JPH086237B2 - Hard cotton molding - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cotton molded product which is a substitute for a polyurethane cushion molded product and has a small morphological change.

[0002]

2. Description of the Related Art Conventionally, a laminated composite of a cloth-like material such as a non-woven fabric, a sheet of a woven or non-woven fabric of polybutylene terephthalate, and a plastic sheet is deep-drawn into a car seat or an automobile interior material. Is the real public 64-
No. 6,284, a high melting point fiber such as a polyester fiber and a low melting point melt adhesive fiber such as a core-sheath type composite fiber using a low melting point component having a melting point lower than that of a core by 30 ° C. or more are mixed, and formed into a spreader by needle processing. The hard felt-like cotton obtained by the entanglement treatment and the heat treatment is used as a cushion body of a bed or a seat or a base material for interiors. -1540
It is proposed in Japanese Patent Publication No. 50.

[0003]

SUMMARY OF THE INVENTION Conventionally proposed hard felt-like cotton beds, seat cushions or interior materials cannot obtain sufficient fiber density and are inferior in shape stability and compression characteristics. There is a problem that the elasticity of the body is small and buckling occurs even with slight bending. Further, even in the draw forming, it is impossible to obtain a product having a good curvature portion.

The present invention is to provide a cotton molded article which is a substitute for the polyurethane cushion molded article having a small change in shape and excellent in moldability.

[0005]

DISCLOSURE OF THE INVENTION The present invention comprises short fibers of crimped polyester hollow fibers having a single fineness of 6 to 80 denier and polyethylene terephthalate as a core component polymer,
A molded product of a fiber entangled body comprising short fibers of a polyester hollow core-sheath type composite fiber having a single fineness of 3 to 50 denier and a polyester having a melting point of 230 ° C. or less as a sheath component polymer. At least a part of the contact points is fused by the sheath component polymer of the core-sheath type composite fiber, the apparent density is 0.12 to 0.45 g / cm ³ , the thickness is 10 mm or more, and the load is 1.0 Kg / cm ^2. Compression rate of 20
% Or less, a cotton molded product.

The polyester hollow fiber constituting the cotton molded article of the present invention is, for example, a polymer selected from polyethylene terephthalate, polybutylene terephthalate, polyhexamethylene terephthalate, polyarylate, etc., in which 80 mol% or more is ethylene terephthalate. A polyester hollow fiber that has been spun, stretched, and mechanically crimped, or two types of polyesters having different thermal properties from the above-mentioned polymer are combined, and composite spinning is performed in a side-by-side type, followed by stretching, if necessary. Accordingly, it is a polyester hollow latent crimpable conjugate fiber obtained by mechanical crimping. The fineness and fiber cross-sectional shape of these polyester hollow fibers are determined depending on the desired application, but usually, the fineness is in the range of 6 to 80 denier and the hollow ratio of 7 to 25%. Square or multilobe hollow profile fibers are used.

Further, since the polyester hollow core-sheath type composite fiber is used as a thermal binder fiber, the sheath component polymer of the core-sheath type composite fiber is the melting point of the main fiber constituting the fiber entanglement and the core component polymer. At least 30 ° C above the melting point of
It is a polyester polymer having a low melting point, and generally, a copolyester having a melting point of 230 ° C. or less, for example, a structural unit of ethylene isophthalate, butylene isophthalate, hexamethylene terephthalate, or the like is 20 to 47.
A mol% ethylene terephthalate polyester or a low melting point polymer selected from polybutylene terephthalate, polypentamethylene terephthalate, polyhexamethylene terephthalate, polybutylene isophthalate and the like can be used. On the other hand, the core component polymer is preferably polyethylene terephthalate composed of 80 mol% or more of ethylene terephthalate.
Then, the core component polymer and the sheath component polymer can be spun, stretched, and mechanically crimped by a usual core-sheath composite spinning method to obtain a polyester hollow core-sheath composite fiber.
The fineness and fiber cross-sectional shape of the polyester hollow core-sheath type composite fiber are determined depending on the intended use, but usually, the fineness is 3 to 50 denier and the hollow ratio is 7 to 25%.
In addition to hollow circular cross-section fibers, polygonal or multilobe hollow profile fibers are used.

Next, in the method for producing a cotton molded article, polyester hollow fibers having a fiber length of 25 to 80 mm and polyester hollow core-sheath type composite fibers are used, and the polyester hollow fibers are 85 to 45 in weight ratio. Mix in the range of%. If the mixing ratio is high, the compression ratio will be high and the shape retention will be poor, and if the mixing ratio is low, the shape retention will be good, but it will be hard, the compression elasticity will be small, and the buckling will be unfavorable. Furthermore, in order to increase the bulkiness of the molded product to obtain a product having good cushioning properties, a polyester hollow latent crimpable conjugate fiber or a crimped polygonal or multilobe hollow profile fiber is used. use. Further, when it is desired to increase the fiber density of the molded product to obtain a hard product having a high compression elasticity, a highly shrinkable polyester hollow fiber or a highly shrinkable polyester hollow fiber and a polyester hollow latent crimpable composite fiber It is preferable to use the mixed fiber cotton.
Then, after the above fibers are mixed at a predetermined fiber ratio, a fiber web having an average weight of 30 to 200 g / m ² is formed by an ordinary dry method, and the fiber web is formed into a predetermined weight or thickness to obtain a molded product. It is laminated and made into a fiber entangled non-woven fabric by a fiber entanglement treatment means such as a needle punch method, a stitch bond method, a high-pressure water stream treatment method or the like.

Then, the fiber-entangled nonwoven fabric is subjected to heat treatment to impart shrinkage to the shrinkable fibers to cause spontaneous crimps in the latently crimpable fibers, and the sheath component weight of the core-sheath type composite fibers which are thermal binder fibers. The fusion fixing between the fibers is performed by uniting. The heat treatment is performed in hot water at 70 to 135 ° C. in a wet heat or dry heat atmosphere at 80 to 185 ° C. by one condition or a combination of two or more conditions. Further, the fiber entangled nonwoven fabric or the fiber entangled non-woven fabric which has been heat-treated in advance is formed by laminating one or a plurality of layers and then hot pressing with a heated die or press plate, or by hot pressing with a heating roll. A molded body is obtained in which at least a part of the contact points of the fibers are fusion-bonded and fixed with the sheath component polymer of the core-sheath type composite fibers. The apparent density of this molded product is 0.12 to 0.45 g.
/ Cm ³ , thickness 10 mm or more, load 1.0 kg / c
The compression rate at m ² is 20% or less. As a result, a cotton molded product having a small amount of morphological change and good elastic properties can be obtained, which is also useful as a cushioning body replacing polyurethane.

Further, the cotton molded article of the present invention is a flame-retardant agent for the production process of fiber entangled body, any processing step or the molded article,
Treatment with an insect repellent, a mildew proofing agent, a heat resistance stabilizer, a coloring agent, an aromatic agent, etc., a resin processing, or a resin coating may be applied.

Next, the cotton molding of the present invention will be described with reference to the drawings. FIG. 1 is a schematic cross-sectional view of a polyester hollow fiber constituting a cotton molded article, and FIG. 1 (1) is a hollow circular cross-section fiber, FIG.
(2) and (3) are hollow modified cross-section fibers, and FIG. 1 (4) is a hollow latent crimpable conjugate fiber in which two types of polyester components 1 and 2 having different thermal properties are joined in a side-by-side type. 1 is polyester component I, 2 is polyester component
II and 3 are hollow parts. FIG. 2 is a schematic cross-sectional view of a polyester hollow core-sheath type composite fiber which is a thermal binder fiber constituting a cotton molded article. FIG. 2 (1) is a hollow circular cross-section fiber, and FIGS. 2 (2) and (3) are Hollow modified cross-section fiber, 3 is a hollow part, 4 is a polyethylene terephthalate core component, and 5 is a low melting point polyester sheath component.

FIG. 3 is a schematic cross-sectional view of a cotton molded body, and shows at least one of fiber intersections of a fiber entangled body in which polyester hollow fibers 7 and polyester hollow core-sheath composite fibers 8 are mixed and entangled. It is a cotton molded body 6 in which the portions are fused and fixed 9.

[0013]

EXAMPLES Next, the present invention will be described with reference to Examples. Parts and% in the examples relate to weight unless otherwise specified.

Example 1 Mechanical crimped fineness of 40 dr,
65 parts of polyethylene terephthalate hollow fibers having a hollowness of 14.7% and a fiber length of 55 mm, as a thermal binder fiber,
50 parts of polyethylene terephthalate having an intrinsic viscosity [η] = 0.85 as a core component and 50 parts of hexamethylene terephthalate / ethylene terephthalate copolymerized polyester (melting point 135 ° C.) as a sheath component are subjected to hollow core-sheath composite spinning, stretching and mechanical winding. A fibrous web having an average weight of 75 g / m ² obtained by mixing 35 parts of a polyester hollow core-sheath type composite fiber having a fineness of 18 dr, a hollowness of 17.4% and a fiber length of 51 mm through a card and a random webber. Laminated by the cross lap method and pre-needle to obtain a non-woven fabric having an average weight of 769 g / m ² . Two sheets of this non-woven fabric are laminated, and a total of 180 are alternately applied from both sides of the non-woven fabric with regular needles with needle number 36.
Needle punching of book / cm ² was performed. Then temperature 1
It was treated in hot air at 50 ° C. and pressed by a calender press roll provided at the exit of the heat treatment machine to obtain a sheet-shaped molded product made of a fiber-entangled nonwoven fabric having a smooth surface in which fibers were fusion-fixed.

This sheet-shaped molded product has an apparent density of 0.14.
9 g / cm ³ , thickness 10.3 mm, load 1.0 Kg / c
The compression rate at m ² is 6.5%, and the width is 25 mm and the length is 20.
Even if the strip-shaped test piece of 0 mm was bent by holding it at both ends, it was a sheet-like molded body having a strong rigidity and no buckling.

This sheet-shaped molded body was suitable as a cushion body to be used by mounting it on a spring such as a seat or a bed. In addition, the results of practical tests such as temperature dependence and thermal deterioration acceleration test of this cushion body,
Unlike the polyurethane cushion body, the temperature dependency was not so great and the molded body was durable and stable.

Comparative Example 1 In place of the polyester hollow core-sheath composite fiber as the thermal binder fiber of Example 1, a polyester core-sheath composite fiber having a normal fineness of 18 dr and a fiber length of 51 mm was used. A sheet-shaped molded body made of a fiber-entangled nonwoven fabric having a smooth surface in which fibers were fused and fixed by the same processing was obtained.

This sheet-shaped molded product has an apparent density of 0.17.
4 g / cm ³ , thickness 8.85 mm, load 1.0 Kg / c
The compression rate at m ² is 4.4%, and the width is 25 mm and the length is 20.
When the strip-shaped test piece of 0 mm was bent while holding both ends, buckling occurred in the middle, and the hardness of the molded body was increased, but the sheet-shaped molded body had a weak stiffness.

Example 2 Polyethylene terephthalate / 8 mol% having a mechanically crimped fineness of 30 dr, a hollow ratio of 15.3% and a fiber length of 51 mm
40. Zide-by-side type hollow latent crimpable conjugate fiber 40 of isophthalate-modified polyethylene terephthalate
Part, fineness with mechanical crimping 40 dr, hollow ratio 14.7
%, 30 parts of poly (ethylene terephthalate) hollow fiber having a fiber length of 55 mm, and 30 parts of the polyester core-sheath type composite fiber of Example 1 were mixed to obtain a fiber web having an average weight of 77 g / m ² obtained through a card or a random web bar. Laminated by the cross-lap method and pre-needle, average weight 792g / m
^Two non-woven fabrics were obtained. Two sheets of this non-woven fabric were laminated, and a total of 180 needles / cm ² were needle punched alternately from both sides of the non-woven fabric with regular needles of No. 36, and then treated in hot water at a temperature of 95 ° C. for spontaneous crimping. And further subjected to drying and free heat treatment with a tenter heat treatment machine to obtain a sheet-shaped molded product made of a fiber-entangled nonwoven fabric in which the fibers are fixed.
This sheet-shaped molded product was punched into a vehicle seat with a certain shape and size, and was heat-press molded with a die to prepare a cushion body for an automobile seat.

This cushion body has an apparent density of 0.206.
It was g / cm ³ , and had an average thickness of 10.4 mm, was strong, was excellent in compression elasticity, and was a stable morphology. In particular, this cushion body is not so temperature-dependent as the polyurethane cushion body, has an appropriate hardness, and its temporal change in hardness is almost negligible, and thus it was suitable as a cushion body for automobile seats.

[0021]

EFFECTS OF THE INVENTION The cotton molded product of the present invention is a product having excellent compression properties and elastic properties and good morphological stability. In particular, as a substitute for applications in which the generation of toxic gas due to thermal decomposition of polyurethane is concerned, for example, cushions for seats, automobiles,
Widely applied to interior and exterior materials such as buildings and furniture, heat insulating materials, toys.

[0022]

[Brief description of drawings]

FIG. 1 is a schematic cross-sectional view of a polyester hollow fiber constituting a cotton molded product of the present invention.

FIG. 2 is a schematic cross-sectional view of a polyester hollow core-sheath type composite fiber as a thermal binder fiber of the present invention.

FIG. 3 is a schematic sectional view of a cotton molded product of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Polyester component I 2 Polyester component II 3 Hollow part 4 Polyethylene terephthalate core component 5 Low melting point polyester sheath component 6 Hard cotton molded product 7 Polyester hollow fiber 8 Polyester hollow core-sheath composite fiber 9 Fiber fusion part

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI Technical display location D01F 6/62 303 E D04H 1/48 B 1/54 A

Claims (1)

[Claims] 1. A monofilament having a fineness of 6 to 80 denier, which is crimped, and a short fiber of a polyester hollow fiber, polyethylene terephthalate as a core component polymer, and a polyester having a melting point of 230 ° C. or lower as a sheath component polymer, having a fineness of 3 to 3. A molded body of a fiber entangled body composed of short fibers of a 50-denier polyester hollow core-sheath type composite fiber, wherein at least a part of the contact points of the fibers of the molded body is a sheath component polymer of the core-sheath type composite fiber. Fused by, apparent density 0.12-0.45g
/ Cm ³ , thickness 1.0mm, load 1.0kg
A cotton molded product characterized by having a compression rate of 20% or less at 1 / cm ² .