tufted carpet, which has a primary base fabric and piles are 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. Further, after the facing material E is laminated on the laminate mat D, the needling may be performed as necessary to intertwine the fiber binder with the facing material E. (2) Production of fibrous laminate In order to produce the fibrous laminate of the present invention, the temperature must be 40°C below the melting point of the thermoplastic fiber binder nonwoven fabric layers A and B.
The back side of a laminate mat D obtained by laminating thermoplastic fiber binder nonwoven fabric layers A and B on 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 as high as above, and needling them. After applying an emulsion of a resin having a glass transition point of 50° C. or higher to impregnate a part of the fiber mat layer C with the emulsion, the facing material E is layered on the surface of the laminate mat D and heated and compressed. By doing so, the fiber binder is melted and the facing material E and the fiber mat layer C are thermally fused. As another manufacturing method, a thermoplastic fiber binder nonwoven fabric layer A,
B is laminated and needled to form a laminate mat D, and the facing material E is layered and heated to heat-seal and laminate, and then the back side has a glass transition point of 50°C.
An emulsion of the above resin is applied and dried to form a resin-impregnated fiber mat layer on the lower layer of the fiber mat layer C.
There is a method to form C ² . Still another method is to apply the resin emulsion from the back side of the fiber mat layer C, then dry or completely dry it, and then sand it with the fiber binder nonwoven fabric layers A and B, and then apply the resin emulsion to the back side of the fiber mat layer C.
may be placed on the fiber binder layer A and heated and molded. 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 by light needling, and the fiber binder nonwoven fabric layer A is placed on top of the fiber binder nonwoven fabric layer A. A method of heat-sealing using binder nonwoven fabric A may also be used. However, with this method, there is a loss due to the roughness of the surface of the covering material E and the addition of one manufacturing process. For applying the emulsion, methods such as roll, spray, and foam coating are used. The heating is performed at a temperature higher than the temperature at which the resin and fiber binder nonwoven fabric layers A and B of the emulsion melt,
Moreover, it is particularly important to heat the surface material E and the fiber mat layer C to a temperature at which they do not melt. 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. ~50Kg/ ^cm2 is required. In the present invention, in order to keep the emulsion-impregnated layer in a part of the fiber mat layer, compression is preferably carried out after the impregnated emulsion has dried to some extent. 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 adhesive layer. This molding can be performed simultaneously with the fusing of the above-mentioned facing material E, or the once heat-sealed material 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 As the fiber binder nonwoven fabric layer A, 16 denier, 50 mm long polypropylene fibers (melting point: 164° C.), 250 g/m ² were webd with a card. Further, as the fiber binder nonwoven fabric layer B, the same material was used at 50 g/m ² . 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
550 g/m ² ) on the front and back sides, and in that state, needling was performed at a rate of 150 pieces per square inch to obtain a laminate Mat D having a wall thickness of about 13 mm and an apparent density of 0.065 g/cm ³ . A plain type needle punch made of 300 g/m ² fiber mat made by randomly stacking colored polyethylene terephthalate (melting point 264°C) fiber cards of 16 denier and fiber length 85 to 120 mm on the resulting laminate Mat D. Carpet is layered as facing material E, and this laminate is needled at a rate of 150 fibers per square inch, with a wall thickness of approximately 15 mm.
A laminate with an apparent density of 0.077 g/cm ² was obtained. From the back B side of this laminate, styrene (85% by weight), methyl acrylate (12% by weight), and acrylic acid (3% by weight)
Aqueous emulsion of terpolymer (resin average particle size is 0.1 μm, solid content is 50% by weight, resin softening point is approx.
120° C.) at a rate of 250 g/m ² and compacted with a roll to a thickness of 6 mm. Then, this laminate was heated to 190°C to dry the impregnated emulsion and melt the polypropylene fiber binder, and then pressure-molded for 60 seconds at a pressure of 10 kg/cm ² using a cooling press mold to form a gold plate. An integrated carpet with a thickness of 6 mm, faithful to the mold, was obtained. 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 set property Whether or not the thickness can be controlled when the laminate Mat D is heated and compressed to a thickness of 5 cm at 180°C for 60 seconds. ○ indicates that the desired thickness can be controlled. 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 ◎. 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 on a table with both ends of the test piece (length: 300 mm x width: 300 mm) and width: height: 250 mm x width: 250 mm, and a pressure of 2.0 Kg/cm ² was applied to the center of the test piece at a diameter of 15 mm. were added, and those within the wall thickness of this sample piece at this time were considered to have good rigidity, and those exceeding the wall thickness were considered to have poor rigidity. Cushionability The initial wall thickness when the fibrous laminate is laid and a load of 50 g/cm ² is applied is t ₀ , then the wall thickness when a load of 400 g/m ² is applied for 1 minute is t ₁ , When this load is removed and the wall thickness after minutes has elapsed is t ₂ , compressibility = t ₀ − _{t 1} / t ₀ × 100 Compressive modulus = t ₂ − _{t 1} / t ₀ − t ₁ × 100 Deformation It was calculated as ratio=(1-t ₂ /t ₀ )×100, and those with a small deformation ratio and a small thickness change ratio were considered to have good cushioning properties. Adhesiveness to other materials When molding, "Felt Top 6+" is placed inside the mold.
The felt that was adhered to the fiber binder B layer on the back side was peeled off, and the adhered "felt top" layer was broken and peeled off, and the case where the felt fiber remained and was adhered to the B side was rated as ◎. Adhesive strength of tape on the back side We observed the degree of adhesion when cloth duct tape was attached to the back side B of the molded product without placing "Felt Tsup" and how the fibers came off when the duct tape was peeled off. ○ indicates that the fibers do not peel off. Comparative Example 1 In Example 1, fiber binder nonwoven fabric layer A
A fibrous laminate was obtained in the same manner as in Example 1 except that B and B were not used. Example 2 The same fiber binder nonwoven fabric layer A and fiber binder nonwoven fabric layer B as in Example 1 were used at 50 g/m ² , and these fiber binder nonwoven fabric layers A and B were used on the front and back surfaces of the phenol felt layer C used in Example 1. Needled in this state at a rate of 150 pieces per square inch, with a wall thickness of approximately 13 mm and an apparent density.
A laminate Mat D weighing 0.065 g/cm ³ was obtained. A plain type needle made of a 300 g/m ³ fiber mat made by randomly stacking colored polyethylene terephthalate (melting point 264°C) fiber cards of 16 denier and a fiber length of 85 to 120 mm on the resulting laminate mat D. A punch carpet is used as a covering material E, and is superimposed on the upper surface of the fiber binder nonwoven fabric layer A of the laminate mat D, and this laminate is
The polypropylene fiber binder was melted and bonded by heating to a temperature of 190° C. and applying a pressure of 10 kg/cm ² for 80 seconds. Then, from the back side of this laminate, styrene (85
Aqueous emulsion of terpolymer of methyl acrylate (12% by weight) and acrylic acid (3% by weight) (resin average particle size 0.1μm, solid content 50% by weight, resin softening point approximately 120%) °C) in a thickness of 4 mm by spraying at a rate of 200 g/ ^m2 ;
A carpet for laying with a thickness of 6 mm was obtained by heating and drying at a temperature of 120°C. The resulting carpet was evaluated for the following various properties. The results are shown in Table 1. Comparative Example 2 In Example 1, the entire laminate Mat D was made of styrene/methyl acrylate/acrylic acid ternary copolymer.

【table】

[Table] A fibrous laminate was obtained in the same manner as in Example 1, except that the entire mat layer C was impregnated with the aqueous emulsion. Comparative Example 3 A fibrous laminate was obtained in the same manner as in Example 1, except that in Example 1, the aqueous emulsion of styrene/methyl acrylate/acrylic acid terpolymer was not sprayed onto the laminate Mat D. Ta. Comparative Example 4 A fibrous laminate was obtained in the same manner as in Comparative Example 1 except that the aqueous emulsion was not used. Table 1 shows the physical properties of these fibrous laminates. [Effects of the Invention] In the fibrous laminate of the present invention, the fiber mat layer C has a resin-impregnated fiber mat layer ^C2 partially containing an emulsion resin solid content, and a fiber mat layer ^C1 containing no resin solid content. By heating the fiber binder nonwoven fabric layers A and B sandwiching both sides of the resin solid content-containing fiber mat layer ^C2 and the resin solid content-free fiber mat layer ^C1 . Therefore, the fiber mat layer C itself is easily heat set, and the presence of the resin-impregnated fiber mat layer ^C2 provides strength, hardness, and shape retention as a base layer, and does not contain the solid content of the emulsion resin. The presence of the fiber mat layer ^C1 provides a carpet with cushioning properties. Moreover, since the fibrous laminate of the present invention has a layer mainly composed of the fiber binder nonwoven fabric layer B in the lower layer, it is also possible to bond it to other materials. In addition, by overlapping the fiber mat layer C and the fiber binder nonwoven fabric layers A and B and intertwining them by needling, there is no need to uniformly mix both fibers as in the conventional method, which simplifies the manufacturing process. It is extremely useful industrially.

[Brief explanation of the drawing]

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, ^C1 ...Fiber mat layer not impregnated with resin, ^C2 ...Resin-impregnated fiber mat layer ,
D...laminate pine, E...facing 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. In a fibrous laminate formed by laminating a facing material E on a laminate mat D comprising a fibrous mat layer C mainly composed of synthetic fibers or natural fibers having a melting point higher than the melting point by 40°C or more, the fiber Glass transition point in part of Matsuto layer C
A fibrous laminate characterized by containing an emulsion resin solid content of a resin having a temperature of 50°C or higher. 2. The fibrous laminate according to claim 1 or 2, wherein 5 to 80% of the thickness of the fiber mat layer C is a resin-impregnated fiber mat layer ^C2 containing an emulsion resin solid content of a resin having a glass transition point of 50° C. or higher. body. 3 Resin-impregnated fiber mat layer C ² is fiber mat layer C
The fibrous laminate according to claim 2, which is a lower layer portion of the fibrous laminate. 4 The stacking amount of fiber binder nonwoven fabric layers A and B is
The fibrous composite material according to claim 1, wherein the amount of each fiber mat layer is 10 to 100% by weight. 5 Thermoplastic fiber binder nonwoven 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 thermoplastic fiber binder nonwoven fabric layers A and B. After applying an elbow of a resin having a glass transition point of 50° C. or higher to the back side of the laminate D formed by laminating and needling and impregnating a part of the fiber mat layer C with the emulsion, the laminate is A method for manufacturing a fibrous laminate, which comprises stacking the facing material E on the surface of the mat D and heating and compressing it to melt the fiber binder, thereby thermally fusing the facing material E and the fiber mat layer C. . 6 Thermoplastic fiber binder On the front and back surfaces of the fiber mat layer C mainly composed of synthetic fibers or natural fibers having a melting point 40°C or more higher than the melting point of the nonwoven fabrics A and B,
Thermoplastic fiber binder nonwoven fabric layers A and B are laminated and needled to form a laminate mat D, and a facing material E is layered and heated to heat-seal and laminate, and then the back side has a glass transition point of 80. A method for producing a fibrous laminate, which comprises applying and drying a resin emulsion at a temperature of at least .degree. C. so that a portion of the fiber mat layer C contains the emulsion.