JPH08188946A - Formed article of fiber and its production - Google Patents

Abstract

PURPOSE: To obtain a formed article of fiber excellent in shape fixability, having soft feeling, low in residual compression strain, little in yielding of bulkiness, resistant to stuffiness because of large air and moisture permeability and comfortable in use. CONSTITUTION: This formed article of fiber is composed of at least two kinds of fibers. One of the constituting fibers is a conjugate fiber containing a thermoplastic polymer R1 having a lower melting point than the other constituting fiber as a sheath part and a thermoplastic polymer R2 having a higher melting point than the polymer R1 as a core part and the weight ratio expressed by R1/R2 is in the range of 20/80 to 60/40. The formed article of fiber contains the conjugate fiber in the range of 20-60wt.%. At least a part of the contacting points between the conjugate fiber themselves and the conjugate fiber with the other constituting fiber is bonded. Further, the surfaces of the constituting fibers are treated with a polyester resin. This formed article of fiber is advantageous as follows: excellent in multidirectional cutting ability; having improved workability on the production of the formed article of fiber because of the ability to easily form the article matching to the application; and accordingly reduced in a production cost. And, the formed article of fiber has flame retardancy and useful for a flame retardancy-required application.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber molding and a method for manufacturing the fiber molding.

More specifically, vehicle seat materials used in trains and automobiles, pad materials, door trims, sun visors, bedding bed materials, mattresses, kotatsu, furniture sofas, cushions, clothing pads, etc. The present invention relates to a fiber molded body that is preferably used as a cushioning material or a shielding material such as a filter, sound insulation for a house, and a heat insulating material, and a method for manufacturing the fiber molded body.

[0003]

2. Description of the Related Art Conventionally, as a cushion material, a resin foam such as polyurethane, Japanese Patent Publication No. 62-2155, Japanese Patent Publication No. 1-18183, and Japanese Patent Publication No. 4-334 are generally used.
No. 78, JP-A-3-140185, etc., a low melting point fiber is used as the thermally adhesive fiber, or a high melting point thermoplastic resin is used as a core portion and a low melting point thermoplastic resin is used as a sheath portion. It has been proposed to use a bicomponent fiber having a core-sheath structure.

[0004]

However, since the cushioning material of these resin foams is inferior in breathability and moisture permeability and inferior in hygroscopicity, it is easy to get stuffy, and the sheet is installed in a place exposed to water or water splashes. When used for etc., water collects,
There is a problem in that the seat is corroded or water leaks out when the seat is seated, which makes the user uncomfortable.

Further, a cushioning material using a fiber having a low melting point has not been disclosed, although it is soft and hard to sag, and has excellent flame retardancy.

An object of the present invention is to provide a fiber molded body and a method for producing the fiber molded body which solve the above problems.

[0007]

The fiber molded article of the present invention comprises:
In order to solve the above-mentioned subject, it has the following composition. That is, a fiber molded product composed of at least two kinds of fibers, one kind of constituent fibers having a thermoplastic polymer R1 having a lower melting point than other fibers as a sheath portion, and a thermoplastic polymer having a higher melting point than R1. The weight ratio of R2 represented by R1 / R2 is 20 /
A composite fiber that is composited as a core in the range of 80 to 60/40, containing 20 to 60% by weight of the composite fiber, and at least part of contact points between the composite fibers and between the composite fiber and other fibers. Is bonded, and a polyester resin is applied to the surfaces of the constituent fibers, which is a fiber molding.

Further, the method for producing a fiber molding of the present invention has the following constitution.

That is, using at least two kinds of fibers,
One of the constituent fibers has a thermoplastic polymer R1 having a lower melting point than other fibers as a sheath portion, and a thermoplastic polymer R2 having a higher melting point than R1 has a weight ratio represented by R1 / R2 of 20/80 to 60.
The composite fibers are composited as a core in the range of / 40, and the composite fibers are mixed with 20 to 60% by weight, opened, and laminated in a sheet shape after heat treatment molding, or the constituent fibers are gas. At the same time, a method for producing a fiber molded body is characterized in that after the material which is blown into and filled in the air-permeable mold is heat-treated and molded, a polyester resin is applied and further heat-treated to fix it.

Hereinafter, the present invention will be described in detail.

The fiber molding of the present invention is composed of at least two kinds of conjugate fibers and fibers, and the fiber molding is such that at least a part of contact points between the conjugate fibers and between the conjugate fibers is adhered. It is formed and polyester resin is applied to the surface of the constituent fibers. The composite fiber used in the fiber molded body of the present invention has a thermoplastic polymer R1 having a lower melting point than other fibers as a sheath portion, and a thermoplastic polymer R having a higher melting point than R1.
2 is a composite of the core.

Examples of the thermoplastic polymer R1 include polyolefins such as polyethylene, polypropylene, ethylene propylene copolymer, ethylene butene copolymer, ethylene vinyl acetate copolymer and olefin copolymers, polyhexamethylene terephthalate, poly At least one polymer selected from thermoplastic polymers such as polyesters such as hexamethylene butylene terephthalate and polyhexamethylene terephthalate isophthalate or copolymerized polyesters can be mentioned. In selecting the thermoplastic polymer R1, the melting point of R1 is lower than the melting points of the thermoplastic polymer R2 and other fibers.

From the viewpoint of thermal adhesiveness, the melting point of R1 is preferably 20 ° C. or more, more preferably 25 ° C. or more lower than the lower melting point of other fibers or R2.

From the viewpoint of improving the recoverability against compression, improving the effect of adhesiveness and preventing thermal deterioration, the melting point of R1 is preferably in the range of 80 to 170 ° C., 100
More preferably, it is included in the range of ˜170 ° C.

The thermoplastic polymer R2 is not particularly limited, but for example, terephthalic acid, 2,6-naphthalenedicarboxylic acid or their ester is a main dicarboxylic acid component, and ethylene glycol or tetramethylene glycol is a main glycol component. Examples thereof include polyethylene terephthalate, polybutylene terephthalate, and polyester such as polyethylene-2,6-naphthalate.

In the present invention, the weight ratio represented by R1 / R2 of the thermoplastic polymers R1 and R2 is 20/80 to 60/40.
It is assumed that. From the viewpoint of imparting thermal adhesiveness and softness to the fiber molded body, preferably 20/80 to 50/50
Range.

If the weight of the thermoplastic polymer R1 is less than 20% in the composite fiber, there is a problem in that the thermal adhesiveness between the fibers cannot be sufficiently obtained, and the morphological fixability of the produced fiber molding is deteriorated. .

On the other hand, if the weight of R1 exceeds 60% in the composite fiber, the softness of the fiber molding becomes poor,
There is a problem that the compressive residual strain also increases.

In addition to the polymer components other than R1 and R2, pigments such as titanium oxide and carbon black, the composite fiber may further contain an antioxidant, a coloring preventing agent, a light resistance agent, an antistatic agent, if necessary. Etc. can be added. Such a conjugate fiber can be produced by a usual conjugate spinning method.

Next, in order to impart bulkiness and a soft feeling to the fiber molding of the present invention and improve the recovery property against compression,
The composite fiber preferably has a mechanical crimp or the like.

The number of crimps may be appropriately selected depending on the use of the fiber molding, but the number of crimps is at least 3 peaks / 25 m.
The degree of crimp is preferably at least 5% when m, and more preferably the number of crimps is at least 5 peaks / 25 mm and the degree of crimp is at least 15%. From the viewpoints of bulkiness and softness, short fibers having a fineness of 1 to 10 denier and a fiber length of 10 to 100 mm are preferably used as the composite fibers.

Next, other fibers used in the fiber molding of the present invention will be described.

Other fibers have a melting point of the thermoplastic polymer R1.
Is higher than the melting point of.

From the viewpoint of thermal adhesiveness, it is preferably 20 ° C. or higher, and more preferably 25 ° C. or higher. What is used as another fiber is not particularly limited. For example, polyester, nylon-6, nylon-6,6,
Nylon-6,10, Nylon-10,9, Nylon-
Examples thereof include polyamides such as 11, and nylon-12.

Next, in order to impart bulkiness and softness to the fiber molded article of the present invention and improve the recovery property against compression,
It is preferred that the other fibers have mechanical crimps or the like.

The number of crimps may be appropriately selected depending on the use of the fiber molding, but the number of crimps is at least 3 peaks / 25 m.
It is preferable that the crimping degree is at least 5% in m.

More preferably, the number of crimps is at least 5 peaks / 25 mm and the crimping degree is at least 15%.

As the other fibers, short fibers having a fineness of 0.5 to 30 denier and a fiber length of 10 to 100 mm are preferably used from the viewpoint of imparting morphological fixability and softness to the fiber molding.

The fiber molding of the present invention contains the above-mentioned composite fiber in an amount of 20 to 60% by weight. If the content of the composite fibers is less than 20% by weight, there is a problem that the number of thermal bonding points between the composite fibers and between the composite fibers and the other fibers is reduced, and the shape fixing property is deteriorated.

On the other hand, if it exceeds 60% by weight, the softness of the fiber molded article is deteriorated, and the tactile feel becomes coarse and hard.

The fiber molding of the present invention comprises a polyester resin provided on the surfaces of the constituent fibers.

By the addition of the polyester resin, the smoothness between the constituent fibers is enhanced, and the fibers are soft and hard to set, and at the same time, it is possible to prevent the deterioration of the compression recovery property due to the sticking which is a problem when the use environment is high temperature.

The polyester resin used in the present invention is not particularly limited as long as it can improve smoothness and prevent sticking, but from the viewpoint of temperature stability and uniform application to constituent fibers, polyethylene is added to polyester. Those which block-polymerize glycol and have self-emulsifying property are preferably used.

Next, the method for producing the fiber molding of the present invention will be described below.

In the method for producing a fiber molded body of the present invention, the above-mentioned composite fiber and other fibers are used.

First, the fiber mixture containing 20 to 60% by weight of the above-mentioned composite fiber is thoroughly mixed and opened by a cotton feeding machine, a cotton mixing machine, a fiber opening machine and the like used in a usual spinning process,
A product obtained by blowing and filling a sheet-like laminated product or a fiber mixture into a breathable form with cotton is heat-treated.

Next, the polyester resin is applied to the heat-treated product, and further heat-treated to fix the polyester resin. By imparting this polyester resin, it is expected that the smoothness between the constituent fibers will be enhanced, the fibers will be soft and hard to set, and at the same time, the action of preventing sticking at the fiber contact point in a high temperature environment can be expected.

As a preferable concrete processing method, for example, there is a method in which a fiber mixture is blown and filled in a mold having a shape suitable for the purpose together with a gas such as an air flow from a cotton feeding fan. In order to blow and fill, it is necessary that the formwork has an appropriate air permeability. For example, JIS
L 1079-1966 When measured with a Frazier type breathability tester, the breathability is 5 to 200 cc /
The range of cm ² · sec is preferable. As such a mold, for example, the molds 4 and 5 using the punching metal plate shown in FIG. 1 can be used. The fibers blown into the air-permeable mold are vertically, horizontally and randomly arranged in the thickness direction.

Next, it is preferable to compress to a suitable density according to the intended use of the fiber molding to be obtained.
For example, the density is preferably 0.01 to 0.1 g / cm ³ from the viewpoint of obtaining a fiber molded body having excellent softness. It is more preferably 0.015 to 0.095 g / cm ³ .

The compacted filling can be heat treated to bond at least some of the points of contact between the composite fibers and between the composite fibers and other fibers to fix the morphology. The heat treatment temperature may be a temperature at which R1 of the composite fiber melts and adheres, and generally 80 to 200 ° C. is preferable.

After the heat treatment, the polyester resin is applied to the fiber molding and heat-treated to fix it. It can be expected that the addition of the polyester-based resin enhances the smoothness between the constituent fibers to make it soft and hard to set, and at the same time, to prevent sticking at the fiber contact point and impart flame retardancy.

The applied amount of the polyester resin is expressed by the applied amount per unit fiber weight, and will be referred to as% owf hereinafter. From the viewpoints of preventing sticking, imparting smoothness and economy, it is preferable to deposit the polyester resin in an amount of about 0.1 to 2% owf.

Generally, the temperature of the heat treatment for fixing the polyester resin to the constituent fibers is preferably 80 to 200 ° C. from the viewpoint of heat deterioration of the constituent fibers.

The heat treatment time can be appropriately selected depending on the density of the fiber molded body and the like.

[0045]

EXAMPLES The present invention will be described in more detail with reference to Examples and Comparative Examples. The measuring methods of various characteristics described in the present invention are as follows.

[Number of Crimps and Degree of Crimp] The number of crimps and the degree of crimp are JIS L 1015-7-12-1 and JIS.
It measured according to the method of L1015-7-12-2.

[Intrinsic Viscosity] It was measured in an o-chlorophenol solution at 25 ° C. according to a conventional method.

[Fineness] JIS L 1015-7-51
It measured according to the method of A.

[Average Fiber Length (Cut Length)] JIS L
It was measured according to the 1015A method (staple diagram method). [Compressive residual strain] Square with one side of 100 mm, thickness 100
mm test piece was compressed by 50% in the thickness direction, and
After being treated in a constant temperature bath at a temperature of 0 ± 1 ° C. for 22 hours, it was decompressed and left at room temperature for 30 minutes. After that, the thickness (t ₁ m
m) was measured, and the compression residual strain was determined by the following formula.

Compressive residual strain (%) = [(100-t ₁ ) /
100] × 100 [Morphability / Softness] The texture was classified into 6 grades from excellent (⊚) to unacceptable (×).

[Multidirectional cutting property] The test pieces were classified into 6 grades from excellent (⊚) to unacceptable (x) depending on the ease of cutting when cutting in arbitrary directions.

[Flame Retardancy] The flame retardance was measured according to the method of the combustion test chamber of the Japan Railway Vehicle Machinery Association.

Example 1 Polyethylene terephthalate polyester copolymerized with 40 mol% of isophthalic acid having an intrinsic viscosity of 0.55 and a melting point of 110 ° C. was used as the thermoplastic polymer R1, and as the thermoplastic polymer R2, the limit was used. Using ordinary polyethylene terephthalate having a viscosity of 0.65 and a melting point of 255 ° C., a spinning temperature of 285 ° C., a spinneret hole number of 24 holes, a take-up speed of 1350 m / min, and a discharge rate of 3
6.22 g / min, the weight ratio R1 / R2 is 20/80,
A core-sheath composite fiber having R1 as a sheath and R2 as a core was spun.

Next, the unstretched yarns were combined to obtain a tow denier of 100,000 denier after stretching, stretched at a stretch ratio of 3.0 times, a stretching bath temperature of 80 ° C., and mechanical crimped by a crimper. Furthermore, after drying with a heat setter at 70 ° C, a finishing oil agent is applied and cut into a cut length of 32 mm, a fineness of 3.9 denier and a melting point of the surface layer of about 110 ° C.
A composite fiber of

Separately from this, polyethylene terephthalate having an intrinsic viscosity of 0.65 and a melting point of 255 ° C. was used, and after ordinary spinning and drawing, a cut length of 32 mm and a fineness of about 1
A 3.1 denier hollow (hollow ratio 38%) round cross-section fiber was obtained.

40% of the obtained fiber was added to the composite fiber in a weight ratio.
%, Other fibers were mixed at 60% and further mixed and opened with a roller card to obtain a fiber mixture. This fiber mixture is punched on each side from a blow port 3 of the die, and a lower die 1 having an inner surface width × length of 500 × 500 mm.
It was blown in with the air flow. By compressing the fiber mixture 4 blown by the upper die 2 having punched surfaces,
It was compressed and fixed to a thickness of 100 mm and a density of 0.041 g / cm ³ . The fiber mixture 4 compressed and fixed in the mold is steamed with a heat setter used for setting the spun yarn.
Heat setting was performed at 0 ° C. for 20 minutes to obtain a fiber molded body. Further, the fiber molded body was dipped in a solution of a commercially available polyester resin (SR1800 manufactured by Takamatsu Oil & Fat Co., Ltd.), centrifugally dehydrated, and then heat-treated at 140 ° C. for 30 minutes using a dry heat setter to be fixed. The adhesion amount of the polyester resin was 0.8% owf in all cases.

This fiber molding has a shape-fixing property, softness,
Excellent recovery from compression and multidirectional cutting, and
The flame retardancy was shown by the evaluation method of the Japan Railway Vehicle Machinery Association.

Table 1 shows the properties of the composite fiber and other fibers constituting the fiber molded body.

[0059]

[Table 1] Table 2 shows the characteristics of the fiber molded body.

[0060]

[Table 2] [Example 2] R1 and R2 used were the same as in Example 1, and a composite fiber represented by R1 / R2 with a weight ratio of 50/50 was obtained in the same manner as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 40.
% And other fibers to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.041 g / cm ³ .

This fiber molding has a shape-fixing property, softness,
Excellent recovery from compression and multidirectional cutting, and
The flame retardancy was shown by the evaluation method of the Japan Railway Vehicle Machinery Association.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the properties of the fiber molding.

[Example 3] R1 to R2 used are the same as in Example 1, and the weight ratio represented by R1 / R2 is 6
A 0/40 composite fiber was obtained in the same manner as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 40.
% And other fibers to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.040 g / cm ³ .

This fiber molding has a shape-fixing property, softness,
Excellent recovery from compression and multidirectional cutting, and
The flame retardancy was shown by the evaluation method of the Japan Railway Vehicle Machinery Association.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Example 4] R1 and R2 used are the same as those in Example 1, and the weight ratio represented by R1 / R2 is 5
A 0/50 composite fiber was obtained in the same manner as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was mixed with the composite fiber in a weight ratio of 20
%, Other fibers were compressed to 80% by the same method as in Example 1 to obtain a fiber molded body having a packing density of 0.041 g / cm ³ .

This fiber molding has a shape-fixing property, softness,
Excellent recovery from compression and multidirectional cutting, and
The flame retardancy was shown by the evaluation method of the Japan Railway Vehicle Machinery Association.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Embodiment 5] R1 to R2 used are the same as in Embodiment 1, and the weight ratio represented by R1 / R2 is 5
A 0/50 composite fiber was obtained in the same manner as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was mixed with the composite fiber in a weight ratio of 60.
%, Other fibers were compressed to 40% by the same method as in Example 1 to obtain a fiber molded body having a packing density of 0.041 g / cm ³ .

This fiber molding has a shape-fixing property, softness,
Excellent recovery from compression and multidirectional cutting, and
The flame retardancy was shown by the evaluation method of the Japan Railway Vehicle Machinery Association.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Embodiment 6] R1 and R2 used are the same as in Embodiment 1, and the weight ratio represented by R1 / R2 is 5
A 0/50 composite fiber was obtained in the same manner as in Example 1.

The other fibers were the same as in Example 1.

The resulting fiber was added to the composite fiber in a weight ratio of 40.
% And other fibers to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.012 g / cm ³ .

This fiber molding has a shape-fixing property, softness,
Excellent recovery from compression and multidirectional cutting, and
The flame retardancy was shown by the evaluation method of the Japan Railway Vehicle Machinery Association.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Example 7] R1 to R2 used are the same as in Example 1, and the weight ratio represented by R1 / R2 is 5
A 0/50 composite fiber was obtained in the same manner as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 40.
%, Other fibers were compressed to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.021 g / cm ³ .

This fiber molding has a shape-fixing property, softness,
Excellent recovery from compression and multidirectional cutting, and
The flame retardancy was shown by the evaluation method of the Japan Railway Vehicle Machinery Association.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Embodiment 8] R1 to R2 used are the same as in Embodiment 1, and the weight ratio represented by R1 / R2 is 5
A 0/50 composite fiber was obtained in the same manner as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 40.
% And other fibers to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.051 g / cm ³ .

This fiber molding has a shape-fixing property, softness,
Excellent recovery from compression and multidirectional cutting, and
The flame retardancy was shown by the evaluation method of the Japan Railway Vehicle Machinery Association.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Embodiment 9] R1 to R2 used are the same as in Embodiment 1, and the weight ratio represented by R1 / R2 is 5
A 0/50 composite fiber was obtained in the same manner as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 40.
%, And other fibers were compressed to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.078 g / cm ³ .

This fiber molding has a shape-fixing property, softness,
Excellent recovery from compression and multidirectional cutting, and
The flame retardancy was shown by the evaluation method of the Japan Railway Vehicle Machinery Association.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Example 10] R1 and R2 used were the same as in Example 1, and a composite fiber represented by R1 / R2 with a weight ratio of 50/50 was obtained in the same manner as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 40.
%, And other fibers were compressed to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.099 g / cm ³ .

This fiber molding has a shape-fixing property, softness,
Excellent recovery from compression and multidirectional cutting, and
The flame retardancy was shown by the evaluation method of the Japan Railway Vehicle Machinery Association.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Example 11] R1 and R2 used were the same as in Example 1, and a composite fiber represented by R1 / R2 and having a weight ratio of 50/50 was obtained by the same method as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 40.
%, Other fibers were compressed to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.042 g / cm ³ and a polyester resin adhesion amount of 0.1% owf.

This fiber molding has a shape-fixing property, softness,
Excellent recovery from compression and multidirectional cutting, and
The flame retardancy was shown by the evaluation method of the Japan Railway Vehicle Machinery Association.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Example 12] R1 and R2 used were the same as in Example 1, and a composite fiber represented by R1 / R2 and having a weight ratio of 50/50 was obtained by the same method as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 40.
%, Other fibers were compressed to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.041 g / cm ³ and a polyester resin adhesion amount of 0.4% owf.

This fiber molding has a shape-fixing property, softness,
Excellent recovery from compression and multidirectional cutting, and
The flame retardancy was shown by the evaluation method of the Japan Railway Vehicle Machinery Association.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber moldings.

[Example 13] R1 to R2 used were the same as in Example 1, and a composite fiber represented by R1 / R2 with a weight ratio of 50/50 was obtained in the same manner as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 40.
%, Other fibers were compressed to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.042 g / cm ³ and a polyester resin adhesion amount of 2.1% owf.

This fiber molding has a shape-fixing property, softness,
Excellent recovery from compression and multidirectional cutting, and
The flame retardancy was shown by the evaluation method of the Japan Railway Vehicle Machinery Association.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Example 14] R1 and R2 used were the same as in Example 1, and a composite fiber represented by R1 / R2 with a weight ratio of 50/50 was obtained by the same method as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 40.
%, Other fibers were compressed to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.040 g / cm ³ and a polyester resin adhesion amount of 2.5% owf.

This fiber molding has a shape-fixing property, softness,
Excellent recovery from compression and multidirectional cutting, and
The flame retardancy was shown by the evaluation method of the Japan Railway Vehicle Machinery Association.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Example 15] R1 and R2 used were the same as in Example 1, and a composite fiber represented by R1 / R2 and having a weight ratio of 50/50 was obtained by the same method as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 40.
%, Other fibers were compressed to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.040 g / cm ³ and a polyester resin adhesion amount of 0.05% owf.

This fiber molded article was excellent in shape fixing property, softness and multidirectional cutting property, and exhibited flame retardancy by the evaluation method of Japan Railway Vehicle Machinery Association.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Example 16] R1 and R2 used were the same as in Example 1, and a composite fiber represented by R1 / R2 and having a weight ratio of 50/50 was obtained by the same method as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 40.
%, Other fibers were compressed to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.008 g / cm ³ and a polyester resin adhesion amount of 0.8% owf.

This fiber molding has a shape-fixing property, softness,
Excellent recovery from compression and multidirectional cutting, and
The flame retardancy was shown by the evaluation method of the Japan Railway Vehicle Machinery Association.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Example 17] R1 and R2 used were the same as in Example 1, and a composite fiber represented by R1 / R2 and having a weight ratio of 50/50 was obtained by the same method as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 40.
%, Other fibers were compressed to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.012 g / cm ³ and a polyester resin adhesion amount of 0.8% owf.

This fiber molding has a shape-fixing property, softness,
Excellent recovery from compression and multidirectional cutting, and
The flame retardancy was shown by the evaluation method of the Japan Railway Vehicle Machinery Association.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber moldings.

[Comparative Example 1] R1 to R2 used were the same as in Example 1, and the weight ratio represented by R1 / R2 was 1.
0/90 composite fiber was obtained in the same manner as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 40.
%, Other fibers were compressed to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.041 g / cm ³ and a polyester resin adhesion amount of 0.8% owf.

Since the weight ratio of R1 constituting the sheath portion of the composite fiber was less than 20%, the shape fixability was poor.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Comparative Example 2] R1 and R2 used were the same as in Example 1, and the weight ratio represented by R1 / R2 was 7
0/30 composite fiber was obtained in the same manner as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 40.
%, Other fibers were compressed to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.042 g / cm ³ and a polyester resin adhesion amount of 0.8% owf.

Since the weight ratio of R1 constituting the sheath portion of the composite fiber exceeded 60%, the softness was poor.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Comparative Example 3] R1 and R2 used are the same as in Example 1, and the weight ratio represented by R1 / R2 is 5
A 0/50 composite fiber was obtained in the same manner as in Example 1.

The other fibers were the same as in Example 1.

The obtained fibers were mixed in a ratio of 10 to 10 by weight.
%, Other fibers were compressed to 90% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.040 g / cm ³ and a polyester resin adhesion amount of 0.8% owf.

Since the mixing ratio of the composite fiber was less than 20%, the shape fixability by heat adhesion was poor, and the multidirectional cutting property was also poor.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Comparative Example 4] R1 and R2 used were the same as in Example 1, and the weight ratio represented by R1 / R2 was 5
A 0/50 composite fiber was obtained in the same manner as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 70
%, Other fibers were compressed to 30% by the same method as in Example 1 to obtain a fiber molded product having a packing density of 0.042 g / cm ³ and a polyester resin adhesion amount of 0.8% owf.

Since the blending ratio of the composite fiber exceeded 60%, the softness was poor. Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[Comparative Example 5] The R1 and R2 used were the same as in Example 1, and the weight ratio represented by R1 / R2 was 5.
A 0/50 composite fiber was obtained in the same manner as in Example 1.

The other fibers were the same as in Example 1.

The obtained fiber was added to the composite fiber in a weight ratio of 40.
%, Other fibers were compressed to 60% by the same method as in Example 1 to obtain a fiber molding having a packing density of 0.040 g / cm ³ and a polyester resin adhesion amount of 0% owf.

Since the polyester resin was not attached, the residual compression strain was large and the softness was poor.

Table 1 also shows the properties of the composite fiber and other fibers constituting the fiber molded body.

Table 2 also shows the characteristics of the fiber molding.

[0185]

According to the present invention, the shape fixing property is good,
In addition, it is soft, has a low residual compression strain, has little bulkiness, and has high breathability and moisture permeability. Further, since it has excellent multidirectional cutting properties and can be easily molded according to the purpose of use, it has the advantages that workability is improved and the manufacturing cost is reduced when manufacturing the fiber molded body.

Further, it has flame retardancy and can be suitably used for applications requiring flame retardancy.

[Brief description of drawings]

FIG. 1 is a schematic perspective view showing an example of a mold used in the method for producing a fiber molded body of the present invention.

FIG. 2 is a schematic vertical cross-sectional view showing an example of a mold used in the method for producing a fiber molded body of the present invention.

[Explanation of symbols]

 1: Lower mold 2: Upper mold 3: Gas blowing port 4: Fiber mixture

Claims (4)

[Claims] 1. A fiber molded article composed of at least two kinds of fibers, wherein one kind of constituent fibers has a thermoplastic polymer R1 whose melting point is lower than those of other fibers as a sheath portion, and has a higher melting point than R1. The weight ratio represented by R1 / R2 of the plastic polymer R2 is 2
It is a composite fiber composed as a core part in the range of 0/80 to 60/40, containing 20 to 60% by weight of the composite fiber, and at least contact points between the composite fibers and between the composite fibers and other fibers. A fiber molded product, characterized in that a part thereof is adhered and a polyester resin is applied to the surface of the constituent fibers. 2. The fiber molded product according to claim 1, wherein the polyester resin has self-emulsifying property. 3. The fiber molding according to claim 1, wherein the constituent fibers are all polyester. 4. A thermoplastic polymer R1 having at least two kinds of fibers, one of which is a constituent fiber having a melting point lower than those of other fibers as a sheath portion, and a thermoplastic polymer R2 having a melting point higher than R1 is R1.
/ R2 is a composite fiber that is compounded as a core in a weight ratio of 20/80 to 60/40, and the composite fiber is mixed with 20 to 60% by weight, opened, and laminated in a sheet form. After heat treatment molding of the above, or after heat treatment molding of the constituent fibers blown into the air-permeable mold together with gas, the polyester resin is added,
A method for producing a fiber molding, which comprises heat-treating and fixing.