JPH0533903B2 - - Google Patents

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a fibrous laminate and a method for producing the same, and in particular to a fibrous laminate that can be deep drawn as an interior material for automobiles and other vehicles and has good shape retention. The present invention relates to a quality laminate and a method for manufacturing the same. [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 non-woven mats made of mixed fibers of high-melting-point fibers and thermoplastic resin fiber binders having a melting point of 100 to 130 degrees Celsius to match the shape of automobile floors. 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 (nonwoven fabric binder) is Since it is discontinuous and has voids, it is excellent in that it does not impair breathability and flexibility. However, with this method, there is a problem with the uniformity of mixing the fiber binder with the fiber mat used for lining, and it is difficult to mix the fiber binder and other fibers sufficiently to ensure moldability and fixation of the fibers as evenly as possible. It is.
In order to ensure more reliable adhesion between the facing material and the fiber mat, a hot melt adhesive (nonwoven fabric binder, thermoplastic resin film, thermoplastic resin powder, etc.) is required between the two. Note that needling alone has the problem of roughening the surface of the facing material and insufficient adhesive strength, and even if needling is used in combination with a hot melt adhesive, there is a problem that the surface of the facing material becomes rough. [Means for Solving the Problems] The present invention further improves the carpet lining method proposed above, and provides a method that is simple, inexpensive, and has excellent moldability and shape retention with rich decorative properties and adhesive properties. The present invention provides a fibrous laminate from which a lined carpet can be produced and a method for producing the same. That is, the first aspect of the present invention is that the covering material A has a melting point of
A base material layer C in which the resin component B of the resin aqueous emulsion is dispersed in a thermoplastic fiber nonwoven fabric B having a temperature of 60 to 200°C and a synthetic fiber or natural fiber having a melting point higher than the melting point of the fiber nonwoven fabric B by 40°C or more. The present invention provides a fibrous laminate having a structure in which these are bonded together in this order (A/B/C). The second aspect of the present invention is to use a thermoplastic fibrous nonwoven fabric B having a melting point of 60 to 200°C at 40°C below the melting point of the fibrous nonwoven fabric B.
Laminated on the surface of a fiber matsutoi made of synthetic fibers or natural fibers having a melting point as high as above to form a laminate mat, needling is performed from the thermoplastic fiber nonwoven fabric B side of the laminate mat to separate the fiber nonwoven fabric B and the fiber matstoi. After intertwining the fibers with each other,
The facing material A is placed on the fibrous nonwoven fabric B side, and then an aqueous resin emulsion is applied to the fibrous matsutoi side of the laminate mat, impregnated, and dried.The fibrous nonwoven fabric is formed without the fibers of the facing material A and the fibrous matsutoi being melted. The present invention provides a method for producing a fibrous laminate in which the fibers of B and the resin component B of the emulsion are heated to a melting temperature. [Specific Description of the Invention] (1) Fibrous Laminate As shown in FIG. A covering material A, for example, needle punch carpet, is layered on the surface of the laminate mat having fiber nonwoven fabrics B stacked on top of each other, and is heated and compressed to melt the resin component B and the fiber nonwoven fabric B, thereby forming the covering material A and the fiber mat toy. It has a structure in which the base material layer C and the nonwoven fabric B are bonded to each other. In the base material layer C of this fibrous laminate, the resin component B may be dispersed throughout the fiber matsutoi, or as shown in FIG.
% may be dispersed only in _C2 . The dispersed portion _C2 of resin component B imparts thermoformability and shape retention to the fibrous laminate, and also
The undispersed portion _C1 of resin component B imparts cushioning properties to the fibrous laminate. Therefore, in the latter case where the resin component B is dispersed at a ratio of 30 to 80% of the wall thickness, compared to the former, the base material layer C is the part where the resin component of the emulsion is not dispersed.
Since it has C ₁ , it has excellent cushioning properties, but on the other hand, it has poor rigidity. In the latter case, in order to prevent delamination between the layers of the fibrous laminate, the fiber nonwoven fabric B and the fiber matstoy should be needled in advance to intertwine their fibers, or the fiber nonwoven fabric B and the fiber matstoy should have a melting point of 200°C or higher. 50 synthetic or natural fibers
It is preferable to use a mixed fiber containing 50 to 15% by weight of fibers having a melting point lower than that of the fiber by at least 40°C. (Face material) The surface material A may be a raw material for tufted carpet, which is made by erecting piles made of polyamide or polyethylene terephthalate on a primary base fabric knitted with flat yarn made of polypropylene, or a primary base fabric made of the above-mentioned needle punch carpet. Materials such as tufted carpet, needle punch carpet, woven fabric, and paper are used. (Fiber nonwoven fabric) The fibrous nonwoven fabric B is a nonwoven fabric made of thermoplastic fibers, and is made of polyethylene, polypropylene, linear polyester, polyamide, composite fibers thereof, etc., and has a melting point of 60 to 200°C, preferably 90 to 170°C, and is suitable for the purpose. It can be thick or thin depending on the situation, but it is usually 3 deniers or more, and the fiber length is preferably 8 mm or more in terms of entanglement.
It is a breathable material obtained by intertwining these fibers using a spunbond method, a needle punch method, or the like. Generally, those having a basis weight of 15 to 600 g/m ² are preferable. In addition, this fibrous nonwoven fabric B is made of polypropylene,
Pellets of resin such as low-melting point polyester or low-melting point polyamide are melted using an extruder and extruded in a continuous shape through a die with many thin holes.The pellets are then carried by wind to pull out the individual fibers so that they do not converge. It may also be produced by depositing it on a screen below and taking it up with a winder. Such fibrous nonwoven fabric B has a large number of holes through which water can pass, and is manufactured by Diabond Industries Co., Ltd. under the trade name Meltron W, and is made of polyamide.
PAY-200, PAS-200, polyester type ES-500, ethylene/acetic acid copolymer type Y-7, and Mitsui Petrochemical Industries, Ltd.
Polypropylene-based products are syntax from
Polyethylene-based products are manufactured by Admel with product names such as PK-103, PK-106, PK-404, and PK-408, and similar nonwoven fabrics are manufactured by Kureha Sen'i Co., Ltd. under the product name DYNAC. LKS−0000, LNS−
2000, ES-00, B-1000, B-2000, B-3000
It is commercially available with grade names such as. The fibrous nonwoven fabric 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 of the fiber matsuti. This is because the temperature at which nonwoven fabric B is melted is usually 20 to 30°C higher than the melting point of the fibers of nonwoven fabric B. In addition, this fiber nonwoven fabric B is manufactured by Fiber Matsutoi.
It is used in a proportion of ~200% by weight. Also, the basis weight is
10-500g/ ^m2 is common. Further, the fibrous nonwoven fabric B does not have to be made of a single type of fiber, and may be made of a mixed fiber of polypropylene and polyamide, for example. That is, as long as it is 40° C. or more lower than the melting point of the fiber matsutoi, it may be made of mixed fibers or a laminated structure of these fibers. Furthermore, a small amount (30% or less) of high melting point fibers may be mixed. In the case of recovered fibers, they are well mixed. (Fiber Mat) Synthetic fibers or natural fibers are used as the fibers for constituting the fiber mat used in the fibrous laminate of the present invention. Examples of synthetic fibers include polyethylene terephthalate, polyamide, polyacrylonitrile, nylon, and polyacetate, which have a melting point higher than the melting point of the fiber nonwoven fabric B by 40°C or higher, preferably 70°C or higher (specifically 200 to 280°C). Thermoplastic resin is used. Further, as natural fibers, cotton, linen, wool, miscellaneous felt, scrap poly fibers, etc. are used. This fiber matstoy may contain 15 to 50% by weight of fibers with a melting point of 60 to 200°C, and the fibers do not necessarily have to be of high quality, and scrap fibers may be used. When the fiber mat toy of the present invention and the fiber nonwoven fabric B laminated on its surface are entangled and integrated by needling, the fiber mat toy itself must be sufficiently bonded by needling in advance. It is not necessary to provide shape retention. 30-80% of the entire area or wall thickness of this fiber matstoy
The base material layer C is obtained by dispersing the resin component B of the aqueous resin emulsion in the portion. This resin aqueous emulsion has a glass transition point of
It is preferable that resin particles (0.05 to 1.5 μm in diameter) at a temperature of 50° C. or higher, preferably 80 to 180° C., are dispersed in water. 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 (T _g 81°C);
Polystyrene (T _g 100℃), polyacrylonitrile (T _g 100℃), polymethyl methacrylate (T _g 105℃), polymethacrylic acid (T _g 130℃), polyitaconic acid (T _g 130℃), polyacrylamide ( aqueous resin emulsions of homopolymers such as (T _g 153°C); (b) vinyl monomers 50, which are the raw materials for these polymers;
~100% by weight, preferably 65-95% by weight and other vinyl monomers such as 2-ethylhexyl acrylate (T _g 85°C), n-butyl acrylate (T _g -54°C), ethyl acrylate (T _g −22℃),
Isopropyl acrylate (T _g -5°C), 2-ethylhexyl methacrylate (T _g -5°C), n-propyl acrylate (T _g 8°C), n-butyl methacrylate (T _g 20°C), vinyl acetate (T _g 30℃),
tert-butyl acrylate (T _g 45℃), 2-hydroxyethyl methacrylate (T _g 55℃), ethyl methacrylate (T _g 65℃), isobutyl methacrylate (T _g 67℃), vinyl chloride (T _g 79℃), or these vinyl monomers and vinylidene chloride (T _g -18℃) (50% by weight or less, preferably 35~
(T _g shown in parentheses is the glass transition temperature of the homopolymer of these monomers); and (c) T _g of +50 to 155°C. resin aqueous emulsion 50
-97% by weight, preferably 55-95% by weight, resin aqueous emulsion with T _g of -85 to less than +50°C 50 to
3% by weight, preferably 45 to 5% by weight. 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 emulsions are generally made of a single layer of fiber matsutoi, or on a laminate obtained by stacking fiber matsutoi and fiber nonwoven fabric B, and performing needling if necessary, it is applied from the back side of the fiber matsutoi, impregnated, and dried. The resin component is dispersed in the fiber matstoy by immersing them in an emulsion bath and drying them. It is preferable that the glass transition point of the resin component (B) of this emulsion is a resin aqueous emulsion component that has a glass transition point that is at least 40°C lower than the heat distortion temperature of the fiber mats toy material of the facing material A and the base layer C. . (Fibrous laminate) In order to produce the fibrous laminate of the present invention, the surface of the fibrous laminate 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 nonwoven fabric B is applied. , an emulsion of a resin having a glass transition point of 50° C. or higher is applied to the back side of a laminate mat made by laminating thermoplastic fiber nonwoven fabric B and needling if necessary, and the emulsion is applied to a part or all of the fiber mat toy. After drying, the surface material A is placed on the surface of the laminate mat and heated and compressed to melt the resin components and low melting point fibers of the emulsion.
and the fiber matstoy are heat fused. Another manufacturing method includes laminating the thermoplastic fiber nonwoven fabric B on the back side of the fiber mat toy and needling it to form a laminate mat, and then layering the facing material A by heating and heat-sealing it. There is a method in which a resin emulsion having a glass transition point of 50° C. or higher is applied to the back surface and dried, and the resin component of the emulsion is dispersed in the fiber mats. Another method is to apply, impregnate, or soak the fiber pine toy with a resin emulsion, and then semi-dry or completely dry the pine C.
There is also a method in which a thermoplastic fiber nonwoven fabric B is placed on the surface of the nonwoven fabric B, and a facing material A is further placed thereon, and the fibrous laminate is formed by heat compression molding. It is particularly important that the heating be carried out at a temperature higher than the temperature at which the resin component B of the emulsion and the fibers of the fibrous nonwoven fabric B melt, and at a temperature at which the high melting point fibers of the facing material A and the fiber matstoi 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. When dispersing the emulsion resin component only in a portion of the fiber mats, compression is preferably carried out after the impregnated emulsion has dried to some extent. In the case of only thermal fusion, heating and compression 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. This molding can be performed simultaneously with the fusing of the above-mentioned facing material A, or the once heat-sealed material can be molded into a required shape depending on the application. Needling, which is performed as necessary, is performed in order to prevent the fibrous laminate from deforming or to facilitate molding workability. In order to obtain a laminate mat in which the fibers of the fiber nonwoven fabric B are entangled with the fiber mat toy, it is necessary to laminate the two to form a laminate mat and then perform needling so as to penetrate the fiber mat toy.
As a result, 5 to 80% of the fibers of the fibrous nonwoven fabric B are inserted into the fiber mats toy over the entire fiber mats toy. However, if the fiber matstoy before needling already contains 15 to 50% by weight of low melting point fibers, it is not necessarily necessary to insert the needle until it completely penetrates the fiber matstoy. Needling may be performed from either side of the laminate mat, but when needling is performed from the fibrous nonwoven fabric B side, the fibers of the fibrous nonwoven fabric B are reduced by 5 to 80% into the fibrous mat toy by needling. However, the remaining 95 to 20% remains as fiber nonwoven fabric B on the surface of the laminate mat, and the layered structure of the fiber nonwoven fabric B and fiber matstoi is clear, and the fibers of fiber nonwoven fabric B are included in the fiber matsutoi. exists.
In this case, as a matter of course, some of the fibers of the fiber matsutoi are inserted into the fiber nonwoven fabric B and intertwined with the fibers of the nonwoven fabric. That is, in the laminate mat, the fibers of the fiber non-woven fabric B are vertically inserted into the fiber mat toi by needling, and the fibers of the fiber mat toi are also inserted into the fiber non-woven fabric B, so that the two layers of fibers are entangled. They come together and become one. Of course, needling may be performed from the fiber matstoy side. Needling is carried out by piercing the needles vertically to the opposite side at a rate of 80 to 300 needles per square inch, so that 5 to 80% of the fibers of the fiber nonwoven fabric B are the fibers of the fiber matsutoi. It is effective to do this until they become intertwined. In addition, needling is performed on the laminate pine facing material A.
This can also be done after laminating the layers. [Example] In order to explain the fibrous laminate of the present invention and the method for producing the same in more detail, the following will specifically explain the fibrous laminate using Examples. However, these Examples are not intended to limit the fibrous laminate of the present invention and its manufacturing method. Example 1 As the fibrous nonwoven fabric B, a 16 denier, 50 mm long polypropylene (melting point: 164° C.) fiber of 250 g/m ² was webbed with a card. The above-mentioned fibrous nonwoven fabric B was layered on the surface of Fiber Matsutoy's phenol felt "Feltop 10t" (trade name of Howa Seni Co., Ltd., 10 mm thick, soft type, basis weight 550 g/m ² ), and in that state 15-18-32- Needled using 3RB needles at a rate of 150 needles per square inch, wall thickness approximately 13 mm, apparent density 0.062 g/cm ³
A laminate pine was obtained. From the phenol felt side of this laminate mat, an aqueous acrylic resin emulsion “Acronal YJ-7082D” manufactured by Mitsubishi Yuka Verdice Co., Ltd. (trade name: T _g 120°C, particle size 0.3 to 0.5μ, solid content concentration 50
%) at 250 g/m ² (solid content), impregnated, and compressed with a squeezing roll. Next, colored 6 denier, fiber length 85 ~
120mm polyethylene terephthalate (melting point 264
°C) Needle punch carpet A (300 g/m ² ), which is made by randomly stacking fiber cards, is superimposed on the top surface of fiber nonwoven fabric B of the laminate mat, and this laminate is heated to 190 °C through a suction dryer to form polypropylene. After melting the fibers and acrylic resin particles, they are immediately pressure-molded using a cooling plane mold at a pressure of 10 kg/cm ² to form an integrated molded 6 mm thick piece that is faithful to the mold. I got a carpet for use. A sample piece of 150 mm x 50 mm was cut from this 6 mm thick carpet and the adhesive strength of the surface layer material was measured using an Instron type tester, and the peel strength was 5.5.
Kg/5cm width. Example 2, Comparative Examples 1 to 2 In Example 1, there are cases in which fiber nonwoven fabric B is not used (Comparative Example 1), resin aqueous emulsion is not used (Comparative Example 2), and nonwoven fabric B has a melting point of 119°C. polyethylene non-woven fabric [manufactured by Mitsui Petrochemical Industries, Ltd. (product name “Admel”, basis weight 100g/
A fibrous laminate was obtained in the same manner except that Example ² ) was used. Example 3 A fibrous laminate was prepared in the same manner as in Example 1 except that Fine Needle 650L (trade name, felt containing 20% low melting point fiber, 650 g/m ² ) manufactured by Aoyama Sangyo Co., Ltd. was used as the fiber mat toy. I got a body. Example 4 A fibrous laminate was obtained in the same manner as in Example 1, except that polyester miscellaneous felt (needle felt 8 mm thick, basis weight 650 g/m ² ) manufactured by Kansai Felt Co., Ltd. was used as the fiber mat toy. Example 5 In Example 1, the acrylic resin aqueous emulsion "Acronal YJ-7082" was applied by spraying, and 30% of the inner thickness was applied from the lower layer side of the fiber matsutoi.
A fibrous laminate was obtained by impregnating the parts. Comparative Example 3 In Example 1, Acronal YJ-7082D
(T _g 120℃) instead of Acronal YJ−1650D
A fibrous laminate was obtained in the same manner except that (T _g 30°C) was used. The following various properties of the obtained fibrous laminate were evaluated. 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 A of the sample and the fiber mats toy or base material layer C was measured using an Instron type tester. It was measured. Formability Shape retention of the product by molding at 180℃ and 10Kg/cm ² . 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 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 marked as ◎. 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/cm ² is applied for 1 minute is t ₁ , When this load is removed and the wall thickness after 1 minute is t ₂ , compression ratio = t ₀ - _{t 1} / t ₀ × 100 Compressive modulus = t ₂ - _{t 1} / t ₀ - _{t 1} × 100 It was calculated as deformation rate = (1- _t2 / _t0 ) x 100, and the cushioning property was determined to be good if the deformation rate was small and the thickness change rate was small. Adhesive strength of the tape on the back side When a cloth packing tape was attached to the back side of the molded product, the degree of adhesion was observed and how the fibers came off when the attached packing tape was peeled off. Those with no peeling of the fibers were rated as ○. Heat-set property: Those whose thickness could be easily controlled during shaping of the fibrous laminate were rated good (○), and those where it was difficult were rated poor (x). 【table】

[Brief explanation of drawings]

Figures 1 and 2 are cross-sectional views of a fibrous laminate obtained by the method of the present invention, which is a laminate in which a fibrous nonwoven fabric B is superimposed on the surface of a fibrous matsutoi in which the resin component B of the emulsion is dispersed. This shows a state in which the mat is needled, and then the facing material A is layered and heated and compressed to melt the fibers of the fibrous nonwoven fabric B and weld A and A together. FIG. 1 shows a state in which the resin component B of the emulsion is dispersed throughout the matsutoi, and FIG. 2 shows a state in which the resin component B of the emulsion is dispersed in the lower layer of the matstoy.

Claims (1)

[Scope of Claims] 1. Surface material A, a thermoplastic fiber nonwoven fabric B with a melting point of 60 to 200°C, and a fiber matsutoi made of synthetic fiber or natural fiber having a melting point 40°C or more higher than the melting point of the fiber nonwoven fabric B, and an aqueous resin. The base material layer C in which the resin component B of the emulsion is dispersed is arranged in this order (A/
A fibrous laminate with a structure bonded together with B/C). 2. The fibrous laminate according to claim 1, wherein the resin component B is dispersed throughout the fiber matstoy. 3. The fibrous laminate according to claim 1, wherein the resin component B is dispersed from the lower layer side of the fibrous pine to a portion of 30 to 80% of the wall thickness of the fibrous pine. 4. An aqueous resin emulsion whose glass transition point is 50°C or higher, and which is at least 40°C lower than the heat distortion temperature of the fiber mats toy material of the facing material A and the base layer C. The fibrous laminate according to any one of claims 1 to 3, wherein the fibrous laminate is a resin component of an emulsion. 5 Fiber Matsutoi is characterized by being made of a mixed fiber consisting of 50-85% by weight of synthetic or natural fibers with a melting point of 200°C or higher and 50-15% by weight of fibers with a melting point at least 40°C lower than that of said fibers. A fibrous laminate according to any one of claims 1 to 4. 6 Thermoplastic fiber nonwoven fabric B with a melting point of 60 to 200°C,
Laminated on the surface of a woven fiber mattoy made of synthetic or natural fibers having a melting point 40°C or more higher than the melting point of the fibrous nonwoven fabric B to form a laminate mat, and needling is performed from the thermoplastic fiber nonwoven fabric B side of this laminate mat. After the fibers of the fiber nonwoven fabric B and the fiber matstoy are intertwined with each other, the facing material A is placed on the fiber nonwoven fabric B side, and then a resin aqueous emulsion is applied to the fiber matstoy side of the laminate mat, impregnated, and dried. The method for producing a fibrous laminate is then heated to a temperature at which the fibers of the fibrous nonwoven fabric B and the resin component B of the emulsion are melted without the fibers of the facing material A and the fiber mats toy melting.