JPH07292552A - Nonwoven fabric composite material and its production - Google Patents

Abstract

PURPOSE:To obtain a nonwoven composite material capable of bonding nonwoven fabric to hot carpet, etc., by only hot pressing without using liquid adhesive such as a urethane resin and capable of shortening bonding time, reducing operation labor and improving productivity thereby. CONSTITUTION:In on line needling processes 5, 6 and 7 producing nonwoven fabric 1 by a fiber web consisting essentially of a synthetic fiber (which partially may contain low-melting synthetic fiber), a nest-like hot melt sheet 3 is fixed to nonwoven fabric in such degree as not to separate the hot melt sheet and the surface of the nonwoven fabric is pressed so as not to expose fuzz out of the surface to provide the objective nonwoven composite fabric.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a non-woven fabric composite material, and more particularly, to a non-woven fabric composite material and a hot melt sheet composite material which are advantageous for producing hot carpets and hot mats.

[0002]

2. Description of the Related Art Conventionally, in the production of hot carpets and hot mats, a heating wire and a detection wire are wrapped as a unit with a non-woven fabric, and a liquid adhesive such as urethane resin is sprayed on the front and back layers by a spray or the like. It has been practiced to sandwich the wrapped heat generating unit between the front and back layers and to bond the heat generating unit from above and below by hot pressing.

[0003]

However, in the above-mentioned bonding method, since liquid adhesive such as urethane resin is sprayed on both the front layer and the back layer, it requires manpower and funds to manage and maintain the spray material. Further, since the hot pressing time is long, the adhesive efficiency is poor and the productivity cannot be improved. Furthermore, liquid adhesives such as urethane resins also have a risk of causing environmental problems such as safety and hygiene and pollution.

The present invention has dealt with the above-mentioned situation and found that a hot melt sheet material is temporarily fixed to a non-woven fabric in advance, so that only a pressure bonding by a hot press can be performed without using a liquid adhesive such as urethane resin. The purpose of the present invention is to improve the productivity by making it possible to perform the adhesive bonding, shortening the pressure bonding time and reducing the number of working steps.

[0005]

In order to meet the above-mentioned object, the present invention firstly proposes an online cobweb-like hot melt of a needling process for producing a nonwoven fabric from a fiber web whose main component is a synthetic fiber as a basic structure. The sheet is fixed by needling so that it does not come off, and pressed to prevent fluff from forming on the surface of the non-woven fabric to form a non-woven composite material.

Here, the conditions for fixing (temporarily adhering) the web-like hot melt sheet to the extent that the fluff does not appear on the surface of the non-woven fabric and does not come off are: penet 20-35 / cm ² , needle penetration depth 10- About 12 mm is preferable.

Further, a part of the synthetic fibers forming the non-woven fabric,
It is also possible to contain a low melting point synthetic fiber, in which case the non-woven fabric formed by suppressing surface fluff is heated at a temperature above the melting point of the low melting point synthetic fiber and the cobweb-shaped hot melt sheet, A part of the low-melting-point fiber component therein is melted, and at the same time, the web-like hot melt sheet is formed so as to be fused to the surface of the nonwoven fabric so that it does not completely melt and penetrate into the nonwoven fabric fiber.

[0008]

The non-woven fabric composite material according to the present invention is used as a front layer and / or a back layer, and a heat wire or the like is sandwiched between both layers with the spider web-shaped hot melt sheet side as the inner surface and hot pressed. Both layers can be easily bonded without using a liquid adhesive as in the past, and it is possible to create a product with various members such as heat wires inside inside in an extremely simple and short-time operation. .

When the non-woven fabric composite material according to the present invention is used for the interior of automobiles, etc., the hot melt sheet improves the wear resistance, facilitates the handling, and facilitates the work for attaching the interior material.

[0010]

Embodiments of the present invention will be described below with reference to the accompanying drawings.

FIG. 1 is a non-woven fabric composite material according to claim 1 of the present invention, FIG. 2 is an embodiment of the non-woven fabric composite material according to claim 2 of the present invention, and FIGS. FIG.

In these figures, 1 is a nonwoven fabric made of a fiber web containing synthetic fibers as a main component, and 1'is the nonwoven fabric 1 described above.
In the above, a nonwoven fabric composed of a fiber web containing a part of low melting point synthetic fibers in synthetic fibers, 2 is a raised portion produced by needling each of the above nonwoven fabrics 1 and 1 ', and 3 is a web-like hot melt sheet. In the structure shown in FIG. 1 which is the basic structure of the present invention, the spider web-shaped hot melt sheet 3 is not peeled off by the needling due to the needling with respect to the nonwoven fabric 1 made of a fiber web containing synthetic fibers as a main component. The fluff on the surface of the non-woven fabric 1 is pressed by the cobweb-shaped hot melt sheet 3 while being fastened to some extent.

Here, the synthetic fibers forming the nonwoven fabric 1 may be known synthetic fibers such as polyester, nylon, acrylic, polypropylene, etc. The polyester, nylon, etc. are not necessarily limited to one kind, and the thickness, length, Two or more of different properties are used. Among them, it is preferable and most practical to mix and use polyester fibers having different lengths and thicknesses.

As shown in FIG. 3, the fiber web usually has a basis weight of 200 to 500 g / m ² and is alternately upper and lower needlings 5 and 6 so that the constituent fibers are entangled with each other to form the nonwoven fabric 1. While being formed, the web-shaped hot melt sheet 3 is unrolled on one surface thereof through the guide rolls 8 and 9, and is superposed and fixed by the need ring 7.

The cobweb-shaped hot melt sheet 3 is usually
The basis weight is 30 to 70 g / m ² , preferably 20 to 40 g / m ² .
It is a thin non-woven fabric of m ² position and has a web structure, and has a melting point of about 120 ° C. and is generally made of modified polyester fiber (modified PET).

Of course, other than the non-woven fabric made of the modified polyester fiber, any hot-meltable sheet can be used. The spider web-shaped hot melt sheet 3 is fixed to one surface of the nonwoven fabric 1 made of the fibrous web, but the hot melt sheet 3 is not embedded in the fiber layer of the nonwoven fabric 1. Fastening that does not come off, and that holds down the fluff on the surface of the nonwoven fabric,
In other words, temporary fixing is applied.

The reason why the fluff is not attached is that the adhesive force is increased and the bonding time is shortened when bonded by hot pressing or the like. So that there is no fluff on the surface,
Moreover, in order to temporarily fix it so that it does not come off, and to laminate it, it is necessary to apply a needling at a penetration of 20 to 35 needles / cm ² , preferably around 30 needles / cm ² and a needle penetration depth of 10 to 12 mm.
It is effective to perform needling under the condition of rank.

If the number of penetrations is too large, or if the penetration depth is deeper than 12 mm, the hot melt sheet 3
Embedded in the non-woven fiber layer, and the fluff tends to appear on the surface, which reduces the adhesive strength.

On the other hand, the number of penetrations is small and the penetration depth is 10
When the thickness is less than mm, the hot melt sheet 3 is easily peeled off from the nonwoven fabric 1, which is not preferable.

The above is the case where the fibers constituting the fiber web are ordinary synthetic fibers, but it is also preferable to partially mix the low melting point synthetic fibers into the synthetic fibers constituting the fiber web.

FIG. 2 shows an example in which such a low melting point synthetic fiber is partially mixed to form the fused portion 4.

This is because a part of the low melting point synthetic fiber is melted by subsequent heating to enhance the pill resistance, and after the spider web type hot melt sheet 3 is attached to the nonwoven fabric 1'as shown in FIG. For the melting step, the material is passed through the heating device 10, and by utilizing this melting step, the composite composite spider web hot melt sheet 3 is fused to the surface of the nonwoven fabric 1 without being melted and permeated into the nonwoven fabric layer. Let it wind up.

A suitable temperature for this purpose is about 150 ° C., and the cohesive web-like hot melt sheet is fused to the surface of the non-woven fabric so as not to permeate into the fiber, thereby increasing the adhesive force in the hot press in the next step. The bonding time can be shortened. Low melting point synthetic fibers mixed in the fiber web are low melting point nylon, polyester, polypropylene,
Known fibers can be used, but the most practical one is a low melting point polyester fiber (PET fiber) having a low melting point (melting point around 110 ° C.).

FIG. 5 shows a case where a hot carpet is produced by using a press by a hot press as an application example of the above-mentioned nonwoven fabric composite material, 13 is an upper heating plate, 14 is a lower heating plate, and 15 is a hot plate. It is a spacer, and the gauge thickness of the spacer 15 is normally about 6 mm, which is formed to be about 0.5 to 1.0 mm narrower than the total thickness of the surface layer 11 and the back layer 11 ′. The heat wire 12 is bonded to the surface layer 11. It is fixed by the agent.

On the other hand, the non-woven fabric 1 described above is used for the back layer 11 ', and the web-like hot melt sheet 3 is temporarily laminated on the inner surface side thereof.

Therefore, when the upper heating plate 13 is lowered to the upper surface of the spacer 15 and stopped from the state shown in FIG. 5, the thickness of the spacer 15 is 6 mm, which is 0.5 to 1.0 mm narrower than the total thickness of the surface layer 11 and the back layer 11 '. Therefore, by the difference between the upper and lower heating plates 13 and 14, the surface layer 11 and the back layer 11 '
180 degrees from the upper surface of the surface layer 11 and the lower surface of the back layer 11 ', respectively.
It is heated at a temperature of ℃ and pressed at the same time. The pressing time is usually about 20 seconds, and by this hot pressing, the front layer 11 and the back layer 11 'are completely adhered by the web-shaped hot melt sheet 3 to obtain a hot carpet containing the heating wire 12.

Before the front layer 11 and the back layer 11 'are set in the press, if normal temperature water is sprayed from the upper surface of the front layer 11 at a rate of about 50 g / m ² in advance, it is sprayed by a hot press at 180 ° C. Due to the characteristics of the polyamide-based spider web-shaped hot melt sheet 3 that can be greatly effective by imparting moist heat to the surface layer, the room temperature water that has become water vapor permeates into the surface layer, and a large peeling strength can be obtained even by hot pressing for a short time. it can.

In particular, since the non-woven fabric 1 is fastened to one side and is temporarily laminated so that the surface of the web-like hot melt sheet 3 is free of fiber fluff, the hot-pressed web-like hot melt sheet is formed. Not hindered by fluff,
It has the effect that it can fully exert its adhesive ability.

Next, the adhesion data of the front and back layers of the hot carpet with the urethane resin and the adhesion data using the web-like hot melt sheet according to the present invention are shown in Table 1. Margin below

[0030]

[Table 1]

[0031]

INDUSTRIAL APPLICABILITY According to the present invention, as described above, the cobweb-shaped hot melt sheet is fastened by needling on-line in the needling process so that the fluff of the fiber layer is not on the surface of the cobweb-shaped hot melt sheet, or In the heat treatment step, the spider web hot melt sheet is melted so that it does not penetrate into the fiber layer and does not fluff on the surface of the hot melt sheet, and the spider web hot melt sheet is fused to the surface of the nonwoven fabric. There is no need to use a liquid adhesive as in the past, and when commercializing using this, a strong adhesive force can be obtained by simply hot pressing, improving the environment of the adhesive process and reducing the number of work steps, personnel It has a remarkable effect that can be saved.

Further, the present invention is superior to the conventional liquid adhesive,
Not only is the crimping time shortened, but it is also easy to handle because the web-shaped hot melt sheet is fastened so that it does not come off, and the fluff on the surface of the nonwoven fabric is suppressed by the hot melt sheet. Therefore, the wear resistance is also good.

Further, since the nonwoven fabric composite of the present invention is fastened to the spun web-like hot melt sheet by needling on-line in the process of producing the nonwoven fabric, the process is very simple and the productivity is high, and it is used in industries such as hot carpets. It is expected to be effective in various fields such as adhesion of materials and interior composite materials, interior materials, and construction materials.

[Brief description of drawings]

FIG. 1 is a schematic partial cross-sectional view showing an example of a nonwoven fabric composite material according to the present invention.

FIG. 2 is a schematic partial cross-sectional view showing an example of a nonwoven fabric composite material according to claim 2 of the present invention.

3 is a schematic view showing a manufacturing process of the nonwoven fabric composite material of FIG. 1. FIG.

FIG. 4 is a schematic view showing a part of the manufacturing process of the nonwoven fabric composite material of FIG. 2 (after the heating process).

FIG. 5 is an explanatory diagram showing a hot carpet production situation using the nonwoven fabric composite material of the present invention.

[Explanation of symbols]

 1,1 'Non-woven fabric 2 Raised part 3 Spider web hot melt sheet 4 Fused part 5,6,7 Needling

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[Procedure amendment]

[Submission date] March 20, 1995

[Procedure Amendment 1]

[Document name to be amended] Statement

[Name of item to be corrected] Claim 4

[Correction method] Change

[Correction content]

[Procedure Amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0006

[Correction method] Change

[Correction content]

[0006] Here, Des fluff the nonwoven fabric surface, the number implantation the focal hotmelt sheet spider so as not come off as a condition for fastened (temporarily bonded) (hereinafter, abbreviated as penetratin
20 to 35 / cm ² and a penetration depth of 10 to 12 mm are preferable. ─────────────────────────────────────────────────── ───

[Procedure amendment]

[Submission date] May 31, 1995

[Procedure Amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0001

[Correction method] Change

[Correction content]

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a non-woven composite material, especially for hot carpets and hot mats or for automobiles and ships.
The present invention relates to a composite material of a non-woven fabric and a hot-melt sheet, which is advantageous for the production of decoration materials, interior composite materials, industrial materials and the like.

[Procedure Amendment 2]

[Document name to be amended] Statement

[Name of item to be corrected] 0002

[Correction method] Change

[Correction content]

[0002]

2. Description of the Related Art Conventionally, in the production of hot carpets and hot mats, a heating wire and a detection wire are wrapped as a unit with a non-woven fabric, and a liquid adhesive such as urethane resin is sprayed on the front and back layers by a spray or the like. It has been practiced to sandwich the wrapped heat generating unit between the front and back layers and to bond the heat generating unit from above and below by hot pressing. Also, interior materials for automobiles and ships
, Backing by foaming or spraying
To prevent wear, and then liquid bond to the bond
Apply the agent, etc. and bond them with a calendar or heat-bonding device.
It was glued.

[Procedure 3]

[Document name to be amended] Statement

[Correction target item name] 0008

[Correction method] Change

[Correction content]

[0008]

[Function] The nonwoven fabric composite material according to the present invention is a hot carpet.
When used as a hot mat or a hot mat, this is used as the front layer and / or the back layer, and a heat wire or the like is sandwiched between the two layers with the side of the cobweb-shaped hot melt sheet as the inner surface, and both layers can be hot pressed. It is possible to easily bond a product without using a liquid adhesive as in the conventional case, and to produce a product in which various members such as a heat wire are internally provided in an extremely simple and short-time operation.

[Procedure amendment 4]

[Document name to be amended] Statement

[Correction target item name] 0009

[Correction method] Change

[Correction content]

Further, the nonwoven fabric composite material according to the present invention is used for automobiles.
When used for the interior of a ship or ship, the hot-melt sheet improves wear resistance and facilitates handling and facilitates the work of installing interior materials.

[Procedure Amendment 5]

[Document name to be amended] Statement

[Name of item to be corrected] 0015

[Correction method] Change

[Correction content]

The cobweb-shaped hot melt sheet 3 is usually
The basis weight is 20 to 70 g / m ² , preferably 20 to 40 g / m ² .
It is a thin non-woven fabric of m ² position and has a web structure, and has a melting point of about 120 ° C. and is generally made of a modified polyester fiber (modified PET).

[Procedure correction 6]

[Document name to be amended] Statement

[Correction target item name] 0018

[Correction method] Delete

[Procedure Amendment 7]

[Document name to be amended] Statement

[Correction target item name] 0019

[Correction method] Delete

[Procedure Amendment 8]

[Document name to be amended] Statement

[Correction target item name] 0033

[Correction method] Change

[Correction content]

Further, since the nonwoven fabric composite of the present invention is fastened to the spun web-like hot melt sheet by needling on-line in the process of producing the nonwoven fabric, the process is very simple and the productivity is high, and it is used in industries such as hot carpets. It is expected to be effective in various fields such as adhesion of materials and interior composite materials, automobiles, interior materials for ships, and building materials.

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Claims (5)

[Claims] 1. A non-woven fabric obtained by subjecting a fibrous web containing synthetic fibers as a main component to needling, and a cobweb-shaped hot melt sheet laminated on one surface thereof. The cobweb-shaped hot melt sheet is a need. A non-woven fabric composite material, which is fastened to one surface of the non-woven fabric by a ring and holds down fluff on the surface of the non-woven fabric. 2. A spun web-shaped hot melt sheet is laminated on one surface of a non-woven fabric obtained by subjecting a fiber web containing synthetic fibers as a main component and partially containing a low melting point synthetic fiber to needling, and the above is formed by needling. Composed of a non-woven fabric composite material fixed to the surface of the non-woven fabric and pressing down the surface fluff, at least a part of the low melting point synthetic fiber is melted by heating, and the constituent fibers are fused together, and a cobweb hot melt Without the sheet completely melting and penetrating into the non-woven fibers,
A non-woven fabric composite material, which is fused to the surface of the non-woven fabric. 3. In a process for producing a nonwoven fabric by needling a fiber web containing synthetic fibers as a main component, a web-like hot melt sheet is joined to the fiber web at an appropriate position during the needling step, A method for producing a non-woven fabric composite material, characterized in that a cobweb-shaped hot melt sheet, which is polymerized and simultaneously subjected to needling, is fastened to the surface of the non-woven fabric so as not to come off, and fluff on the surface is pressed. 4. A web of sponge-like hot melt sheet is polymerized on a fibrous web to obtain 20 to 35 penes per cm ² and a penetration depth of 1
The method for producing a nonwoven fabric composite material according to claim 3, wherein the needling is performed at 0 to 12 mm. 5. A needling is applied to a fiber web made of synthetic fibers including a low melting point synthetic fiber, and one side of the web is laminated with a spider web-shaped hot melt sheet and further fixed by the needling. Low melting point synthetic fibers and spider webs that hold down fluff are heated at a temperature higher than the melting point of the hot melt sheet to melt and fuse a part of the low melting point synthetic fibers in the non-woven fabric and at the same time spider webs. A process for producing a non-woven composite material, which comprises fusing a hot-melt sheet to the surface of a non-woven fabric so that the hot-melt sheet does not completely melt and penetrate into the non-woven fabric fibers.