JPH09324357A - Nonwoven fabric molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce a nonwoven fabric thermally fused molded product excellent in cushioning, heat-resisting, heat-insulating and soundproofing properties at a low cost. SOLUTION: This nonwoven fabric molded product contains acryl fibers and/or acrylic or polychlal fibers in an amount of >=50wt.%. The characteristic of a method for producing the nonwoven fabric thermally fused molded product comprises carrying out the thermal fusion of the thermal fusing parts at a temperature of 90-130 deg.C under a pressure of >=30kg/cm<2> .

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The non-woven fabric molded article of the present invention relates to a molded article for a packaging material, a molded article for transportation, a filter molded article, a cushion material, a soundproofing material, a heat insulating material and the like.

[0002]

2. Description of the Related Art Many molded products utilizing heat fusion are manufactured, but most of them are molded films or sheet materials, and generally vacuum molding is performed. The molded product had a drawback that the meat pressure was thin and the cushioning property was poor. On the other hand, a molded product obtained by molding a non-woven fabric or a knitted fabric is generally press-molded using a male mold and a female mold.

Molded articles of non-woven fabrics usually use non-woven fabrics of melt-spun fibers such as polyesters, polyamides, polyolefins. This utilizes the property of being easily heat-sealed. Among them, a core-sheath composite fiber, which uses a low melting point polymer as a sheath component, is easily manufactured by heat fusion, and is also manufactured.

On the other hand, a wet type having a melting point and a thermal decomposition point in the vicinity,
Alternatively, the non-woven fabric of acrylic, acrylic, and polyclar fiber produced by dry spinning is difficult to heat-fuse, easily shrinks by heat, and has poor dimensional stability, so the production of heat-fusion molded products has not been successful yet. .

[0005]

SUMMARY OF THE INVENTION An object of the present invention is to provide, at a low cost, a heat-fusion molded article of a nonwoven fabric having excellent cushioning properties, heat insulating properties, heat retaining properties and soundproofing properties.

[0006]

Means for Solving the Problems The present inventor has completed various aspects of the present invention as a result of various studies on the conditions for heat fusion molding and the preparation of nonwoven fabric. The present invention is a heat-fusion-molded article of a non-woven fabric, characterized by containing 50% by weight or more of acrylic and / or acrylic or polyclar fiber. Further, when producing a heat-fusion-molded article of a non-woven fabric containing acrylic and / or acrylic-based or polyclar fiber in an amount of 50% by weight or more, the heat-fusion-bonded portion at a temperature of 90 ° C. or higher and lower than 130 ° C.
The manufacturing method is characterized in that a pressure of g / cm ² or more is applied to perform heat fusion.

BEST MODE FOR CARRYING OUT THE INVENTION

In the molded article of the present invention, a non-woven fabric containing 50% by weight or more of acrylic and / or acrylic or polyclar fiber is used as the non-woven fabric. It is preferably 70% by weight or more, more preferably 100% by weight.
If the mixing ratio is less than 50% by weight, heat fusion will be insufficient.

Acrylic fiber is a fiber containing 50% by weight or more of acrylonitrile, acrylic fiber is a fiber containing 40 to 50% by weight of acrylonitrile, and polyclar fiber is a fiber composed of a polyblend of polyethylene and polyvinyl chloride. It is stipulated by the quality indication method for use.

The fineness and cut length of the fibers may be appropriately selected according to the method for producing the non-woven fabric and the required performance of the non-woven fabric molded product. Generally, the fineness is 0.8 to 30 denier,
A cut length of 30 to 150 mm is often used, but the cut length is not limited to this.

The non-woven fabric molded article of the present invention may contain a heat fusion binder fiber. The binder fiber has a melting point of 1
It is preferably lower than 30 ° C. Binder fiber content is 10
It is preferably not less than 15% by weight, more preferably not less than 15% by weight, further preferably not less than 30% by weight and less than 50% by weight. By mixing the binder fibers, it becomes easy to thermally bond to other films, non-woven fabrics, cloths and the like made of the same material as the low melting point polymer of the binder fibers.

Binder fibers are already on the market, and side-by-side type and core-sheath type binder fibers are often used. These are fibers composed of polymers having different melting points, and the melting points differ depending on the type of polymer. About 1
There are also binder fibers with low melting point components of 10,130.

As the type of polymer, polyolefin, copolymerized polyester, nylon and modified products thereof are often used as the low melting point polymer. Polypropylene, polyethylene terephthalate, polybutylene terephthalate, nylon 6, nylon 66, etc. are often used as the high melting point polymer. The denier of the binder fiber is usually 2 denier, but the denier may be appropriately changed depending on the required performance such as texture.

As fibers other than acrylic and / or acrylic or polyclar fibers, there are commonly used synthetic fibers such as polypropylene, polyethylene terephthalate, polybutylene terephthalate, nylon 6, nylon 66, aramid, amide imide, carbonized carbon fiber, etc. Examples of the recycled fiber include viscose rayon and acetate, and examples of the natural fiber include cotton, hemp, wool, silk and the like, which may be appropriately selected and used according to the application.

Flame-retardant acrylic and / or acrylic or polyclar fibers with aramid, amide imide, carbonized,
Since a non-woven fabric prepared by mixing carbon fibers and the like has flame retardancy, it can be imparted with flame retardancy as a non-woven fabric molded product.

The above-mentioned non-woven fabric manufacturing method is, for example, a card,
A manufacturing method using a cross ray, a draw, or a needle punch may be used. Alternatively, a random card or needle punching method may be used.

When binder fibers are mixed and used, thermal bonding may be performed instead of needle punching. Bonding can be performed with a hot air circulating type heat treatment machine with hot air having a melting point of the low melting point component of 10 ° C. or more. The amount of air flow, the direction of air flow, and the like may be appropriately selected depending on the density of finishing. It is preferable that the fibers of the non-woven fabric do not have a biased orientation. Preferably, the ratio of the tensile elongation of the nonwoven fabric in the machine direction to the width direction is 0.7 to 1.3.

When forming a nonwoven fabric, the preheating temperature of the nonwoven fabric is set to 9
Press molding is performed at 0 to 130 ° C. using a mold at room temperature. Preferably, a mold heated to a molding temperature of 90 to 130 ° C. is used. When a mold at room temperature is used, the molding temperature becomes lower than the preheating temperature, and the heat fusion becomes weak. Especially when forming a non-woven fabric with a small basis weight, deep drawing is possible by using a heated mold.

The molding temperature is 90 to 130 ° C. 90 ° C
If it is less than this, sufficient heat fusion cannot be obtained. Further, when the temperature exceeds 130 ° C., the non-woven fabric undergoes heat shrinkage, which makes it difficult to mold. The pressure during molding is 30 kg / cm ² or more. 30 kg /
If it is less than cm ² , sufficient heat fusion cannot be obtained. It is more preferably 50 kg / cm ² or more, and preferably 70 kg / cm ² or more for forming a nonwoven fabric into a film. When the non-woven fabric is molded with water retained, water has a plasticizing effect and can be molded into a more heat-sealed product. The water content is preferably 5% by weight or more.

The shape of the non-woven fabric molded product of the present invention is fixed by an embossed pattern, a lattice pattern, etc. by utilizing the characteristics of acrylic and / or acrylic-based or poly-clar fiber in which only the pressure-heat-sealed portion is heat-sealed. By using a mold that takes into consideration the formation of the portion (frame portion), it is possible to improve the dimensional stability and mechanical strength of the nonwoven fabric molded product.

By pasting or inserting a thermoplastic film on one side of the non-woven fabric or in the vicinity thereof, the non-woven fabric molded article can be vacuum-molded. It can also be used in combination with hot press molding.

The film is, for example, a synthetic film of polypropylene, polyethylene terephthalate, polybutylene terephthalate, nylon 6, nylon 66, polyvinyl alcohol, polyvinyl chloride, polyethylene, etc.,
There are recycled films such as cellophane.

The film is preferably an unstretched film. The stretched film is not preferable because it has anisotropy and cannot be stretched further to obtain a large amount of deformation associated with molding. The thickness of the film is related to the strength of the film and needs to be at least as strong as the deformation of the nonwoven fabric to be molded. Since the strength varies depending on the material of the film, the thickness of the film should be appropriately selected. Generally, a film of about 30 to 500 μ is often used.

The non-woven fabric molded article of the present invention can be subjected to post-processing such as dyeing, flame retardancy, antibacterial property, deodorant property, insect repellent property, and resin processing. Further, fibers having such properties can be mixed and used. It can also be used by laminating it with other non-woven fabrics, films and structures.

[0024]

The non-woven fabric molded article of the present invention can be used as a heat insulating and heat retaining material. In order to improve heat insulation and heat retention effects, it is preferable that the density of the nonwoven fabric is low. Normal,
The density of the non-woven fabric is 0.01-0.3 g / cm ³ ,
It is preferably 0.1 g / cm ³ or less. It can also be used as a sound absorbing and sound insulating material. In order to improve the sound absorption and sound insulation effects, it is preferable that the density of the non-woven fabric is low, 0.1 g / c
m ³ or less is good.

[0025]

【Example】

Example 1 Rufnene (trade name) D2d, 5 which is a flame-retardant acrylic fiber manufactured by Kanebo Co., Ltd., which has an LOI value of 29, which is an index of flame retardancy.
1 mm was carded, cross laid and drawn by a standard method, and then lightly needle punched to produce a nonwoven fabric having a basis weight of 500 g / m ² . The breaking elongation of this non-woven fabric in the machine direction is 86.
%Met. The breaking elongation in the width direction was 92%. The thickness of the non-woven fabric was 8 mm.

This non-woven fabric was formed by a press type non-woven fabric forming machine. When forming a non-woven fabric, preheat temperature of the non-woven fabric is 120 ℃
And using a mold heated to 120 ° C, 50 kg /
Press molding was performed for 30 seconds at a pressure of cm ² . 3 for mold
0 cm square top opening and 20 cm square bottom 2 cm deep
I used a trapezoidal mold. The mold had a clearance of zero so that only the edge and a 3 cm square grid portion having a width of 3 mm were thermally fused by pressure, and the other portions had a clearance of 10 mm.

The non-woven fabric molded product of the present invention was molded neatly in a rectangular plate shape in which only the pressure heat-sealing portion was heat-sealed, with almost no unevenness in thickness. 21 kg / in tensile strength
It showed a strength of 5 cm and was almost formed into a film.

Example 2 In the same manner as in Example 1, the press temperature was changed to produce a non-woven fabric molded article. The molding conditions and the tensile strength (kg / 5 cm) of the heat-bonded portion under pressure were measured and shown in Table 1. The molding condition was that the test No. 6 and the depth is not 2 cm, and the test No. 6 has poor dimensional stability. 2 is ×
Was evaluated. Test No. with a depth of 2 cm Test Nos. 3 and 4 were evaluated as ◯, and dimensional stability was good, and the squeeze was clean. 5
Was marked as ◎.

[0029]

[Table 1]

Example 3 In the same manner as in Example 1, the press pressure was changed to produce a nonwoven fabric molded article. The molding conditions and the tensile strength (kg / 5 cm) of the heat-bonded portion under pressure were measured and shown in Table 2.

[0031]

[Table 2]

As for the molding condition, the depth was not 2 cm, and the test No. with poor dimensional stability was used. 7 was evaluated as x. Depth 2c
Test No. No. 8 is ◯, the dimensional stability is good, and the test No. with a fine diaphragm is shown. 9 and 10 are marked with ⊚.

Example 4 The present invention was carried out by changing the flame-retardant acrylic fiber manufactured by Kanebo Co., Ltd., Rufunen (trade name) D2d, 51 mm, in Example 1 to a regular acrylic fiber manufactured by Kanebo Co., Ltd., D2d, 51 mm. The non-woven fabric molded product of The non-woven fabric molded product of the present invention was molded neatly into a rectangular dish shape in which only the pressure-heat-bonded portion was heat-bonded, with almost no unevenness in thickness. The pressure-heat-bonded portion showed a tensile strength of 22 kg / 5 cm and was almost formed into a film.

Example 5 The flame-retardant acrylic fiber manufactured by Kanebo Co., Ltd., Rufnene (trade name) D2d, 51 mm, in Example 1 was changed to polyclar fiber (Cordelan trade name), D2d, 51 mm, and the nonwoven fabric of the present invention was used. A molded product was produced. The non-woven fabric molded product of the present invention was molded neatly into a rectangular dish shape in which only the pressure-heat-bonded portion was heat-bonded, with almost no unevenness in thickness. The pressure-heat-bonded portion showed a tensile strength of 18 kg / 5 cm and was almost formed into a film.

Example 6 A flame-retardant acrylic fiber manufactured by Kanebo Co., Ltd. of Example 1, Rufunen (trade name) D2d, polyethylene terephthalate containing 51% of 51 mm, FD6d, 51 mm was used as a non-woven fabric. A molded product was produced. The molding conditions and the tensile strength (kg / 5 cm) of the heat-bonded portion under pressure were measured and shown in Table 3. The depth of molding is not 2 cm,
Test No. with poor dimensional stability 13 was evaluated as x. Test No. with a depth of 2 cm No. 14 is ◯, the dimensional stability is good, and the test No. with a fine diaphragm is shown. 15, 16 are marked with ⊚.

[0036]

[Table 3]

Claims (2)

[Claims] 1. A heat-fusion-molded article of a non-woven fabric, characterized by containing 50% by weight or more of acrylic and / or acrylic or polyclar fiber. 2. When producing a heat-sealed molded article of a non-woven fabric containing acrylic and / or acrylic-based or polyclar fiber in an amount of 50% by weight or more, the heat-sealed portion is 90 ° C. or higher, 1
A manufacturing method characterized in that a pressure of 30 kg / cm ² or more is applied at a temperature of less than 30 ° C. to perform heat fusion.