JPS62133166A - Production of bulky nonwoven fabric - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a bulky nonwoven fabric, and more specifically,
This relates to a process for manufacturing bulky nonwoven fabrics that are inexpensive, have excellent strength and formability, and are made using thermoplastic resin.

Conventionally, thermosetting resin powder is mixed into opened animal and vegetable fibers, synthetic resin fibers, and other materials, and a fleece is formed using a 7' J-forming machine, and then heated to form a bulky non-woven fabric. is manufactured. These bulky nonwoven fabrics are used in the felt state as they are for the purpose of soundproofing and heat insulation, but most of them are molded under heat and pressure to improve the soundproofing effect and strength by forming irregularities of the desired shape into buildings, automatic Ills, etc. It is used in

Therefore, the greater the amount of resin powder mixed as a binder and shape-imparting agent in the bulky nonwoven fabric, the greater the strength can be obtained and the better the moldability.

However, increasing the amount of resin cannot be left to chance due to the fact that excess resin may fall off the net conveyor in the process and there are economic constraints. Also, from an economic standpoint, I was still not satisfied.

In view of the current situation, as a result of intensive research, the present inventors have developed a thermosetting U (a bulky non-woven fabric with excellent strength and moldability by mixing it with fat) that conventionally uses a specific thermoplastic resin. The present invention was developed based on the discovery that this can be obtained at a low cost, and an object of the present invention is to provide a method for producing an inexpensive bulky nonwoven fabric with excellent strength and formability.

That is, the key points of the present invention are as follows:
To 100 parts by weight of a discontinuous fiber material consisting of T96 and mineral fibers of 10 to 90% by weight, a polyethylene tree layer and/or a thermosetting resin of 10 to 90% by weight are added as a binder.
Alternatively, a process for producing a bulky nonwoven fabric includes mixing 5 to 50 parts by weight of a resin powder component containing 90 to 10% by weight of a vinyl chloride resin, forming a fleece to a predetermined thickness.

Examples of the discontinuous yL fiber material used in the present invention include synthetic T3+ oily fibers such as bistoothrayon, acetate, acrylic, nylon, polyester, and vinyl chloride, and examples of vegetable and animal fibers include wool. Examples of mineral fibers include fiber materials such as glass wool, rock wool, and asbestos fibers.

Needless to say, fiber materials obtained by opening industrial waste such as recycled wool, fallen cotton, and fiber waste can be suitably used.

Conventionally known thermosetting resins as binders, moldable resins, and OH resins used with specific thermoplastic resins include epoxy resins, urethane FJllJff, 7-El resins,
Examples include thermosetting acrylic paste. Most preferred is the use of phenolic resins.

The resin powder component consisting of thermosetting resin powder and the specific thermoplastic resin powder of the present invention is preferably mixed in an amount of 5 to 501 parts by weight per 100 parts by weight of the discontinuous fiber material. 5
If the 0 parts by weight is different, the mixture with the fibers may become uneven, the mold release property during heat and pressure molding may be poor, and S
If the mff1 end threshold is used, a problem arises in that adhesiveness and strength cannot be obtained.

The manufacturing process for manufacturing the bulky nonwoven fabric according to the present invention may be a conventionally known process. For example, a fiber material is subjected to secondary spinning using a veil-figu, and a web of considerable thickness is formed using a wrapper. Then, a specific thermoplastic resin powder or a resin powder component consisting of a thermosetting resin powder and a thermoplastic resin powder is sprayed onto the formed web using a resin scattering machine, and the rfrI fibers and the resin powder are mixed again using a beater in a homing machine. The fleece is then mixed with a wrapper again to form a fleece of the desired thickness, and the fleece is sequentially poured onto a net conveyor in a heating furnace.

The obtained fleece may be heated and pressure-molded as is in a molding machine, or it may be heated in a heating furnace to make it easier to handle, and taken out in a semi-cured state in which a part of the mixed υf fat granule powder is hardened and heated and pressure-molded. Alternatively, the mixed resin powder may be sufficiently hardened to give elasticity and
It may also be taken out as a felt-like material with excellent cushioning properties.

Examples are given below for a more detailed understanding.

Naturally, the present invention is not limited to the following examples.

Example 1 Recycled wool 40mff1%, cotton drop 40% by weight, and glass wool 2Off! 100 parts by weight of a discontinuous fiber material consisting of
Powder F311M consisting of 30% by weight of polyethylene resin powder and 20% by weight of vinyl chloride resin powder was dispersed and mixed with 30% by weight and formed into a fleece on a fleece-forming rock.
Semi-cured type with some uncured resin remaining after heating in a heating furnace at 0°C. Thickness: 221,671 m, areal density: 880
A bulky nonwoven fabric of H/m' was obtained.

Then, it was heated and pressed for 1 minute at a temperature of 190°C and a pressure of 3KH7cm2 to a width of 1,00m/n and a length of 300mm.
A molded flat plate with a thickness of m/m S of 4+n/m was obtained.

Example 2 Acrylic fiber 10% by weight, polyester fiber 10% by weight
, 20% cotton, 20% linen, X: 10% by weight wool, and 30% by weight glass wool, discontinuous fiber material 100
fffffi part opened and mixed waist phenol tJ1 fat powder 4
Powder tj + fat component 3 consisting of 0 weight%, polyethylene tH fat powder 30mm% and vinyl chloride resin powder 30% by weight
After scattering and mixing 5 parts by weight to form a fleece on a fleece-forming stone, it was passed through a heating oven at 180°C to partially uncure υtm'r.
The remaining semi-cured type of 17mm/23m/+o,
A bulky nonwoven fabric having a density of 91 OH of 7 m2 was obtained.

The molded plate was then heated and pressed for 1 minute at a temperature of 190 DEG C. and a pressure of 3 Kg/am2 to obtain a molded flat plate having a length of 300111/Ia and an I7 diameter of 4+a/+n.

Comparative Example 1 A bulky nonwoven fabric was prepared by spreading and mixing 100 parts of a discontinuous fiber material having the same components as in Example 1, and then sprinkling and mixing 30 parts by weight of phenolic resin powder instead of the powdered resin that was sprinkled and mixed in Example 1. A molded flat plate similar to that of Example 1 was obtained.

Comparative Example 2 100 parts by weight of a discontinuous fiber material having the same components as in Example 2 was added to J
Powder mixed with UL fibers and sprinkled in Example 2! ■
A +12 high-strength nonwoven fabric was obtained by sprinkling and mixing 35 parts by weight of 7-technol oil powder instead of the molten powder, and a molded flat plate similar to that in Example 2 was obtained.

Test Method The tensile strength and glabellar peel strength of the bulky nonwoven fabrics obtained in the Examples and Comparative Examples, and the tensile strength and tear strength of the molded flat plate obtained by heating and pressure molding the bulky nonwoven fabrics, were measured.
The average of the measured values of 10 samples for each sample was determined.

Test contents 1. Tensile strength (Khi/c [112) Cut the test piece using a No. 2 dumbbell specified in JIS K G301, and store it in a constant temperature and humidity room (20 ± 2 °C 1 RII).
GS±5%) for 2 hours, the sample was immediately fixed in a tensile tester and pulled at a tensile rate of 200++ ua/min, and the maximum load was measured and calculated using the following formula.

Tensile strength = maximum load (Kg) / cross-sectional area of test piece (cm2)
)2.Delamination strength K Bi/JI #2) Cut a 1100x1OO/+n test piece from the sample,
A jig with 00XI 00 adhesion surface was sufficiently adhered to the upper and lower surfaces with adhesive, and a tensile test was performed at room temperature! 9, and measured the maximum load (K Bi) by pulling at a pulling speed of 200+++ m/+nin, and displaying the measured value.

3.Tear strength Kg/cm) Cut the test piece using a B-type punching die specified in JIS K 6301, and store it in a constant temperature and humidity room (20±2℃, Rl-1
65±5%) for 2 hours, and then immediately conducted a tensile test (fixed to a wall and pulled at 200 ml 1/rein, the maximum load was measured and calculated using the following formula).

Tear strength = maximum load (h) / 1!7 cm of test piece, .
) Properties of bulky non-woven fabric Properties of molded flat plate Based on the above results, the present invention was obtained by heating and press-molding a 1-4 high-performance nonwoven fabric containing a specific thermoplastic resin powder and the +R4 high-performance nonwoven fabric. It was found that the molded product obtained by this method had strength and moldability superior to conventional products.

Claims (1)

[Claims] Synthetic resin fiber 10-90% by weight, vegetable fiber 0-60%
% by weight, 0-60% by weight of animal fibers and 10% by weight of mineral fibers
100 parts by weight of a discontinuous fiber material consisting of ~90% by weight, 10 to 90% by weight of a thermosetting resin as a binder, and 90% of a polyethylene resin and/or a vinyl chloride resin.
A method for manufacturing a bulky nonwoven fabric, which comprises mixing 5 to 50 parts by weight of a resin powder component containing ~10% by weight, forming a fleece to a predetermined thickness.