JPS6310286Y2 - - Google Patents

Description

[Detailed explanation of the idea]

The present invention relates to a hard cotton composite, which not only strengthens the heat retention properties of the composite, but also improves cutting strength, cutting elongation, and peeling strength to provide durability, and at the same time improves dimensional stability, air permeability, and compressive elasticity. For the purpose of this, a fiber web containing low-melting point polyester is layered on a sheet made by bonding and integrating a metal-deposited film and a long-fiber nonwoven fabric, and a portion of the fiber web is metal-deposited by needling between the two. After forming a protruding fiber web layer by penetrating the sheet, the whole is heat-treated to melt the low melting point polyester and firmly bond it. Conventionally, it has been known to use a synthetic resin film coated with a metal such as aluminum by needling in order to improve the heat retention of a fiber web assembly. In other words, this type of conventional film does not use low melting point polyester cotton, nor does it bond polyester long fiber nonwoven fabric, but instead uses a polyester film on which aluminum is vapor-deposited, and needling is performed between them. In such structures, the needling process causes the metal vapor deposited film to peel, tear, or curl up, resulting in a significant drop in the desired heat retention performance, and the overall structure also suffers from its cutting strength and cutting elongation. , peel strength is unsatisfactory, and good performance in durability, dimensional stability, and compressive elasticity cannot be obtained, and when used for carpet liners, bedding, etc., bulk performance decreases due to repeated loading and shear stress. However, the problem was that the constituent layers could come off, shear, or wrinkle. Or again, Kimiaki Sane
As shown in Japanese Patent No. 50-22150, a method of using metal-deposited long fiber nonwoven fabrics has also been proposed, but with this method, it is difficult to obtain a smooth, homogeneous, and durable metal film, and it also has poor heat retention, strength, and elongation. However, a satisfactory structure could not be obtained. The inventors of the present invention have studied these points in detail, and have found that even if the needling process is used, there will be no significant drop in heat retention performance due to damage to the metal vapor deposited film.
In addition, they have achieved a structure that increases the cutting strength, cutting elongation, and peel strength of the entire structure, and have completed the present invention. That is, the present invention superimposes a web layer consisting of a low-melting point polyester fiber and a relatively high-melting point synthetic fiber, natural fiber, or recycled fiber on a sheet made of a metal-deposited polymer film and a long-fiber nonwoven fabric, and A needle punch is performed between the two to penetrate a portion of the web layer into the sheet, and heat treatment is performed to melt the low melting point polyester fibers between the fibers of the web layer and between the fibers and the sheet. This is a newly created stiff cotton composite material with a structure characterized by forming a large number of fixed connection parts. Hereinafter, the stiff cotton composite of the present invention will be explained with reference to the drawings. 1 to 3 show cross-sectional views of respective examples of the hard cotton composite according to the present invention, in which 1 is a metallized polymer film, 2 is a reinforced nonwoven fabric, and 3 is a low melting point polyester. 4 is a protruding short fiber web layer containing a low melting point polyester produced by needling, and 5 is a bonding medium. The hard cotton composite of the present invention is produced by firstly laminating a metal-deposited polymer film 1 and a long fiber nonwoven fabric 2 as a reinforcing material, directly or by bonding with a bonding medium 5 to form a single sheet 6. form. In addition, a low melting point polyester made using a copolymerized polyester component with a melting point of 210°C or less is mixed with base fibers such as synthetic fibers, natural fibers, or recycled fibers with a relatively high melting point, and carded with a carding machine. A short fiber web layer 3 is prepared. Next, the short fiber web layer 3 and the sheet 6 are stacked on top of each other and needled with a needle machine so that some of the fibers of the short fiber web layer 3 penetrate through the sheet 6 to form the protruding short fiber web layer 4. It is being formed. Subsequently, the unheat-treated laminate 7 thus formed is heat-treated to heat and melt the copolymerized polyester components of the short fiber web layer 3 and the protruding short fiber web layer 4, and then cooled to form the short fiber web layer. The protruding short fibers between the fibers of No. 3 are formed between the fibers of the short fiber web layer 4 and between the fibers of the short fiber web layer 3 and the sheet 6. Melting and fixing contacts are formed between the short fiber web layer 4 and the sheet 6 to make the fibers firm. Therefore, the sheet 6, the short fiber web layer 3, and the protruding short fiber web layer 4 constitute a solid cotton composite that is three-dimensionally firmly bonded as a whole by needling and melting and fixing of the copolyester component. become. The metal-deposited polymer film 1 is obtained by vapor-depositing a metal such as aluminum on the surface of a polymer film obtained by melting and extruding a polymer such as polyethylene terephthalate. Note that, as the polymer film, films made of nylon, polyolefin, polyvinyl alcohol, polyimide, etc. may also be used depending on the purpose. As the metal vapor deposited film 1, a thin film with a thickness of about 8 to 15 microns is preferable because it has a soft feel as a hard cotton composite and does not have a stiff feel, but it is difficult to use this film alone in a needle machine. Since there is a risk that the deposited metal film may peel off or break into pieces due to the force of the needling of the needle machine, the nonwoven fabric 2 is bonded to the metal deposited film 1 using a bonding medium 5 as a reinforcing material. Join them in advance. The nonwoven fabric 2 is preferably a polyethylene terephthalate long fiber nonwoven fabric or a nylon long fiber nonwoven fabric having a basis weight of 15 to 50 grams per square meter. The film 1 and the nonwoven fabric 2 are bonded together in advance using a bonding medium 5 as shown in FIGS. 2 and 3. In this case, a polyethylene film is used as the bonding medium 5 and polysand bonding is performed by heating, or A method such as gluing them together using adhesive is used. However, it is also effective to use a method of directly dry laminating and heating bonding using an aluminum vapor-deposited polyethylene terephthalate film and a polyolefin long fiber nonwoven fabric, as shown in FIG. 1, without using a special bonding medium 5. . The short fiber web layer 3 is made by stacking the base fibers and low melting point polyester fibers at a predetermined ratio into a cotton blending machine and carding them using a carding machine so as to have a predetermined basis weight. It is. The short fiber web layer 3 is provided on one side of the sheet 6 as shown in FIG. 2, or on both sides of the sheet 6 as shown in FIG. Polyester staple fiber can be suitably used as the base fiber of the short fiber web layer 3, but the fiber cross section and denier are selected depending on the intended use. In addition, when using short fibers of hollow fiber side-by-side conjugates with a cut length of 32 mm to 76 mm and a cut length of 32 mm to 76 mm as the base fiber of the short fiber web layer 3, the carpet liner has less set after repeated compression. A stiff cotton composite with high air content and excellent cushioning properties can be obtained. On the other hand, the base fiber is a round cross section fiber machine crimped from 6 denier to 15 denier and the cut length is 32 mm to 76 mm.
When using mm short fibers, a hard cotton composite with high hardness and low compressibility is obtained. The low melting point polyester fiber of the short fiber web layer 3 is a polyester staple fiber which is obtained by melt spinning a polyethylene terephthalate copolymer and has a portion with a melting point of 90° C. to 210° C. as a constituent element in the fiber cross section. In particular, as a low melting point polyester fiber, the fiber cross section has a core-sheath shape, and the core part is a polyethylene terephthalate homopolymer, and the sheath component is a polyethylene terephthalate copolymer with a melting point of 90°C to 210°C, which is melt-spun using a conjugate drawing machine. Crimp type, 4 denier to 6 denier, cut length 32 mm to 76
It is preferable to use short fibers of mm in diameter to prevent cutting and shedding caused by carding and needling, and to prevent the production of white powder in the product. In addition, the melting point of the copolyester component of the low melting point polyester fiber is 110℃,
Select according to the intended use, such as 130℃ or 200℃. The low melting point polyester fiber 3 or cotton is mixed with base fiber or cotton and carded to be used as a cross weave or random weave aggregate, and the ratio of the low melting point polyester cotton to the base cotton is 5% to 50% by weight. Particularly preferably between 10 and 30 weight percent is used. Note that this ratio is 5%
If it is less than 50%, it is difficult to obtain sufficient firmness, and if it is more than 50%, distortion due to heat shrinkage will be exerted on the whole. The unheat-treated laminate 7 is hardened by heat-treating it. The unheated laminate 7 may be heat-treated by a conventionally known method such as a heating zone or a heat roller. The heating temperature for such heat treatment is preferably higher than the melting point of the copolymerized polyester component, preferably 30°C to 50°C higher, and a short heat treatment time of 30 seconds to 3 minutes is sufficient. In addition, because the aluminum vapor-deposited polymer film has excellent thermal conductivity, by passing the unheated laminate through the heating zone, it can be continuously produced in a short period of time, making it a hard cotton with excellent uniformity with little density unevenness or heat shrinkage unevenness. It has the characteristics of giving a complex. Note that these heat treatments are performed during the carding process,
It can be continuously processed as an integrated continuous process together with the laminated web forming process and the needle punching process. Another effective method is to adjust the thickness of the product by providing press rollers in the final zone following the final stage of heat treatment and passing the heat-treated laminate between the rollers. Furthermore, as a heat treatment method for the unheated laminate 7, it is also effective to carry out the heat treatment by supplying the unheated laminate to a heating mold in batches. According to this method, a hard cotton molded body can be formed into an integral molded product consisting of a high-compression, high-density heat-formed part that is heat-treated to become a bone part under compression press, and a low-compression, low-density heat-formed part that has air permeability. It can be used as a hard cotton composite for molded wall materials for automobiles, body cases for musical instruments, hats, bulletproof pads, etc. Furthermore, in the case of these heat treatments, it is also an effective method to superimpose various types of fibers and knitted fabrics as surface decoration materials on the unheat-treated laminate via a bonding agent, and then heat compression molding. As mentioned above, the hard cotton composite according to the present invention is made of a sheet made of a long fiber nonwoven fabric bonded to a metal-deposited polymer film, and a polyester fiber with a low melting point and a synthetic fiber, a natural fiber, or a recycled fiber with a relatively high melting point. The web layers consisting of the above are superimposed, and a needle punch is performed between the two so that a part of the web layer penetrates the sheet, and a heat treatment is performed,
The present invention is characterized in that a large number of joints are formed by melting and fixing the low melting point polyester fibers between the fibers of the web layer and between the fibers and the sheet. Therefore, the hard cotton composite of the present invention retains a metal-deposited aluminum film made porous by needle punching and has excellent heat retention, but it also has a fiber web layer and a fiber web layer on the aluminum, film layer or nonwoven fabric layer. It has a bonding structure in which the protruding short fiber web layer is three-dimensionally penetrated and integrated, and the bonding point is a strong hot melt bonding point of the copolymerized polyester component. Due to the distribution, tension,
It has excellent tearing and bending strength, each layer does not peel, come off, shift, or wrinkle, and has a billing-resistant surface and durable dimensional stability. Therefore, it has a suitable air permeability that is controlled by the composition and a suitable stiffening density that is controlled by the blending ratio of the low melting point polyester and the heat treatment conditions. Note that the number of layers and the order of stacking of the laminated structure of the stiff cotton composite of the present invention are not particularly limited.
A fiber web layer with long fiber nonwoven fabric layered as a surface layer, or a sandwich structure in which a fiber web layer is placed on the surface of the long fiber nonwoven fabric and a metal-deposited aluminum film layer, or a fiber web layer with different blending ratios of low melting point polyester can be used. Applications of this invention include stacking layers and using a plurality of metal-deposited films. Example 1 Fineness 6 denier fiber length 75 mm obtained by hollow side-by-side composite spinning and drawing and heat cutting
Conjugate 30 parts and 60 parts of 15 denier fiber length 75 mm polyester base cotton, respectively, and a polyester homopolymer with a melting point of 255°C in the core and a low melting copolymer polyester with a melting point of 110°C in the sheath at a joining ratio of 1:1. Ten parts of low melting point polyester cotton with a fineness of 4 denier and a fiber length of 61 mm obtained by spinning and drawing were mixed together and fed to a carding machine to produce a short fiber nonwoven fabric with a basis weight of 240 g/m ² . After inserting a sheet in which a 12 micron thick aluminum-deposited polyester film was bonded to a polyester long fiber nonwoven fabric with a basis weight of 50 g/m ² in advance with a polyester adhesive between the centers of the two short fiber nonwoven fabrics, Feed to needle machine with needle count of 325 and 60
After needling with a number of needle penetrations per ^cm2 , the material was fed to a heating zone set at 160°C and heat treated for 1 minute to melt the low melting point polyester component, then cooled to form a hard cotton composite. I got a body. The hard cotton composite thus obtained had no aluminum deposited film, no cutting or peeling, and exhibited good performance, particularly in terms of strength, elongation, compressive strain, bending resistance, etc. This performance is as shown in Product A in Table 1. On the other hand, as a conventional comparative example, a thickness of 12% was obtained by vapor-depositing aluminum without using low-melting point polyester cotton and without bonding polyester long fiber nonwoven fabric.
In products using micron polyester films and needling between them, the aluminum evaporated film was torn and turned into small pieces, and good performance could not be obtained. The present invention and conventional products A and B as described above were subjected to strength and elongation measurements using the cut strip method, bending resistance tests using the 45° cantilever method, compressive strain tests repeated 500 times according to JIS K-6401, and heat retention tests using the constant temperature method. Table 1 shows the results of a peel test on the metallized film sheet.

[Table] Figure 4 is a structural explanatory diagram of a micrograph (microscope magnification x 20, photo enlargement magnification x 33, total magnification x 66) of the melted and fixed contact portion of the nonwoven fabric constructed in the stiff cotton composite according to the present invention. Shown below. The shaded area in the drawing shows the melted and fixed contact area, and it can be seen that a sufficient adhesion effect is achieved.

[Brief explanation of the drawing]

1 to 3 are cross-sectional views showing examples of the stiff cotton composite according to the present invention, and FIG. 4 is a structural explanation of a microscopic photograph of the melted and fixed contact formed in the stiff cotton composite of the present invention. It is a diagram. 1...metalized polymer film, 2...reinforced nonwoven fabric, 3...short fiber web layer containing low melting point polyester, 4...protruding short fiber web layer containing low melting point polyester produced by needling,
5... Bonding medium.

Claims (1)

[Scope of utility model registration request] A web layer made by mixing 5 to 50% by weight of low-melting point polyester fibers with relatively high-melting point synthetic fibers, natural fibers, or recycled fibers is added to a sheet made by bonding a long-fiber nonwoven fabric to a metal-deposited polymer film. They are stacked one on top of the other, and then a needle punch is applied between the two to penetrate a portion of the web layer into the sheet, and a heat treatment is performed to form the low-temperature layer between the fibers of the web layer and between the fibers and the sheet. A stiff cotton composite structure characterized by forming a large number of joints in which melting point polyester fibers are melted and fixed.