KR20060132594A - Stretchable nonwoven fabric - Google Patents

Abstract

The present invention aims to improve the stretchability of a spun-bonded nonwoven fabric. By providing a spun- bonded nonwoven fabric with many pores (2) using a needle punch, stretchability is imparted to the nonwoven fabric. A stretchable nonwoven fabric (1) may be impregnated with a synthetic resin such as a thermosetting resin.

Description

Stretchable Nonwovens {STRETCHABLE NONWOVEN FABRIC}

The present invention relates to a nonwoven fabric obtained by the spunbond method.

Conventionally, many needle nonwoven fabrics are used as a skin material. However, needle nonwovens are not possible to be thin.

Therefore, a thin nonwoven fabric is provided by the spun bond method (for example, refer patent document 1).

Patent Document 1: Japanese Patent Application Laid-Open No. 2002-105832

However, the nonwoven fabric obtained by the said spunbond method lacks the longitudinal and horizontal elongation, and when the said nonwoven fabric is adhere | attached with a base material as a skin material and shape | molded, there exists a problem that wrinkles and a crack generate | occur | produce in the deep drawing part of the obtained molded object.

The present invention provides a stretchable nonwoven fabric in which pores are formed by needle punching on a nonwoven fabric produced by a spun bond method as a means for solving the above problems.

It is preferable that the elastic nonwoven fabric is impregnated with a synthetic resin, and the synthetic resin is preferably a thermosetting resin.

The present invention also provides an interior material in which an elastic nonwoven fabric is bonded to the surface of a substrate as a skin material and formed into a predetermined shape.

Effects of the Invention

Pores by the needle punch improve the longitudinal and horizontal elongation of the nonwoven fabric. Therefore, even when the elastic nonwoven fabric of the present invention is bonded to a substrate and molded, wrinkles and cracks do not occur in the deep drawing portion.

1 is a perspective view of a stretchable nonwoven fabric.

2 is an explanatory diagram of a molding die.

3 is a side cross-sectional view of the molding.

<Description of Symbols for Major Parts of Drawings>

1: elastic nonwoven fabric 2: (C) ball

The nonwoven fabric used in the present invention is produced by a spunbond method, that is, a thermoplastic resin is melted and extruded as a plurality of filaments from the spinneret, and the filaments are fused together in a sheet form.

Alternatively, a plurality of nonwoven fabrics produced by a spunbond method may be laminated, and a nonwoven fabric having needle punched them may be used.

Examples of the thermoplastic resin used in the present invention include polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, ethylene propylene terpolymer, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl acetate, Fluoropolymer, thermoplastic acrylic resin, thermoplastic polyester resin, thermoplastic polyamide resin, acrylonitrile-butadiene copolymer, styrene-butadiene copolymer, acrylonitrile-styrene-butadiene copolymer and the like are used. These thermoplastic resins are used individually or in combination of 2 or more types.

The thickness of a nonwoven fabric is 0.05 mm-1 mm normally, a fineness is 0.05 dtex-5 dtex, and a unit weight is 10 g / m <2> -200 g / m <2>.

The nonwoven fabric obtained by the spun bond method forms pores by needle punching. The shape of the hole formed in the nonwoven fabric may be any shape such as circular, elliptical or rectangular. The pores formed in the nonwoven fabric need not all have the same shape, and may be made of a plurality of shapes.

The hole diameter is 0.1 mm to 2 mm, preferably 0.2 mm to 1.5 mm. If the hole is circular, the hole diameter is the diameter of the circle, and in the case of the rectangle, the longest diagonal line is the hole diameter. The number of holes formed in the nonwoven fabric is 10 / cm 2 to 100 / cm 2.

The nonwoven fabric of the present invention is impregnated with a synthetic resin. Examples of the synthetic resin to be impregnated include thermosetting resins such as phenol resins, urethane resins, melamine resins, urea resins, epoxy resins, and thermosetting polyesters.

Hereinafter, the phenol resin used by this invention is demonstrated.

[Phenolic resin]

Phenolic resins are obtained by condensation of phenolic compounds with aldehydes and / or aldehyde donors. The phenolic resin may be sulfomethylated and / or sulfimethylated to impart water solubility.

The phenol resin of the present invention is impregnated into the nonwoven fabric as an initial condensate. The initial condensate is usually prepared as an aqueous solution, but as desired, methanol, ethanol, isopropanol, n-propanol, isopropanol, n-butanol, isobutanol, sec-butanol, t-butanol, n-amyl alcohol, isoamyl Alcohol, n-hexanol, methylamyl alcohol, 2-ethylbutanol, n-heptanol, n-octanol, trimethylnonyl alcohol, cyclohexanol, benzyl alcohol, furfuryl alcohol, tetrahydrofurfuryl alcohol, abiethyl alcohol Alcohols such as diacetone alcohol, acetone, methyl acetone, methyl ethyl ketone, methyl-n-propyl ketone, methyl-n-butyl ketone, methyl isobutyl ketone, diethyl ketone, di-n-propyl ketone and diiso Ketones such as butyl ketone, acetonyl acetone, methyl oxide, cyclohexanone, methylcyclohexanone, acetophenone, camphor, ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, trimethylene glycol, polyethylene Glycols such as glycol, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, ethylene glycol isopropyl ether, diethylene glycol monomethyl ether, triethylene glycol monomethyl ether and other glycol ethers, ethylene glycol diacetate, diethylene Esters of the above glycols such as glycol monoethyl ether acetate, derivatives thereof, ethers such as 1,4-dioxane, diethyl cellosolve, diethyl carbitol, ethyl lactate, isopropyl lactate, and diglycol di You may use water-soluble organic solvents, such as an acetate and dimethylformamide.

(Phenolic compound)

As a phenol type compound used for the said phenol resin, monohydric phenol may be sufficient, polyhydric phenol may be sufficient, and a mixture of monohydric phenol and polyhydric phenol may be sufficient, but when monohydric phenol is used, formaldehyde at the time of hardening and after hardening is used. Since is liable to be released, polyhydric phenol or a mixture of monohydric phenol and polyhydric phenol is preferably used.

(Monohydric phenol)

Examples of the monohydric phenol include phenol, o-cresol, m-cresol, p-cresol, ethyl phenol, isopropyl phenol, xylenol, 3,5-xylenol, butyl phenol, t-butyl phenol and nonyl phenol. Alkyl phenols, o-fluorophenol, m-fluorophenol, p-fluorophenol, o-chlorophenol, m-chlorophenol, p-chlorophenol, o-bromophenol, m-bromophenol, such as p-bromophenol, o-iodinephenol, m-iodinephenol, p-iodinephenol, o-aminophenol, m-aminophenol, p-aminophenol, o-nitrophenol, m-nitrophenol, p-nitrophenol And monocyclic phenol substituents such as monovalent phenol substituents such as 2,4-dinitrophenol, 2,4,6-trinitrophenol, and naphthol, and the like. These monovalent phenols may be used alone or in combination of two or more thereof. Can be used.

(Polyhydric phenol)

Examples of the polyhydric phenol include resorcin, alkyl resorcin, pyrogarol, catechol, alkyl catechol, hydroquinone, alkylhydroquinone, fluoroglucin, bisphenol, dihydroxynaphthalin, and the like. A phenol can be used individually or in mixture of 2 or more types. Among the polyhydric phenols, preferred is resorcin or alkylresorcin, and particularly preferred is alkylresorcin, which has a faster reaction rate with aldehyde than resorcin.

As alkyl resorcin, 5-methylresorcin, 5-ethyl resorcin, 5-propyl resorcin, 5-n-butyl resorcin, 4, 5- dimethyl resorcin, 2, 5- dimethyl resorcin, 4,5-diethylresorcin, 2,5-diethylresorcin, 4,5-dipropylresorcin, 2,5-dipropylresorcin, 4-methyl-5-ethylresorcin, 2-methyl- 5-ethylresorcin, 2-butyl-5-propylresorcin, 2,4,5-trimethylresorcin, 2,4,5-triethylresorcin and the like.

The polyhydric phenol mixture obtained by dry distillation of estonia oil shale is a particularly preferred polyhydric phenol raw material in the present invention because it contains a large amount of various alkyl resorcines which are inexpensive and highly reactive in addition to 5-methylresorcin. .

In the present invention, the phenolic compound and the aldehyde and / or aldehyde donors (aldehydes) can be condensed, but the aldehyde donor means a compound or a mixture thereof that produces aldehyde when decomposed. Such aldehydes include formaldehyde, acetaldehyde, propionaldehyde, chloral, furfural, glyoxal, n-butylaldehyde, caproaldehyde, allylaldehyde, benzaldehyde, crotonaldehyde, acrolein, phenylacetaldehyde, o-tolualdehyde Silaldehyde and the like are exemplified, and examples of the aldehyde donor include paraformaldehyde, trioxane, hexamethylenetetramine, tetraoxymethylene and the like.

As described above, in order to improve the stability of the water-soluble phenolic resin, it is preferable to sulfomethylate and / or sulfimethylate the phenolic resin.

(Sulfomethylating agent)

Examples of the sulfomethylating agent that can be used to improve the stability of the water-soluble phenolic resin include sulfurous acid, bisulfite or metabisulfite, and quaternary amines such as alkali metals or trimethylamine and benzyltrimethylammonium or quaternary ammonium. The water-soluble sulfite obtained by making it react, and the aldehyde adduct obtained by reaction of these water-soluble sulfite and an aldehyde are illustrated.

The aldehyde adduct is formaldehyde, acetaldehyde, propionaldehyde, chloral, furfural, glyoxal, n-butylaldehyde, caproaldehyde, allylaldehyde, benzaldehyde, crotonaldehyde, acrolein, phenylacetaldehyde, o- Aldehydes, such as salicylic aldehyde, and the said water-soluble sulfite are addition reaction, For example, the aldehyde adduct which consists of formaldehyde and a sulfite is hydroxymethane sulfonate.

(Sulfymethylating agent)

Examples of the sulfylalkylating agent that can be used to improve the stability of the water-soluble phenolic resin include aliphatic and aromatic aldehyde alkali metal sulfoxylates and sodium hydrosulfite, such as formaldehyde sodium sulfoxide (longalit) and benzaldehyde sodium sulfoxylate. Alkali metals such as magnesium hydrosulfite, hydrosulfite (adithionate) of alkaline earth metals, and hydroxyalkanesulfinates such as hydroxymethane sulfinate.

(Third component)

In the preparation of the phenol resin, if necessary, for example, hydrochloric acid, sulfuric acid, orthophosphoric acid, boric acid, oxalic acid, formic acid, acetic acid, butyric acid, benzenesulfonic acid, phenolsulfonic acid, paratoluenesulfonic acid, naphthalin-α-sulfonic acid, naph Esters of inorganic or organic acids such as tallin-β-sulfonic acid, organic acids such as oxalic acid dimethyl ester, acid anhydrides such as maleic anhydride and phthalic anhydride, ammonium chloride, ammonium sulfate, ammonium nitrate, ammonium oxalate, ammonium acetate, ammonium phosphate, Ammonium salts such as ammonium thiocyanate and ammonium sulfonate, monoacetic acid or its sodium salt, organic halides such as α, α'-dichlorohydrin, hydrochlorides of amines such as triethanolamine hydrochloride and aniline hydrochloride, and salicylic acid urea Urea adducts such as duct, stearic acid urea adduct, heptanoic acid urea adduct, acidic substances such as N-trimethyltaurine, zinc chloride, ferric chloride, ammonia, amine Weak salts of alkali metals such as alkali metals such as sodium hydroxide, potassium hydroxide, barium hydroxide, calcium hydroxide, hydroxides of alkaline earth metals, alkali earth metals such as lime, alkali metals such as sodium carbonate, sodium sulfite, sodium acetate and sodium phosphate You may mix alkaline substance as a catalyst or a pH adjuster.

(Production of Phenolic Resin)

The said phenol resin (initial condensate) can be manufactured by a conventional method, Specifically, (a) The method of condensing monohydric phenol and / or polyhydric phenol, and aldehydes, (b) monohydric phenol and aldehydes A condensed initial condensate and / or an initial condensate obtained by condensing polyhydric phenol and aldehydes, a method of condensing monohydric phenol and / or polyhydric phenol, (c) an initial condensation of monohydric phenol, polyhydric phenol and aldehydes A method of condensing a condensate with a monohydric phenol and / or a polyhydric phenol, (d) a method for condensing an initial condensate obtained by condensing monohydric phenol and aldehydes, and an initial condensation product having condensed polyhydric phenol and aldehydes, (e) A method of condensing an initial condensate obtained by condensing monohydric phenol and aldehydes and / or an initial condensate obtained by condensing monohydric phenol and aldehydes, and an initial condensate containing monohydric phenol, polyhydric phenol and aldehydes. It can manufacture by etc.

In the present invention, preferred phenol resins are phenol-alkylresorcin cocondensates. The said phenol-alkyl resorcin cocondensate is said to be stable in the aqueous solution of the said cocondensate (initial cocondensate), and can be stored for a long term at normal temperature compared with the condensate (initial condensate) which consists only of phenol. There is an advantage. Moreover, the stability at the time of impregnating the said aqueous solution to the nonwoven fabric, and precure | cure to B state is good, and the said nonwoven fabric does not lose moldability even if it preserve | preserves for a long time. Moreover, since alkylresorcin has high reactivity with an aldehyde and captures and reacts with free aldehyde, it also has the advantage of reducing the amount of free aldehyde in resin.

A preferred method for preparing the phenol-alkylresorcin cocondensate is to first prepare a phenol resin initial condensate by reacting phenol and an aldehyde, and then add alkylresorcin to the phenol resin initial condensate, and, if desired, add aldehyde. It is a method of reacting.

For example, in the condensation of the above-mentioned (a) monohydric phenol and / or polyhydric phenol, and aldehydes, 0.2-3 mol of aldehydes per 1 mol of monohydric phenols, and 0.1-0.8 mol of aldehydes per 1 mol of polyhydric phenols; As needed, a solvent and a 3rd component are added and it heat-reacts at liquid temperature of 55-100 degreeC for 8 to 20 hours. At this time, all the aldehydes may be added at the start of the reaction, or may be dividedly added or continuously added dropwise.

When the phenol resin initial condensate is sulfomethylated and / or sulfimethylated, a sulfomethylating agent and / or a sulfimethylating agent is added to the initial condensate at any stage, thereby sulphating the phenolic compound and / or the initial condensate. Methylated and / or sulfimethylated.

The addition of the sulfomethylating agent and / or sulfimethylating agent may be performed at any stage after the reaction before the condensation reaction.

The total addition amount of a sulfomethylating agent and / or a sulfimethylating agent is 0.001-1.5 mol normally with respect to 1 mol of phenolic compounds. In the case of 0.001 mol or less, the hydrophilicity of a phenol resin is not enough, and in the case of 1.5 mol or more, the water resistance of a phenol resin worsens. In order to maintain favorable performances, such as the hardenability of the initial condensate manufactured and the physical property of resin after hardening, it is preferable to set it as about 0.01-0.8 mol.

The sulfomethylating agent and / or sulfimethylating agent added in order to sulfomethylate and / or sulfimethylate the initial condensate reacts with the methirol group of the initial condensate and / or the aromatic ring of the initial condensate, thereby adding to the initial condensate. Sulfomethyl group and / or sulfimethyl group are introduced.

The aqueous solution of the initial condensate of the phenol resin sulfomethylated and / or sulfimethylated in this manner is stable in a wide range of acidic (pH 1.0) to alkaline properties and can be cured in any of acidic, neutral and alkaline regions. . In particular, when cured on the acidic side, the residual methirol group is reduced, and there is no fear that the cured product is decomposed to generate formaldehyde.

In the present invention, as the phenol resin, urea, thiourea, melamine, thiomelamine, dicyandiamine, guanidine, guanamine, acetoguanamine, benzoguanamine, 2,6diamino-1,3-diamine, if desired You may add an amino resin monomer and / or the initial condenser which consists of the said amino resin monomer to co-condense with a phenol type compound and / or initial condensate.

Moreover, you may add and mix the hardening | curing agent, such as an aldehyde and / or an aldehyde donor or an alkyrylated triazone derivative, to the initial condensate (including an initial cocondensate) of the phenol resin of this invention.

As the aldehyde and / or aldehyde donor, an aldehyde and / or an aldehyde donor used in the preparation of the initial condensate (initial cocondensate) of the phenol resin is used, and the alkyrylated triazone derivative is an urea compound, an amine compound, Obtained by reaction with an aldehyde and / or an aldehyde donor. As the urea-based compound used in the preparation of the alkyrylated triazone derivatives, alkyl urea such as urea, thiourea, methylurea, alkylthiourea such as methylthiourea, phenylurea, naphthylurea, halogenated phenylurea, nitration Single or mixture of 2 or more types, such as an alkyl element, is illustrated. Particularly preferred urea compounds are urea or thiourea. As amines, amines such as aliphatic amines such as methylamine, ethylamine, propylamine, isopropylamine, butylamine and amylamine, benzylamine, furfurylamine, ethanolamine, ethylenediamine, hexamethylenediamine and hexamethylenetetramine Besides, ammonia is also exemplified, and these are used alone or as a mixture of two or more kinds. The aldehyde and / or aldehyde donor used in the preparation of the alkyrylated triazone derivatives is the same as the aldehyde and / or aldehyde donor used in the preparation of the initial condensate of the phenol resin.

In the synthesis of the alkyrylated triazone derivatives, amines and / or ammonia are usually 0.1 to 1.2 moles and aldehyde and / or aldehyde donors at a rate of 1.5 to 4.0 moles per 1 mole of the urea compound. In the above reaction, the order of addition thereof is arbitrary, but as a preferred reaction method, first, the required amount of aldehyde and / or aldehyde donor is introduced into the reactor, and the required amount of amines and / or ammonia is gradually maintained while maintaining the temperature below 60 ° C. There is also a method of adding a required amount of urea-based compound, and stirring and heating at 80 to 90 ° C. for 2 to 3 hours for reaction. Although 37% formalin is usually used as the aldehyde and / or aldehyde donor, a part thereof may be substituted with paraformaldehyde in order to increase the concentration of the reaction product. If hexamethylenetetramine is used, a higher solids reaction product is obtained. The reaction between the urea compound, the amines and / or ammonia, and the aldehyde and / or aldehyde feed is usually carried out in an aqueous solution, but instead of part or all of the water, methanol, ethanol, isopropanol, n-butanol, ethylene glycol, diethylene glycol A single or a mixture of two or more of these alcohols may be used, and a single or a mixture of two or more kinds of water-soluble organic solvents such as ketones such as acetone and methyl ethyl ketone may be added. The amount of the curing agent added is 10 to 100 parts by mass based on 100 parts by mass of the initial condensate (initial cocondensate) of the phenolic resin of the present invention in the case of aldehyde and aldehyde donor, and in the case of an alkyrylated triazone derivative. It is 10-500 mass parts with respect to 100 mass parts of initial condensate (initial cocondensate).

The synthetic resin of the present invention is usually prepared as a solution, but the solution includes polyvinyl alcohol, sodium arginate, starch, starch derivative, glue, gelatin, blood powder, methyl cellulose, carboxymethyl cellulose, polyacrylate, polyacrylamide, and the like. Water-soluble polymers or natural rubbers; Calcium carbonate, magnesium carbonate, barium sulfate, calcium sulfate, calcium sulfite, calcium phosphate, calcium hydroxide, magnesium hydroxide, aluminum hydroxide, magnesium oxide, titanium oxide, iron oxide, zinc oxide, alumina, silica, diatomaceous earth, roadite, gypsum, talc, Clay, Asbestos, Mica, Calcium Silicate, Bentonite, White Carbon, Carbon Black, Iron Powder, Aluminum Powder, Glass Powder, Stone Powder, Synthetic Resin Powder, Blast Furnace Slag, Fly Ash, Cement, Dizirconia Powder, Wood Powder, Wheat Flour, Walnut Powder Fillers such as starch, coconut shell meal and rice flour; Surfactants; Higher fatty acids such as stearic acid and palmitic acid, higher alcohols such as paltimin alcohol and stearyl alcohol; Esters of fatty acids such as butyl stearate and glycerin monostearate; fatty acid amides; Natural waxes such as carnauba wax and synthetic waxes; Pigments, dyes, flame retardants, flame retardants, insect repellents, preservatives, anti-aging agents, ultraviolet absorbers, fluorescent dyes, surfactants, foaming agents, oil repellents and the like may be added.

In the case where the nonwoven fabric of the present invention is impregnated with a thermosetting resin, the thermosetting resin in the nonwoven fabric may be dried in advance to leave the B-state.

In the nonwoven fabric of the present invention, a polyolefin resin such as polyethylene, polypropylene, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, or a modified product of polyolefin resin, polyvinyl chloride, polyurethane, polyester, poly You may apply | coat and laminate powder and film of hot melt adhesives, such as an ester copolymer, a polyamide, a polyamide copolymer, a cellulose derivative, and a polyvinyl ether.

Since the elastic nonwoven fabric 1 (refer FIG. 1) of this invention improves the longitudinal and horizontal elasticity by the porous hole 2 by a needle punch, it is easy to adhere | attach another member without forming a wrinkle. Even when adhering to the surface of the member having unevenness, the stretchable nonwoven fabric can be adhered cleanly.

The stretchable nonwoven fabric 1 can be used as the skin material 1 of the interior material 3, for example.

Although the nonwoven fabric of this invention is manufactured by the spun bond method, besides, you may use the nonwoven fabric obtained by the melt-blowing method and the calendar process as the nonwoven fabric of this invention, for example.

[Internal materials]

An interior material can be manufactured by adhering the stretchable nonwoven fabric of the present invention to the surface of the substrate as a skin material and molding it into a predetermined shape.

As said base material, For example, synthetic fiber, pulp, cotton, such as polyester fiber, polyethylene fiber, polypropylene fiber, polyamide fiber, acrylic fiber, urethane fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, acetate fiber, Of regenerated fibers obtained by decomposing scraps of vegetable fibers such as palm fibers, hemp fibers, bamboo fibers, kenaf fibers, inorganic fibers such as glass fibers, carbon fibers, ceramic fibers, asbestos fibers, or fiber products using these fibers Knitted fabrics, nonwoven fabrics, felts, and laminates thereof, or polyurethanes (soft polyurethanes, rigid polyurethanes), polyethylene, polypropylene, polyamides, polyesters, polyvinyl chlorides, composed of fibers of mixed species using two or more fibers Plastic continuous foam bodies, such as a sintered compact of plastic beads, etc. are used.

The substrate includes polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl acetate, fluororesin, thermoplastic acrylic resin, thermoplastic polyester resin, Thermoplastic resins such as thermoplastic polyamide resins, acrylonitrile-butadiene copolymers, styrene-butadiene copolymers, acrylonitrile-styrene-butadiene copolymers, urethane resins, melamine resins, urea resins, thermosetting acrylic resins, phenol resins, You may impregnate thermosetting resins, such as a resorcin resin, an alkyl resorcin resin, an epoxy resin, and a thermosetting polyester.

When the base material is impregnated with a thermosetting resin, the thermosetting resin in the base material may be dried in advance to leave the B-state.

The base material and the skin material are adhered to each other by laminating a skin material made of the stretchable nonwoven fabric of the present invention on the surface of the base material and cold pressing after hot pressing or overheating.

When shaping | molding to a predetermined shape, it is preferable to carry out simultaneously with the adhesion of a base material and a skin material. When molding is carried out simultaneously with the bonding, the skin material is stretched and adhered to the surface of the substrate cleanly.

The interior materials of the present invention are used in automobile parts such as door trims, dashboards, ceiling materials, hood insulators, engine covers, insulation materials or sound insulation materials, building materials for buildings, wall materials, insulation materials, sound insulation materials and the like.

Hereinafter, an Example demonstrates this invention. In addition, this invention is not limited only to the Example shown below.

Example 1

The nonwoven fabric (fineness: 3.5 dtex, unit weight: 40 g / m <2>) which consists of polyester fiber obtained by the spun bond method was obtained. Next, in order to form a hole in the said nonwoven fabric, the said nonwoven fabric was press-welded with the roll in which the needle of the largest thickness 1mm is provided at random.

15 holes / cm <2> were formed in the obtained nonwoven fabric with a hole diameter of 0.1 mm-0.3 mm.

Moreover, the said woven fabric was impregnated so that phenol-formaldehyde initial condensate (solid content: 30 mass%) may be content of 30 mass% as solid content. After impregnation, the nonwoven fabric was dried at 150 ° C. for 3 minutes and precured to obtain an elastic nonwoven fabric.

Example 2

An elastic nonwoven fabric was obtained in the same manner as in Example 1 except that 50 holes / cm 2 of holes having a hole diameter of 0.1 mm to 0.3 mm were formed in the nonwoven fabric.

Example 3

An elastic nonwoven fabric was obtained in the same manner as in Example 1 except that 100 holes / cm 2 were formed in the nonwoven fabric having a hole diameter of 0.1 mm to 0.3 mm.

Comparative Example 1

An elastic nonwoven fabric was obtained in the same manner as in Example 1 except that eight holes / cm 2 of holes having a hole diameter of 0.1 mm to 0.3 mm were formed in the nonwoven fabric.

Comparative Example 2

An elastic nonwoven fabric was obtained in the same manner as in Example 1 except that 110 holes / cm 2 were formed in the nonwoven fabric having a hole diameter of 0.1 mm to 0.3 mm.

[exam]

Glass wool obtained by applying the stretchable nonwoven fabric 1 obtained in Examples 1 to 3 and Comparative Examples 1 and 2 to the skin material 1A and applying the skin material 1A to the phenol-formaldehyde initial condensate. (Base material) 200 degreeC, by the shaping | molding die 3 which overlaps with (7) (unit weight: 800 g / m <2>, thickness: 50 mm), and consists of the upper frame 4 and the lower frame 5 shown in FIG. The molded article 6 (thickness 5 mm) was obtained by press molding on 60 second conditions (refer FIG. 3).

A visual observation test of the appearance of each of the obtained molded articles 6 was performed. The results of the test are shown in Table 1.

Molded article (6) Number of holes (pcs / ㎠) Appearance of molding 6 (especially skin material 1A) Example 1 15 Clean without wrinkles or peeling Example 2 50 Clean without wrinkles or peeling Example 3 100 Clean without wrinkles or peeling Comparative Example 1 8 Creases enter the corners 9 of the molding Comparative Example 2 110 The nonwoven fabric is peeled off the rising surface 8

Example 4

The nonwoven fabric (fineness: 0.1 dtex, unit weight: 30 g / m <2>) which consists of polypropylene fiber obtained by the spun bond method was obtained. Next, in order to form a hole in the said nonwoven fabric, the said nonwoven fabric was press-welded with the roll in which the needle of the largest thickness 1mm is provided at random.

In the obtained nonwoven fabric, 25 holes / cm <2> of holes of 0.8-1.2 mm of hole diameters were formed.

Moreover, the said woven fabric was impregnated so that phenol-formaldehyde initial condensate (solid content: 40 mass%) may be content of 25 mass% as solid content. After impregnation, the nonwoven fabric was dried at 150 ° C. for 3 minutes, and precured to obtain an elastic nonwoven fabric.

The resulting stretchable nonwoven fabric was used as a skin material, and the skin material was laminated on a glass wool (unit weight 600 g / m 2, thickness: 40 mm) coated with a phenol-formaldehyde initial condensate and precured at a temperature of 210 ° C. for 45 seconds. Press molding was carried out to obtain a molded product. The molded article had no wrinkles or other defects in appearance.

Example 5

The nonwoven fabric (fineness: 2.0 dtex, unit weight: 60 g / m <2>) which consists of polyester fiber obtained by the spun bond method was obtained. Next, in order to form a hole in the said nonwoven fabric, the said nonwoven fabric was press-welded with the roll in which the needle of the largest thickness 1mm is provided at random.

In the obtained nonwoven fabric, 18 holes / cm <2> were formed with hole diameters of 0.5 mm-0.8 mm.

Further, the nonwoven fabric was impregnated with a phenol-alkylresorcin-formaldehyde initial condensate (solid content: 40 mass%) used in Example 4 so as to have a content of 30 mass% in solid content, and 200 on the back surface of the nonwoven fabric. The polyamide type hot melt adhesive of melting | fusing point 130 degreeC which consists of a particle size of a mesh passage was spray-coated. Then, the said nonwoven fabric was dried at 150 degreeC for 2 minutes, and the elastic nonwoven fabric which has a hot melt powder adhesive was obtained.

Comparative Example 3

An elastic nonwoven fabric was obtained in the same manner as in Example 5 except that the hole diameter of the nonwoven fabric in Example 5 was 2.1 to 2.4 mm.

[Comparative Example 4]

Nonwoven fabric (unit weight :) by needle punching using a mixed fiber composed of 90% by mass of polyester fiber used in Example 5 and 10% by mass of low melting point polyester fiber (degree of fineness: 2.0 dtex, softening point: 110 ° C) 60 g / m 2) was obtained.

The nonwoven fabric was impregnated with a phenol-alkylresorcin-formaldehyde initial condensate (solid content: 40% by mass) used in Example 5 so as to have a content of 30% by mass in solid content, and the polyamide used in Example 5 above. A spray coating system was applied. Thereafter, the nonwoven fabric was dried at 150 ° C. for 2 minutes to obtain a stretchable nonwoven fabric having a hot melt adhesive.

Glass wool (unit weight: 1000 g / m 2, thickness 70 mm), wherein the stretchable nonwoven fabric obtained in Examples 5 and Comparative Examples 3 and 4 was used as a skin material, and the skin material was coated with a phenol-formaldehyde initial condensate. ), And press-molded in a predetermined shape at 200 ° C. for 50 seconds to obtain a molded article. Visual observation test of each external appearance of the obtained molding was done. The results of the test are shown in Table 2.

sample Appearance of moldings (especially skin materials) Example 5 The outer skin was very clean without wrinkles, peeling or tearing. Comparative Example 3 The skin was torn at the uneven portion of the molding. Comparative Example 4 The moldability was good, but fluff occurred on the skin material having a large thickness.

Since the nonwoven fabric obtained by the conventional spun bond method etc. does not have the longitudinal and transverse direction elongation, when the said nonwoven fabric is adhere | attached to another base material as a skin material, it is easy to produce wrinkles in the outer skin material of the uneven part of another base material, and also bad adhesiveness. It turns out that (moxibustion) is easy to generate | occur | produce.

Moreover, although the nonwoven fabric obtained by the needle punching method has good longitudinal and lateral elongation, and the adhesiveness to another base material is favorable, fluff arises on the surface of the said nonwoven fabric, the appearance of the molded object obtained worsens.

The appearance of the molded product using the stretchable nonwoven fabric of the present invention as a skin material is good and is excellent in moldability.

The stretchable nonwoven fabric of the present invention can be used as a skin material such as door trims, dashboards, ceiling materials, hood insulators, engine interiors such as engine covers, insulation materials or sound insulation materials, building materials for construction, walls, insulation materials, sound insulation materials and the like. have.

Claims (4)

An elastic nonwoven fabric comprising pores formed by a needle punch on a nonwoven fabric produced by a spunbond method. The stretchable nonwoven fabric of claim 1, wherein the stretchable nonwoven fabric is impregnated with a synthetic resin. The stretchable nonwoven fabric as claimed in claim 2, wherein the synthetic resin is a thermosetting resin. A nonwoven fabric according to any one of claims 1 to 3, wherein the nonwoven fabric is bonded to the surface of the substrate as a skin material and formed into a predetermined shape.

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