JPH0782645A - Hot melt nonwoven fabric, core material for formation of ceiling and ceiling material - Google Patents

Abstract

PURPOSE:To produce a ceiling material covered with a surface material and excellent in touch, flexibility and design by putting nonwoven fabric having a hot melt layer laminated to one side thereof on a thermoformable core material composed of an inorganic fiber and a thermoplastic fiber or resin in layers and subsequently thermally forming it into a prescribed shape. CONSTITUTION:To one of the outsides of nonwoven fabric made of one or more kinds of natural and synthetic fibers, e.g. a polyester fiber, a thermoplastic fiber or resin layer having a melting point lower than that of the above-mentioned polyester fiber, e.g. a high-density polyethylene resin layer is laminated to prepare hot melt nonwoven fabric having a hot melt layer. On the other hand, an inorganic fiber such as glass fiber is blended with a high- density polyethylene fiber and the blended material is allowed to pass through cards to form a web. A needle punch treatment is applied to the resultant web to form a mat-shaped material and a high-density polyethylene film is subsequently laminated to each side thereof. A hot press treatment is then applied thereto using a flat press to obtain a thermoformable core material. After heating the hot melt layer of the hot melt nonwoven fabric, it is put on the above mentioned core material in layers and the resultant material is subsequently formed into a prescribed ceiling material shape, thus producing the objective ceiling material covered with a surface material.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a heat-adhesive non-woven fabric, a core material for ceiling molding, and a ceiling material used as a skin material for a ceiling material of buildings, vehicles, ships and the like.

[0002]

2. Description of the Related Art Ceiling materials for buildings, vehicles, ships, etc. are generally composed of a core material and a skin material. Conventionally, as a method of adhering the core material and the skin material, generally, an adhesive is applied to the surface of the core material and / or the back surface of the skin material and laminated and bonded, or the surface of the core material and the back surface of the skin material are laminated. A method has been adopted in which a sheet-like thermoactive substance is sandwiched between them and thermocompression-bonded to bond them.

However, in the former method, there is a problem that the step of coating and drying the adhesive is required, the step is complicated, and the working environment is polluted. In the latter case,
Due to the adhesion, it is necessary to separately provide a heating step for the core material and the skin material, and there is a problem that it is complicated.

Thus, for example, Japanese Patent Laid-Open No. 58-8735.
As described in Japanese Patent No. 3, a moldable non-woven fabric is proposed in which a mat obtained by needling two kinds of fibers having different melting points is heated to melt only the low melting point fibers and the mat is compressed. In Japanese Patent No. 31153, there is proposed a molding material in which a fibrous material is bound by an adhesive composed of two or more kinds of thermoplastic resins having different glass transition temperatures and incompatible with each other. Japanese Patent No. 71154 proposes an automobile ceiling interior material in which a polyester nonwoven fabric impregnated with a modified polystyrene resin is heat-sealed on both sides of a modified polystyrene resin foam, but both are core materials for interior materials. However, it cannot be used as a skin material excellent in texture, flexibility and design.

Further, in Japanese Patent Laid-Open No. 4-241159,
A heat-adhesive non-woven fabric made of heat-adhesive fibers using an ethylene copolymer as one component of a bicomponent fiber has been proposed. However, since this heat-adhesive non-woven fabric does not adhere to the core material via the adhesive layer, the adhesiveness to the core material made of different materials is not sufficient, and in order to increase the adhesive strength, Similar to the above-mentioned conventional technique, an adhesive is applied to the surface of the core material and / or the back surface of the heat-adhesive non-woven fabric to be laminated and laminated, or a sheet-like heat-activated material is applied between the surface of the core material and the back surface of the heat-adhesive non-woven fabric. It is necessary to sandwich objects by thermocompression bonding and stick them together, and again, it is necessary to apply and dry the adhesive, and for bonding, it is necessary to provide a separate heating step for the core material and the thermoadhesive non-woven fabric, which is complicated. There is a problem.

[0006]

DISCLOSURE OF THE INVENTION The present invention, in the step of adhering a skin material made of a non-woven fabric to one side of a core material, does not increase the number of working steps, does not pollute the working environment, and is inexpensive. In order to provide a heat-adhesive non-woven fabric capable of providing a skin material excellent in texture, flexibility, and designability, a core material for ceiling molding and a ceiling material using the heat-adhesive non-woven fabric. Is.

[0007]

Means for Solving the Problems The present invention is to provide a thermoplastic resin fiber having a melting temperature lower than that of the synthetic fiber or a heat activated resin on one outer side of a base layer made of at least one kind of natural fiber and synthetic fiber. A heat-adhesive non-woven fabric in which a heat-adhesive layer of resin is laminated.

In the present invention 1, the natural fibers forming the base layer include, for example, fibers made of cotton, wool, hemp, etc., and the synthetic fibers include, for example, fibers made of polyester, polyamide, polyureta and the like. To be These natural fibers and synthetic fibers may be used alone,
You may use 2 or more types together.

The base layer is composed of at least one of these natural fibers and synthetic fibers, and is appropriately formed into a nonwoven fabric having excellent surface performance such as flexibility, texture, and design, depending on the use of the skin material. ing. The basis weight of the base layer is 10 in order to exhibit the above-mentioned excellent surface performance as a skin material.
It is preferably 0 g / m ² or more.

In the present invention 1, a thermal adhesive layer is formed,
Examples of the thermoplastic resin fiber having a lower melting temperature than the synthetic fiber of the base layer include fibers made of polyethylene, polypropylene, polystyrene and the like, and as the thermoactive resin having a lower melting temperature than the synthetic fiber of the base layer, heat bonding Possible resins can be used, for example, polyamide-based copolymer, polyester-based copolymer, acid-modified polyethylene,
Examples thereof include acid-modified ethylene-vinyl acetate copolymer and the like.
These thermoplastic resin fibers and thermoactive resins may be used alone or in combination of two or more.

The form of the heat-adhesive layer may be, for example, film-like, mesh-like, dot-like or sea-island-like. As a method of laminating the heat-adhesive layer to the base layer, for example, when the form of the heat-adhesive layer is a film, various laminating methods typified by extrusion lamination, and when the form of the heat-adhesive layer is a mesh, When the spun bonding method and the heat-bonding layer have a dot-like or sea-island shape, a coating method such as spray coating or gravure printing can be used.

For the heat-bonding layer, it is necessary to appropriately select the type of material, layer thickness, etc., depending on the type, shape, etc. of the adherend (eg, thermoformable core material). That is, when the adherend has a uniform surface with no unevenness, the adherence with the adherend is an interface at the interface, and it is necessary to use a material having a high affinity with the adherend material. There is, when the adhesive surface of the adherend is porous, the adhesion form with the adherend is a structural adhesion due to the anchor effect that is exhibited by impregnating the material of the thermal adhesive layer layer inside the adherend, A material having a low melt viscosity at the time of heat bonding of the heat bonding layer, that is, a melt flow rate (JIS
A test temperature of 230 ° C. and a test load of 2.
A material composed of a resin having a mass g of the sample extruded in 10 minutes measured at 16 kgf) (hereinafter referred to as MFR) of 3 or more is preferably used.

The ceiling molding core material of the present invention 2 comprises a thermoformable core material formed by binding inorganic fibers with a thermoplastic resin fiber or a melt of a thermoplastic resin, the present invention being provided on the outside of the thermoformable core material. The core material for ceiling molding is characterized in that the heat-adhesive non-woven fabric is laminated so that the heat-adhesive layer faces the heat-adhesive layer.

In the core material for ceiling molding of the present invention 2, examples of the inorganic fiber forming the thermoformable core material include glass fiber and rock wool. The length of the inorganic fibers is preferably from 5 to 250 mm, more preferably from 50 to 150 mm, from the viewpoint of forming the base layer, and has a distribution of 70% by weight or more. Further, the thickness of the inorganic fiber is preferably 5 to 20 μm, more preferably 7 to 1 from the viewpoint of bending strength and thickness recoverability of the obtained thermoformed core material.
It is 3 μm.

The thermoplastic resin fiber is preferably a resin which is easily melted and bound to the glass fiber. Examples of such thermoplastic resin fibers include fibers made of resins such as polyethylene, polypropylene and polystyrene.
The length and thickness of the thermoplastic resin fiber are preferably such that the base layer can be easily formed by mixing with the inorganic fiber with good dispersibility.
Specifically, the length is preferably 5 to 200 mm, more preferably 20 to 100 mm. Thickness is 5-70 μm
Is preferable, and more preferably 15 to 40 μm.

It is preferable that the thermoplastic resin is easily impregnated between the inorganic fibers in a molten state and easily binds to the glass fibers. Examples of such a thermoplastic resin include thermoplastic resins such as polyethylene, polypropylene, polystyrene, ethylene-vinyl acetate copolymer, saturated polyester, and modified products thereof (for example, maleic anhydride-modified polyethylene).

The thermoformable core material according to the second aspect of the present invention is expanded in the thickness direction. The degree of expansion depends on the porosity of the base layer being 5
The range is preferably 0 to 99%. This allows
In the base layer, the inorganic fibers are bound to each other by the melt of the thermoplastic resin fibers and the thermoplastic resin at the intersections thereof,
In addition, it has a large void throughout.

In order to laminate the thermoadhesive nonwoven fabric on one side of the thermoformable core material, for example, the thermoadhesive layer of the thermoadhesive nonwoven fabric is heated to a temperature lower than the melting temperature of the synthetic fiber of the base layer, Thermoplastic resin fibers or heat-activatable resin are melted and laminated so that the heat-adhesive layer faces toward one outside of the thermoformable core material and then pressure-bonded, or heat-adhesive of heat-adhesive non-woven fabric Without heating the layers, laminate the thermoadhesive non-woven fabric on one side of the thermoformable core material so that the thermoadhesive layer faces the heat-adhesive layer, and then from above, to a temperature lower than the melting temperature of the synthetic fiber of the base layer. For example, a method of melting the thermoplastic resin fibers or the thermoactive resin and press-bonding them with a heated press is adopted.

The ceiling material of the present invention 3 is the ceiling material in which the core material for ceiling molding of the present invention 2 is shaped in the shape of the ceiling material.

In the ceiling material of the third aspect of the present invention, the method for shaping the ceiling molding core material into the shape of the ceiling material is appropriately selected so as to obtain the shape of the ceiling material of the target building, vehicle, ship or the like. A known method such as a press forming method, a vacuum forming method, or a pressure forming method can be used.

[0021]

The thermoformable non-woven fabric of the present invention 1 comprises a thermoplastic resin fiber or a thermoactive resin having a melting temperature lower than that of the synthetic fiber on the outer side of the base layer composed of at least one kind of natural fiber and synthetic fiber. Since the heat-adhesive layer is laminated, it is laminated on the outer side of the core material, and the thermoplastic resin fiber and the thermoactive resin are simply pressure-bonded in a molten state to give a texture on the outer side of the core material. A skin material having excellent flexibility and designability can be provided, and the skin material can be provided as an inexpensive material for forming a skin material without increasing the number of working steps and without contaminating the working environment.

The core material for ceiling molding according to the present invention 2 comprises a thermoformable core material comprising inorganic fibers bound by a thermoplastic resin fiber or a melt of a thermoplastic resin to the outside of the thermoformable core material. The heat-adhesive non-woven fabric is laminated so that the heat-adhesive layer faces the outer side, so that a skin material that has a good texture, flexibility and design on one side of the core material, and has a strong adhesive strength to the core material The formed ceiling material can be suitably used as a material by molding.

In the ceiling material of the present invention 3, the core material for ceiling molding of the present invention 2 is shaped in the shape of the ceiling material, so that the texture, flexibility, and design are provided outside the core material. Excellent skin material is formed with excellent adhesive strength,
It can be suitably used as a ceiling material for vehicles, ships and the like.

[0024]

EXAMPLES The present invention will be described below with reference to examples. To one outer side of the Example 1 basis weight 200 g / m ² made of a polyester fiber non-woven fabric, a high-density polyethylene resin [manufactured by Asahi Kasei Corporation,
A trade name "Suntech J-320", MFR12] layer was laminated by an extrusion laminating method to obtain a thermoformable nonwoven fabric in which a thermal adhesive layer was laminated on one side of the nonwoven fabric.

On the other hand, the length is 40 to 75 mm and the diameter is 9 μm.
Glass fiber and 6-denier, 50 mm cut high-density polyethylene fiber were blended in a weight ratio of 2: 1 and supplied to a card machine to be defibrated and mixed to obtain a cotton-like material. Next, the cotton-like material was needle punched at a density of 20 points / cm ² to obtain a mat-like material having a basis weight of about 500 g / m ² . Next, a high-density polyethylene resin (melting point: 135 ° C, MFR:
A thermoplastic resin film composed of 7) having a thickness of about 100 μm was laminated to obtain a laminated sheet having a thickness of about 7 mm and a weight of about 700 g / m ² .

The produced laminated sheet was sandwiched from both outer sides with a Teflon-coated glass cloth sheet,
It is supplied to a hot air heating furnace at 0 ° C and left for 5 minutes, then 200
It was transferred to a flat plate press heated to 0 ° C., compressed so that the thickness of the laminated sheet was 0.9 mm, and held for 5 seconds. Next, the flat sheet press is spread out so that the interval is about 7 mm, and the laminated sheet is sandwiched with the glass cloth sheet and transferred to a flat plate-shaped vacuum expanding device, and the glass sheet is moved from both sides by 0.5.
Suction was performed at a speed of mm / sec, the distance between the suction plates was expanded to 6 mm, the suction was released, the product was taken out and air-cooled for 3 minutes.
Next, peel off the glass cloth sheet to a thickness of about 5.5 m.
A flat thermoformable core material having a m and a weight of about 700 g / m ² was obtained.

The thermoadhesive layer of the thermoformable non-woven fabric is heated to 140 ° C. by an infrared heater and laminated so that the thermoadhesive layer faces one outside of the thermoformable core material. Then, transfer this to a flat plate press with a predetermined shape,
Compress it so that the interval becomes 4.0 mm, hold it for 10 seconds, shape the ceiling moldable core material, and at the same time bond the thermoformable non-woven fabric, take out the laminate from the flat plate press and attach the skin material. Got the ceiling material.

The obtained ceiling material with skin material has a texture composed of at least one kind of natural fiber and synthetic fiber,
A skin material excellent in flexibility and design was formed. or,
When the adhesive strength of the skin material of the obtained ceiling material with skin material was measured, it was confirmed that the skin material was broken and had sufficient adhesive strength.

Example 2 An acid-modified polyethylene resin (manufactured by Mitsubishi Kasei Co., Ltd., trade name "VOTATEC-AP, 281L", melt flow rate MFR 7.1) was formed on one side of a nonwoven fabric made of polyester fiber and having a basis weight of 200 g / m ^2. ) Roll the layer at 140 ° C
Was laminated by the heat lamination method so as to have a weight of 100 g / m ² to obtain a thermoformable nonwoven fabric.

The thermoadhesive layer of the thermoformable non-woven fabric is heated to 160 ° C. by an infrared heater and laminated so that the thermoadhesive layer faces one side of the thermoformable core material. Then, transfer this to a flat plate press with a predetermined shape,
Compress it so that the interval becomes 4.0 mm, hold it for 10 seconds, shape the ceiling moldable core material, and at the same time bond the thermoformable non-woven fabric, take out the laminate from the flat plate press and attach the skin material. Got the ceiling material.

The obtained ceiling material with skin material has a texture made of at least one kind of natural fiber and synthetic fiber,
A skin material excellent in flexibility and design was formed. or,
When the adhesive strength of the skin material of the obtained ceiling material with skin material was measured, it was confirmed that the skin material was broken and had sufficient adhesive strength.

Example 3 A non-woven fabric made of polyester fiber and having a basis weight of 200 g / m ² is provided on one side with a mesh sheet made of a polyamide copolymer (manufactured by Toyobo Co., Ltd. under the trade name "Dynac LNS-130".
0 ") was laminated by a heat laminating method at a roll temperature of 80 ° C. to obtain a thermoformable nonwoven fabric in which a thermal adhesive layer was laminated on one surface of the nonwoven fabric.

The heat-bonding layer of the obtained thermoformable non-woven fabric was heated at 140 ° C. with an infrared heater to give an average pore diameter of 150 μm.
m laminated on the surface of a porous wooden board having a large number of pores with the heat-adhesive layer facing toward 50 kg /
Press-pressing was applied at a pressure of m ² to obtain an interior material with a skin material.

On the surface of the obtained interior material with skin material, a skin material composed of at least one kind of natural fiber and synthetic fiber, which was excellent in texture, flexibility and design, was formed. Further, when the adhesive strength of the skin material of the obtained interior material with skin material was measured, it was confirmed that the skin material was broken and had sufficient adhesive strength.

COMPARATIVE EXAMPLE 1 Ethylene copolymer (15 parts by weight of methyl acrylate, 5 parts by weight of acrylic acid, 80 parts by weight of ethylene) was used as the first component, and polyethylene terephthalate was used as the second component.
The sheath-core type composite fiber was spun using the ratio of component / second component = 40/60 (weight ratio). Then, this was subjected to a roller card method to obtain a thermoformable nonwoven fabric having a basis weight of 200 g / cm ² .

Using the obtained thermoformable nonwoven fabric, a thermoformable core material similar to that of Example 1 was laminated under the same conditions as in Example 1 to try to produce a ceiling material with a skin material. When the skin material adhesive strength of the obtained ceiling material with skin material was measured,
The skin material was easily peeled off, and sufficient adhesive strength was not obtained.

[0037]

EFFECTS OF THE INVENTION The thermoformable non-woven fabric of the present invention 1 having the above-mentioned constitution is laminated on the outer side of the core material, and the thermoplastic resin fiber and the thermoactive resin are melted in a molten state. By simply crimping, a skin material excellent in texture, flexibility, and design can be provided on one side of the core material, which does not increase the number of work steps, does not pollute the work environment, and is inexpensive. It can be used as a material for forming a skin material.

Since the core material for ceiling molding of the present invention 2 has the above-mentioned constitution, the skin material excellent in texture, flexibility and design is excellent in adhesive strength to one side of the core material. Since it is formed in a closed state, it can be suitably used as a ceiling material for buildings, vehicles, ships and the like.

Since the ceiling material of the third aspect of the present invention is configured as described above, the skin material excellent in texture, flexibility, and design is provided on one side of the core material in a state of excellent adhesive strength. Since it is formed as described above, it can be suitably used as a ceiling material for buildings, vehicles, ships and the like.

Claims (3)

[Claims] 1. A thermoadhesive layer of a thermoplastic resin fiber or a thermoactive resin having a melting temperature lower than that of the synthetic fiber is laminated on one outside of a base layer made of at least one kind of natural fiber and synthetic fiber. A heat-adhesive non-woven fabric characterized by being 2. The thermoadhesive non-woven fabric according to claim 1 is provided outside the thermoformable core material comprising inorganic fibers bound by a thermoplastic resin fiber or a melt of a thermoplastic resin. A core material for a ceiling molding, characterized in that the core materials are laminated so as to face each other. 3. A ceiling material, wherein the ceiling molding core material according to claim 3 is shaped in the shape of a ceiling material.