JPS63159563A - Production of needle carpet molded product - Google Patents
Production of needle carpet molded productInfo
- Publication number
- JPS63159563A JPS63159563A JP61303534A JP30353486A JPS63159563A JP S63159563 A JPS63159563 A JP S63159563A JP 61303534 A JP61303534 A JP 61303534A JP 30353486 A JP30353486 A JP 30353486A JP S63159563 A JPS63159563 A JP S63159563A
- Authority
- JP
- Japan
- Prior art keywords
- fibers
- needle
- melting point
- molded product
- fiber
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 8
- 239000000835 fiber Substances 0.000 claims description 52
- 238000002844 melting Methods 0.000 claims description 27
- 229920002972 Acrylic fiber Polymers 0.000 claims description 18
- 230000008018 melting Effects 0.000 claims description 16
- 239000004416 thermosoftening plastic Substances 0.000 claims description 6
- 229920001169 thermoplastic Polymers 0.000 claims description 4
- 238000010438 heat treatment Methods 0.000 claims description 3
- 229920006397 acrylic thermoplastic Polymers 0.000 claims description 2
- 239000000047 product Substances 0.000 description 17
- 238000000034 method Methods 0.000 description 6
- 238000000465 moulding Methods 0.000 description 5
- 239000004745 nonwoven fabric Substances 0.000 description 5
- 239000012467 final product Substances 0.000 description 4
- 239000013067 intermediate product Substances 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- -1 polyethylene Polymers 0.000 description 4
- 239000004743 Polypropylene Substances 0.000 description 3
- 238000004049 embossing Methods 0.000 description 3
- 230000014759 maintenance of location Effects 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 229920000728 polyester Polymers 0.000 description 3
- 229920001155 polypropylene Polymers 0.000 description 3
- 229920000297 Rayon Polymers 0.000 description 2
- 238000009960 carding Methods 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 239000002657 fibrous material Substances 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 230000000877 morphologic effect Effects 0.000 description 1
- 229920000058 polyacrylate Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
- 239000012209 synthetic fiber Substances 0.000 description 1
- 230000009897 systematic effect Effects 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 210000002268 wool Anatomy 0.000 description 1
Landscapes
- Nonwoven Fabrics (AREA)
Abstract
(57)【要約】本公報は電子出願前の出願データであるた
め要約のデータは記録されません。(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.
Description
【発明の詳細な説明】
産業上■且里分亘
本発明はニードルカーペット成形品の製造方法に関する
。DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing needle carpet molded articles.
従来■肢査
建築物のフロアマットや自動車の内装材としてニードル
カーペットが使用されている。このような二一ドルカ一
ペソトの製造手段として、例えば米国特許第４．２５８
．０９８号明細書には、高融点繊維に５重量部以上の低
融点繊維を混合ｔてなる繊維ウェッブにニードルパンチ
加工を施こして不織布に形成した後、加熱成形すること
によってニードルカーペット成形品を製造する方法が開
示されており、また米国特許第４，３４２．８１３号明
細書には、高融点繊維に低融点を有する熱可塑性繊維を
混合してなるニードルパンチ不織布を両面から赤外線ヒ
ータで加熱し、この後、加熱ロールによってこのニード
ルパンチ不織布の片面を押圧し、この押圧面倒に配設さ
れている低融点繊維を溶融させて一体構造の型押し成形
品を製造する方法が開示されている。Traditionally, needle carpets have been used as floor mats in buildings and interior materials for automobiles. As a method for producing such 21 dollars and 1 pesos, for example, US Pat. No. 4.258
．． No. 098 discloses that a fiber web made of a mixture of high melting point fibers and 5 parts by weight or more of low melting point fibers is needle punched to form a nonwoven fabric, and then heated to form a needle carpet molded product. A manufacturing method is disclosed in US Pat. No. 4,342.813, in which a needle-punched nonwoven fabric made of a mixture of high-melting-point fibers and low-melting-point thermoplastic fibers is heated on both sides with an infrared heater. Then, a method is disclosed in which one side of the needle-punched nonwoven fabric is pressed with a heated roll to melt the low-melting point fibers disposed on the pressed surface to produce a molded product with an integral structure. .
ベ ° ′ 口
上記の如き成形手段を利用することによって、高融点繊
維と低融点繊維を混合してなる不織布状の繊維構造体か
らニードルカーペット成形品を製作するこができるが、
これ迄、ニードルカーペット成形品の構成材料として使
用される高融点繊維と低融点繊維の組合わせに関しては
繊維特性上の考慮が殆ど払われておらず、最終製品の保
形性が低下する場合が少なくなかった、更に詳しく説明
すると、在来方法では不織布中に配合されている高融点
繊維に無理な押し曲げ力を作用させた状態で低融点繊維
を熔融し、前記高融点繊維を低融点繊維に接着固定して
いるため、高融点繊維が十分に熱固定されず、成形後、
時間の経過と共にニードルカーペント成形品に形崩れが
発止する欠点が見受けられた。By using the above-mentioned molding method, it is possible to produce a needle carpet molded product from a non-woven fiber structure made of a mixture of high-melting point fibers and low-melting point fibers.
Until now, little consideration has been given to the fiber properties of the combination of high-melting point fibers and low-melting point fibers used as constituent materials for needle carpet molded products, and the shape retention of the final product may deteriorate. To explain in more detail, in the conventional method, the high melting point fibers mixed in the nonwoven fabric are melted by applying an excessive pressing and bending force, and the high melting point fibers are converted into low melting point fibers. Because the high-melting point fibers are not heat-fixed sufficiently, after molding,
A drawback was observed that the needle carpent molded product began to lose its shape over time.
本発明は、在来のニードルカーペット成形品で問題にな
っていた形態安定性の経時的低下の防止手段を提供せん
とするものである。The present invention aims to provide a means for preventing the deterioration of shape stability over time, which has been a problem with conventional needle carpet molded products.
ロ − −−るための −
上記目的に鑑みて本発明は、アクリル繊維と、このアク
リル繊維よりも低い融点を有する熱可塑性ｖ４維からな
るニードルカーペットを、前記熱可塑性繊維の溶融温度
迄加熱しながら形押し成形するニードルカーペット成形
品の製造方法を提供するものである。In view of the above object, the present invention provides a needle carpet made of acrylic fibers and thermoplastic V4 fibers having a lower melting point than the acrylic fibers, heated to the melting temperature of the thermoplastic fibers. The present invention provides a method for producing a needle carpet molded product by stamping and molding.
作里
本発明者は、高融点繊維および低融点繊維からなるニー
ドルカーペット成形品の保形性向上手段を見出すべく系
統的な実験を繰返した結果、型押し成形後のニードルカ
ーペット成形品に発生する保形性の低下、所謂、形崩れ
が、高融点繊維の初期ヤング率によって大きな影響を受
ける事実を見出した。第１図に各種の繊維材料について
水中の温度（℃）と初期ヤング率（ｇ／ｄ）の関係を測
定した結果を示す、第１図から理解されるように、アク
リル繊維の初期ヤング率のみが８０℃付近で急激に低下
する。これに対しポリアミド繊維やポリエステル繊維の
ような熱可塑性合成繊維やアセテートやビスコースレイ
ヨンのような化学繊維、あるいは羊毛のような天然繊維
は、アクリル繊維に比較して水中温度の上昇に対する初
期ヤング率の低下割合が小さい、このアクリル繊維特有
の８０℃付近での初期ヤング率の急激な低下は、元来結
晶構造が不明瞭で８７℃〔あるいは８０℃〜１１０℃〕
なる二次転移温度を有するアクリル高分子の構造的特性
に起因するものと考えられるが、何れにしても高融点繊
維としてアクリル繊維を配合してなるニードルカーペッ
トをこのニードルカーペットの第２の構成成分として配
合された低融点＆！ｉ維の溶融温度に加熱することによ
って、型押し成形工程に導入されたアクリル繊維は、初
期ヤング率を低下させたままの状態で型押し成形される
。しかも低融点繊維の熔融温度に加熱されたアクリル繊
維は、低融点繊維との接着に好適な親和力の大きな表面
特性を具えているので、型押し成形された不織布構造物
の温度を常温迄下げることによって、アクリル繊維と低
融点繊維とが強固に接着され、且つアクリル繊維が最終
製品において保形性向上材料として機能するニードルカ
ーペット成形品が得られる０本発明の実施に際しアクリ
ル繊維に配合する低融点繊維としては、型押し成形工程
に導入され高温に加熱されたアクリル繊維との接着性な
らびに成形品として使用した場合、相当の高温になって
も軟化しないという熱的特性を考慮し、ポリプロピン繊
維もしくはポリエチレン繊維を使用することが望ましい
、低融点繊維は、比較的硬質のニードルカーペット成形
品、例えば自動車のトランクルーム用内張り材を製造す
る場合には、最終製品の全重量に対し１５乃至８０パー
セントの割合で、また嵩高なニードルカーペア）成形品
、例えば自動車のフロアマットを製造する場合には、最
終製品の全重量に対し１０乃至５０パーセントの割合で
配合する。Sakuri: As a result of repeated systematic experiments to find a means for improving the shape retention of needle carpet molded products made of high-melting point fibers and low-melting point fibers, the present inventor discovered that the problem that occurs in needle carpet molded products after embossing molding. It has been found that the decline in shape retention, so-called shape loss, is greatly affected by the initial Young's modulus of the high melting point fiber. Figure 1 shows the results of measuring the relationship between temperature (°C) in water and initial Young's modulus (g/d) for various fiber materials.As can be understood from Figure 1, only the initial Young's modulus of acrylic fibers. decreases rapidly at around 80°C. On the other hand, thermoplastic synthetic fibers such as polyamide fibers and polyester fibers, chemical fibers such as acetate and viscose rayon, and natural fibers such as wool have a higher initial Young's modulus with respect to increases in water temperature than acrylic fibers. The rapid drop in initial Young's modulus at around 80°C, which is unique to this acrylic fiber, is due to the fact that the crystal structure is originally unclear at 87°C [or 80°C to 110°C].
This is thought to be due to the structural characteristics of the acrylic polymer, which has a second-order transition temperature of Low melting point formulated as &! By heating the acrylic fiber to the melting temperature of the i-fiber, the acrylic fiber introduced into the embossing process is embossing-molded with its initial Young's modulus still reduced. In addition, acrylic fibers heated to the melting temperature of low-melting point fibers have surface characteristics with a high affinity suitable for adhesion with low-melting point fibers, so the temperature of the embossed nonwoven fabric structure can be lowered to room temperature. By this method, it is possible to obtain a needle carpet molded product in which the acrylic fibers and the low-melting point fibers are firmly bonded together, and in which the acrylic fibers function as a shape-retaining improving material in the final product. As for the fibers, polypropyne fibers or It is desirable to use polyethylene fibers, and when manufacturing relatively hard needle carpet molded products, such as lining materials for automobile trunk rooms, the low melting point fibers are preferably used in a proportion of 15 to 80% of the total weight of the final product. When manufacturing bulky needle car parts (for example, car floor mats), it is added in a proportion of 10 to 50% of the total weight of the final product.
皇施皿
先染めされた＊ｍ維デニール１５ｄのアクリル繊維７０
重量部と、先染めされた単ｔｉ＆維デニール１５ｄのポ
リプロピレンｔａｍ３０重量部とを混合してなる原料繊
維を梳綿機に供給し、て繊維ウェッブに形成した後、こ
の繊維ウェッブを所定枚数積層し、３５０ ｇ ／イな
る単位面積当たり重量を有する不織布状の繊維積層体を
準備した。この繊維積層体に８０回／−なるニードリン
グ条件に従ってニードリング加工を施し、成形品の表層
部材として機能する第１のニードルカーペットを製造し
た。上記第１のニードルカーペットとは別に、先染めさ
れたｆＲ１ｉｌ＋維デニール１５ｄのポリエステル繊維
を梳綿機に供給して繊維ウエップに形成した後、この繊
維ウェッブに表面側から６０回／−１裏側から５０回／
−なるニードリング条件に従ってニードリング加工を施
こし、成形品の裏打ち部材として機能する第２のニード
ルカーペットを製造した。第１のニードルカーペットと
第２のニードルカーペットを重ね合わせ、７５回／−す
るニードリング条件に従ってニールリング加工を施こし
てニードルカーペット成形品の中間製品を形成した後、
この中間製品を加熱炉に導入し、２００℃に３分間維持
しながら型押し加工を施こし、自動車の車室内でタイヤ
ハウス部分を被覆するニードルカーペント成形品を製造
した。得られたニードルカーペット成形品を車室内の所
定部位にフロアマントとして取付け、通常の使用条件下
における成形形状の経時変化を１５０日間に亘って目視
検査した。Yarn-dyed *m fiber denier 15d acrylic fiber 70
A raw material fiber made by mixing 30 parts by weight of Yarn-dyed single Ti & fiber denier 15D polypropylene TAM is fed to a carding machine and formed into a fiber web, after which a predetermined number of sheets of this fiber web are laminated. A nonwoven fiber laminate having a weight per unit area of , 350 g/i was prepared. This fiber laminate was subjected to needling according to needling conditions of 80 times/- to produce a first needle carpet functioning as a surface layer member of a molded article. Separately from the first needle carpet, yarn-dyed polyester fibers of fR1il + fiber denier 15d are fed to a carding machine to form a fiber web, and then the fiber web is coated 60 times from the front side/-1 from the back side. 50 times/
- A second needle carpet was produced which functioned as a backing member for the molded article by performing needling according to the needling conditions. After overlapping the first needle carpet and the second needle carpet and performing a needle ring process according to the needling conditions of 75 times/- to form an intermediate product of the needle carpet molded product,
This intermediate product was introduced into a heating furnace and subjected to embossing while being maintained at 200° C. for 3 minutes to produce a needle carpent molded product for covering a tire house inside an automobile. The obtained needle carpet molded product was attached to a predetermined location in the vehicle interior as a floor mantle, and changes in the molded shape over time under normal usage conditions were visually inspected for 150 days.
、このフロアマットにおいては、初期ヤング率の低下割
合が大きなアクリル繊維の配合に起因して形崩れが全く
発生しなかった。In this floor mat, no deformation occurred due to the combination of acrylic fibers which had a large initial Young's modulus reduction rate.
尚、上記実施例においてはアクリル繊維とポリプロピレ
ン繊維からなる表層部材と、ポリエステル繊維製の裏打
ち部材とをｐｌｒｇすることによってニードルカーペッ
ト成形品の中間製品を形成しているが、アクリル繊維と
低融点！’！＋維、例えばポリプロピレン繊維の混合ウ
ェッブから単層構造を有するニードルカーペット成形品
の中間製品を形成することも可能である。In the above example, an intermediate product of a needle carpet molded product is formed by PLRGing a surface layer member made of acrylic fibers and polypropylene fibers and a backing member made of polyester fibers, but acrylic fibers and low melting point! '! It is also possible to form an intermediate product of a needle carpet molding with a single layer structure from a mixed web of fibers, for example polypropylene fibers.
血皿■立果
本発明によれば、アクリル繊維がその初期ヤング率に起
因して型押しされたままの形状に保持され、また低融点
繊維がアクリル繊維に対して接着材として働くため、ア
クリル繊維の配合率を変化せしめることによって、剛性
もしくは嵩高性の調節可能な形態安定性に優れたニード
ルカーベント成形品が得られる。従って本発明に係るニ
ードルカーペット成形品は、建築物や自動車のフロアマ
ントあるいは自動車のトランクルーム等の内張り部材と
して使用した場合、長期間に亘って優れた形態安定性を
保持することができる。According to the present invention, the acrylic fiber retains its embossed shape due to its initial Young's modulus, and the low melting point fiber acts as an adhesive for the acrylic fiber. By changing the blending ratio of fibers, it is possible to obtain a needle curved molded product with excellent morphological stability and adjustable rigidity or bulkiness. Therefore, when the needle carpet molded product according to the present invention is used as a lining member for a building, a floor cape of an automobile, a trunk room of an automobile, etc., it can maintain excellent form stability for a long period of time.
第１図は各種の繊維材料について水中温度と初期ヤング
率の関係を測定した結果を示す線図である。
特許出願人 東曲紡ｍ株式会社゛
代 理 人 江 原 省
吾 ”第 １ 図
＞Ｆ−度 （Ｃ）FIG. 1 is a diagram showing the results of measuring the relationship between underwater temperature and initial Young's modulus for various fiber materials. Patent applicant Tokyokubo Co., Ltd. Managing Director Gangwon Province
Figure 1 > F-degree (C)
Claims (1)
点を有する熱可塑性繊維からなるニードルカーペットを
、前記熱可塑性繊維の溶融温度迄加熱しながら型押し成
形することを特徴とする、ニードルカーペット成形品の
製造方法。(1) A needle carpet molded product, characterized in that a needle carpet made of acrylic fibers and thermoplastic fibers having a lower melting point than the acrylic fibers is pressed and molded while heating to the melting temperature of the thermoplastic fibers. manufacturing method.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP61303534A JPS63159563A (en) | 1986-12-18 | 1986-12-18 | Production of needle carpet molded product |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP61303534A JPS63159563A (en) | 1986-12-18 | 1986-12-18 | Production of needle carpet molded product |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPS63159563A true JPS63159563A (en) | 1988-07-02 |
Family
ID=17922145
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP61303534A Pending JPS63159563A (en) | 1986-12-18 | 1986-12-18 | Production of needle carpet molded product |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS63159563A (en) |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5643457A (en) * | 1979-09-18 | 1981-04-22 | Japan Vilene Co Ltd | Production of nonwoven fabric molded article |
-
1986
- 1986-12-18 JP JP61303534A patent/JPS63159563A/en active Pending
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5643457A (en) * | 1979-09-18 | 1981-04-22 | Japan Vilene Co Ltd | Production of nonwoven fabric molded article |
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