Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
  • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
  • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
  • D04H3/105—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by needling
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
  • Y10T442/601—Nonwoven fabric has an elastic quality

Definitions

• the present invention relates to a nonwoven fabric obtained by a spunbond method.
• a thin nonwoven fabric is provided by a spun bond method (for example, see Patent Document 1).
• Patent Document 1 Japanese Patent Application Laid-Open No. 2002-105832
• the present invention provides, as a means for solving the above-mentioned problems, a stretchable nonwoven fabric in which a nonwoven fabric manufactured by a spunbonding method is provided with porosity by a one-dollar punch. It is desirable that the stretchable nonwoven fabric is impregnated with a synthetic resin, and the synthetic resin is desirably a thermosetting resin.
• the present invention provides an interior material formed into a predetermined shape by bonding a stretchable nonwoven fabric as a skin material to the surface of a base material.
• the vertical and horizontal elongation of the nonwoven fabric is improved by the porosity of the needle punch. Therefore, even when the stretchable nonwoven fabric of the present invention is bonded to a substrate and molded, no wrinkles or cracks occur in the deeply drawn portion.
• the nonwoven fabric used in the present invention is manufactured by a spunbond method, that is, a method in which a thermoplastic resin is melted, extruded as a large number of filaments from a spinneret, and the filaments are fused to each other in a sheet shape. Is done.
• nonwoven fabric obtained by laminating a plurality of nonwoven fabrics manufactured by the spunbond method and punching them by one dollar.
• thermoplastic resin used in the present invention includes, for example, polyethylene, polypropylene, ethylene propylene copolymer, ethylene butyl acetate copolymer, ethylene propylene terpolymer, polyvinyl chloride, and polychloride vinylidene.
• thermoplastic resins are used alone or in combination of two or more.
• the thickness of the nonwoven fabric is usually 0.05 mm to lmm, the fineness is 0.05 dtex to 5 dtex, and the basis weight is lOgZm 2 to 200 gZm 2 .
• the nonwoven fabric obtained by the spun bond method is provided with porosity by needle punching.
• the shape of the holes provided in the nonwoven fabric may be any shape such as a circle, an ellipse, and a rectangle.
• the porosity provided in the nonwoven fabric may not necessarily have the same shape, but may have a plurality of shapes.
• the pore size is between 0.1 mm and 2 mm, preferably between 0.2 mm and 1.5 mm. If the hole is circular, the hole diameter is the diameter of the circle; if it is rectangular, the longest diagonal is the hole diameter.
• the nonwoven fabric of the present invention is impregnated with a synthetic resin.
• the synthetic resin to be impregnated include thermosetting resins such as phenol resin, urethane resin, melamine resin, urea resin, epoxy resin, and thermosetting polyester.
• the phenolic resin is obtained by condensing a phenolic compound with an aldehyde and Z or an aldehyde donor.
• the phenolic resin is for imparting water solubility. May be sulfomethylated and z- or sulfimethylated.
• the phenolic resin of the present invention is impregnated into the nonwoven fabric as an initial condensate.
• Initial condensate usually by the force desired to be prepared as an aqueous solution, methanol, ethanol, I isopropanol, n - propanol, isopropanol, n- butanol, isobutanol, sec- butanol, t chromatography butanol, n- ⁇ mill alcohol , Isoamyl alcohol, n-xanol, methyl-amyl alcohol, 2-ethylbutanol, n-ptanol, n-year-old tannonole, trimethinolenoninolenolenocone, cyclohexanole, benzinolenolenocone, furfuryl alcohol, tetrahydrofurol Alcohols such as furyl alcohol, abiethyl alcohol, diacetone alcohol, acetone,
• the phenolic compound used in the phenolic resin may be a monovalent phenol, a polyvalent phenol, or a mixture of a monovalent phenol and a polyvalent phenol.
• a monovalent phenol When only a monovalent phenol is used, formaldehyde is easily released at the time of curing and after the curing, so that a polyvalent phenol or a mixture of a monovalent phenol and a polyvalent phenol is preferably used.
• monovalent phenol examples include phenols and alkylphenols such as ⁇ -cresol, m-cresol, p-tarrezonole, ethylphenol, isopropylphenol, xylenol, 3,5-xylenol, butylphenol, tbutylphenol, and norphenol.
• alkylphenols such as ⁇ -cresol, m-cresol, p-tarrezonole, ethylphenol, isopropylphenol, xylenol, 3,5-xylenol, butylphenol, tbutylphenol, and norphenol.
• polyvalent phenol examples include resorcin, alkyl resorcin, pyrogallol, catechol, alkyl catechol, hydroquinone, alkyl hydroquinone, phloroglucin, bisphenol, dihydroxynaphthalene, etc., and these polyphenols may be used alone or in combination of two or more. Can be used.
• Preferred among polyvalent phenols are resorcinol and alkylresorcin, and particularly preferred is alkylresorcinol, which has a higher reaction rate with aldehyde than resorcinol.
• alkyl resorcinol examples include 5-methyl resorcin, 5-ethyl resorcin, 5-propyl resorcinol, 5-n-butyl resorcinol, 4,5 dimethyl resorcinol, 2,5-dimethyl resorcinol, 4,5 g Tilresorcin, 2,5 getylresorcin, 4,5-dipropylresorcinol, 2,5-dipropylresorcinol, 4-methyl-5-ethyl resorcinol, 2-methyl-5-ethyl resorcinol, 2-methyl-5-propyl resorcinol, There are 2, 4, 5-trimethyl resorcin, 2, 4, 5-triethyl resorcin and the like.
• the polyhydric phenol mixture obtained by dry distillation of an Estonian oil shale is inexpensive, highly reactive in addition to 5-methylresorcin, and contains a large amount of various alkylresorcinols.
• a polyvalent phenol raw material A polyvalent phenol raw material.
• the above-mentioned phenolic compound and aldehyde and Z or aldehyde donor (Aldehydes) condensing ability
• the above aldehyde donor means a compound or a mixture thereof which decomposes to produce an aldehyde to provide an aldehyde.
• aldehydes examples include formaldehyde, acetoaldehyde, propionaldehyde, chloral, furfural, glyoxal, n-butyraldehyde, forceproaldehyde, acrylaldehyde, benzaldehyde, crotonaldehyde, acrolein, phenylacetaldehyde, Examples thereof include o-tolualdehyde and salicylaldehyde, and examples of the aldehyde donor include paraformaldehyde, trioxane, hexamethylenetetramine, and tetraoxymethylene.
• Sulfomethylating agents that can be used to improve the stability of water-soluble phenol resins include, for example, sulfurous acid, bisulfite or metabisulfite, alkali metals or trimethylamine or benzyltrimethylammonium.
• examples include water-soluble sulfites obtained by reacting quaternary amines or quaternary ammoniums, and aldehyde adducts obtained by reacting these water-soluble sulfites with aldehydes.
• the aldehyde adducts include formaldehyde, acetoaldehyde, propionaldehyde, chloral, furfural, glyoxal, n-butyraldehyde, forceproaldehyde, arylaldehyde, benzaldehyde, crotonaldehyde, acrolein, phenylacetaldehyde, o—
• An aldehyde such as tolualdehyde and salicylaldehyde is subjected to an addition reaction with the above-mentioned water-soluble sulfite.
• an aldehyde adduct formed of formaldehyde and sulfite is a hydroxymethane sulfonate.
• Examples of the sulfialkylating agents that can be used to improve the stability of the water-soluble phenol resin include alkali metal salts of aliphatic and aromatic aldehydes such as formaldehyde sodium sulfoxylate (Rongalit) and sodium benzaldehyde sodium sulfoxylate.
• Alkali metals such as sulfoxylates, sodium hydrosulfite and magnesium hydrosulfite, alkaline earth metal hydrosulfites (dithionites), Examples thereof include hydroxyalkanesulfinates such as tansulfinates.
• phenolic resin When producing the above phenolic 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, naphthalene ⁇ - Inorganic or organic acids such as sulfonic acid and naphthalene j8-sulfonic acid, esters of organic acids such as dimethyl oxalate, acid anhydrides such as maleic anhydride and phthalic anhydride, ammonium chloride, ammonium sulfate, and ammonium nitrate.
• hydrochloric acid sulfuric acid, orthophosphoric acid, boric acid, oxalic acid, formic acid, acetic acid, butyric acid, benzenesulfonic acid, phenolsulfonic acid, paratoluenes
• the above-mentioned phenol resin (initial condensate) can be produced by a conventional method. Specifically, (a) a method of condensing monohydric phenol and Z or polyhydric phenol with an aldehyde, A method of condensing an initial condensate obtained by condensing a phenol and an aldehyde and an initial condensate obtained by condensing Z or a polyhydric phenol with an aldehyde with a monovalent phenol and Z or a polyhydric phenol, (c) A method of condensing an initial condensate obtained by condensing a monovalent phenol, a polyvalent phenol and an aldehyde with a monovalent phenol and Z or a polyvalent phenol, and (d) an initial condensate of the monovalent phenol and an aldehyde.
• a method of condensing a condensate with an initial condensate obtained by condensing a polyhydric phenol and an aldehyde (e) an initial condensate obtained by condensing a monovalent phenol and an aldehyde Preliminary / or the initial condensation product by condensation of a polyvalent phenol with aldehydes, mono- phenol and polyhydric phenol and Al It can be produced by a method of condensing an initial condensate obtained by condensing with a aldehyde or the like.
• the phenol resin is a phenol-alkylresorcinol co-condensate.
• the phenol-alkyl resorcinol co-condensate has a better aqueous solution stability of the co-condensate (initial co-condensate) and is stored at room temperature for a longer period of time compared to a condensate consisting of phenol alone (initial condensate)
• the nonwoven fabric is impregnated with the aqueous solution and precured to obtain a state B. The nonwoven fabric does not lose its moldability even when stored for a long period of time.
• Alkyl resorcin also has the advantage of reducing the amount of free aldehydes in the resin, because it reacts by capturing free aldehydes which have high reactivity with aldehydes.
• the above-mentioned phenol-alkyl resorcinol co-condensate is preferably produced by first reacting phenol with an aldehyde to produce a phenol-resin precondensate, and then to the phenol-resin precondensate. This is a method in which an alkyl resorcinol is added and, if desired, an aldehyde is added and reacted.
• aldehydes for example, in the condensation of the above-mentioned (a) —valent phenol and Z or polyhydric phenol with aldehydes, 0.2 to 3 mol of aldehydes and 1 mol of polyhydric phenol are usually added to 1 mol of monovalent phenol. Add 0.1-0.8 moles of aldehydes and, if necessary, a solvent and a third component to the moles, and react by heating at a liquid temperature of 55-100 ° C for 8-20 hours. At this time, the aldehyde may be added in its entirety at the start of the reaction, or may be added dropwise or continuously.
• a sulfomethylating agent and Z or a sulfimethylating agent are added to the precondensate at any stage to obtain a phenolic compound and Z
• the initial condensate is subjected to sulfomethyl i and z or sulfimethyl i.
• the sulfomethylating agent and / or the sulfomethylating agent may be added at any stage before, during, or after the condensation reaction.
• the total amount of the sulfomethylating agent and the Z or sulfimethylating agent is usually 0.001 to 1.5 mol per 1 mol of the phenolic compound. If the amount is less than 0.001 mol, the hydrophilicity of the phenol resin is not sufficient. It becomes worse. In order to maintain good properties such as the curability of the produced initial condensate and the physical properties of the cured resin, the amount is preferably about 0.01 to 0.8 mol.
• the sulfomethylating agent and the Z or sulfimethylating agent added for sulfomethylidation and Z or sulfimethylidation of the precondensate are combined with the methylol group of the precondensate and Z or the aromatic ring of the precondensate.
• the reaction introduces a sulfomethyl group and a Z or sulfamethyl group into the precondensate.
• the aqueous solution of the initial condensate of the phenolic resin sulfomethylated and Z- or sulfimethylated in this way is stable over a wide range of acidic (PHI. 0) -alkaline properties. Can be cured even in the region of In particular, when cured on the acidic side, residual methylol groups are reduced, and there is no danger that the cured product will be decomposed to formaldehyde.
• the phenolic resin may be urea, thiourea, melamine, thiomelamine, dicyandiamine, guanidine, guanamine, acetoguanamine, benzoguanamine, benzoguanamine, or 2,6-diamine 1,3-diamine.
• An amino resin monomer and Z or an initial condensate comprising the amino resin monomer may be added to co-condensate with the phenol compound and Z or the initial condensate.
• the phenol resin initial condensate (including the initial cocondensate) of the present invention is further mixed with a curing agent such as an aldehyde and Z or an aldehyde donor, such as an alkylollide triazone derivative. Good.
• aldehyde and / or aldehyde donor those similar to the aldehyde and Z or the aldehyde donor used in the production of the initial condensate (initial cocondensate) of the phenol resin are used. Are obtained by the reaction of urea compounds, amines, aldehydes and Z or aldehyde donors.
• Examples of the urea-based compound used in the production of the alkylolated triazone derivative include urea, thiourea, alkyl ureas such as methyl urea, alkyl thioureas such as methyl thiourea, phenyl urea, naphthyl urea, halogenated phenyl urea, and the like.
• alkyl ureas such as methyl urea
• alkyl thioureas such as methyl thiourea
• phenyl urea phenyl urea
• naphthyl urea halogenated phenyl urea
• a particularly desirable urea compound is urea or thiourea.
• amines such as methylamine, ethylamine, propylamine, and isoamine
• Aliphatic amines such as propylamine, butylamine and amylamine, benzylamine, furfurylamine, ethanolamine, ethylenediamine, hexamethylenediamine, hexamethylenetetramine and other amines are also exemplified, and these are singly or alone. Used as a mixture of two or more.
• the aldehyde and Z or aldehyde donor used for producing the above alkylolyl ani triazone derivative are the same as the aldehyde and Z or aldehyde donor used for producing the initial condensate of phenol resin.
• alkylolyl triazole derivative usually 0.1 to 1.2 mol of amines and Z or ammonia, and 1.5 to 5 mol of aldehyde and Z or aldehyde donor per 1 mol of urea compound.
• the reaction is performed at a ratio of 4.0 mol.
• the order of addition is arbitrary.
• the preferred reaction method is to first charge the required amount of aldehyde and Z or aldehyde donor to the reactor and keep the temperature at usually 60 ° C or lower.
• the required amount of S-amines and Z or ammonia is gradually added, and the required amount of urea compound is further added.
• the mixture is stirred and heated at 80-90 ° C for 2-3 hours to react. is there .
• the addition amount of the above curing agent is 10-100 parts by mass with respect to 100 parts by mass of the initial condensate (initial cocondensate) of the phenol resin of the present invention, In the case of a riazone derivative, the amount is 10 to 500 parts by mass with respect to 100 parts by mass of the above-mentioned phenol resin initial condensate (initial cocondensate).
• the synthetic resin of the present invention is usually prepared as a solution.
• Water-soluble polymers and natural gums such as rucol, sodium alginate, starch, starch derivatives, yuka, gelatin, blood starch, methylcellulose, carboxymethylcellulose, polyacrylate, polyacrylamide; calcium carbonate, magnesium carbonate, barium sulfate, sulfuric acid Calcium, calcium sulfite, calcium phosphate, calcium hydroxide, magnesium hydroxide, aluminum hydroxide, magnesium oxide, titanium oxide, iron oxide, zinc oxide, alumina, silica, diatomaceous earth, dolomite, gypsum, talc, clay, asbestos , My strength, calcium silicate, bentonite, white carbon, carbon black, iron powder, aluminum powder, glass powder, stone powder, synthetic resin powder, blast furnace slag, fly ash, cement, zirconia powder, wood powder, flour, Fillers such as powdered starch, starch, coconut husk, rice flour; surfactants; higher fatty
• Fatty acid esters may be added.
• fatty acid amides such as carnauba wax; synthetic waxes; pigments, dyes, flame retardants, flame retardants, insect repellents, preservatives, anti-aging agents, ultraviolet absorbers, fluorescent dyes, interfaces
• An activator, a foaming agent, an oil repellent and the like may be added.
• thermosetting resin in the nonwoven fabric may be dried in advance to be in the B state.
• the nonwoven fabric of the present invention includes a polyolefin-based resin such as polyethylene, polypropylene, ethylene-vinyl acetate copolymer, and ethylene-ethyl acrylate copolymer, or a modified polyolefin-based resin, polyvinyl chloride, and polyurethane.
• a powder or film of a hot melt adhesive such as polyester, polyester copolymer, polyamide, polyamide copolymer, cellulose derivative, or polybutyl ether may be applied and laminated.
• the stretchable nonwoven fabric (1) of the present invention (see Fig. 1) is improved in vertical and horizontal stretchability by the porosity (2) of a single-dollar punch, so that it can be easily bonded to other members without forming wrinkles. . Even in the case of bonding to the surface of a member having irregularities, the stretchable nonwoven fabric can be cleanly bonded.
• the stretchable nonwoven fabric (1) can be used, for example, as a skin material (1) for an interior material (3).
• the nonwoven fabric of the present invention is produced by a spunbond method.
• a nonwoven fabric obtained by a melt blow method and a calendering process may be used as the nonwoven fabric of the present invention.
• An interior material can be manufactured by adhering the stretchable nonwoven fabric of the present invention as a skin material to the surface of a base material and molding it into a predetermined shape.
• the base material examples include synthetic fibers such as polyester fibers, polyethylene fibers, polypropylene fibers, polyamide fibers, acrylic fibers, urethane fibers, polyvinyl chloride fibers, polyvinyl chloride fibers, and acetate fibers, pulp, and cotton.
• synthetic fibers such as polyester fibers, polyethylene fibers, polypropylene fibers, polyamide fibers, acrylic fibers, urethane fibers, polyvinyl chloride fibers, polyvinyl chloride fibers, and acetate fibers, pulp, and cotton.
• Vegetable fiber such as coconut fiber, hemp fiber, bamboo fiber, kenaf fiber, inorganic fiber such as glass fiber, carbon fiber, ceramic fiber, asbestos fiber, or fiber products using these fibers.
• the base material examples include polyethylene, polypropylene, ethylene propylene copolymer, ethylene butyl acetate copolymer, polychloride butyl, polychlorinated bilidene, polystyrene, poly butyl acetate, fluorine resin, thermoplastic acrylic resin. , Thermoplastic polyester resin, thermoplastic polyamide resin, acrylonitrile-butadiene copolymer, styrene-butadiene copolymer, acrylonitrile-styrene-butadiene copolymer, etc., thermoplastic resin, urethane resin, melamine resin, urea resin, etc.
• a thermosetting resin such as a thermosetting acrylic resin, a phenol resin, a resorcin resin, an alkyl resorcin resin, an epoxy resin, or a thermosetting polyester may be impregnated.
• the base material When the base material is impregnated with the thermosetting resin, the base material may be dried in advance to bring the thermosetting resin in the base material into the B-state.
• the skin material of the present invention which also has the strength of an elastic nonwoven fabric, is overlaid on the surface of the base material, and the base material and the skin material are bonded by hot pressing or cold pressing after overheating.
• the interior materials of the present invention include, for example, automobile members such as door trims, dashboards, ceiling materials, hood insulators, engine covers, heat insulating materials or soundproofing materials, building materials for buildings, wall materials, heat insulating materials. Used for soundproofing materials.
• a nonwoven fabric having a polyester fiber strength (fineness: 3.5 dtex, basis weight: 40 gZm 2 ) obtained by a spun bond method was obtained.
• the nonwoven fabric was pressed with a roll in which needles having a maximum thickness of lmm were randomly arranged.
• the nonwoven fabric 15 holes having a pore size of 0.1 to 0.3 mm, Zcm 2, were formed. Further, the nonwoven fabric was impregnated with a phenol-formaldehyde precondensate (solid content: 30% by mass) so as to have a solid content of 30% by mass. After the impregnation, the nonwoven fabric was dried at 150 ° C. for 3 minutes and precured to obtain a stretchable nonwoven fabric.
• the nonwoven fabric except that the pores of 0. lmm- 0. 3mm was 50 ZCM 2 formed in the same manner as in the actual Example 1, to obtain a stretchable nonwoven fabric.
• the nonwoven fabric except that the pores of 0. lmm- 0. 3mm to 100 ZCM 2 formed in the same manner as in Example 1 to obtain a stretchable nonwoven fabric.
• the nonwoven fabric except that the pores of 0. lmm- 0. 3mm to eight ZCM 2 formed in the same manner as the actual Example 1, to obtain a stretchable nonwoven fabric.
• the nonwoven fabric except that the pores of 0. lmm- 0. 3mm was 110 amino ZCM 2 formed in the same manner as in Example 1 to obtain a stretchable nonwoven fabric.
• the stretchable nonwoven fabrics (1) obtained in Examples 13 and 13 and Comparative Examples 1 and 2 were used as skin materials (1A), and these skin materials (1A) were coated with a phenol-formaldehyde precondensate. , Precure (7) (weight per unit area: 800 gZm 2 , thickness: 50 mm), and a mold (3) consisting of an upper mold (4) and a lower mold (5) shown in Fig. 2
• press molding was performed at 200 ° C for 60 seconds to obtain a molded product (6) (5 mm thick) (see Fig. 3).
• a nonwoven fabric (fineness: 0.1 ldtex, basis weight: 30 gZm 2 ) having a polypropylene fiber strength obtained by a spunbond method was obtained.
• the nonwoven fabric was pressed with a roll in which needles having a maximum thickness of lmm were randomly arranged.
• the nonwoven fabric 25 holes having a pore diameter of 0.8 mm to 1.2 mm were formed in Zcm 2 . Further, the nonwoven fabric was impregnated with a phenol-formaldehyde precondensate (solid content: 40% by mass) so as to have a solid content of 25% by mass. After the impregnation, the nonwoven fabric was dried at 150 ° C. for 3 minutes and precured to obtain a stretchable nonwoven fabric.
• a phenol-formaldehyde precondensate solid content: 40% by mass
• the obtained stretchable nonwoven fabric was used as a skin material, and the skin material was superimposed on glass wool (amount per unit area: 600 gZm 2 , thickness: 40 mm) coated with a phenol-formaldehyde initial condensate and precured. It was hot-pressed into a predetermined shape at 45 ° C for 45 seconds to obtain a molded product. The moldings suffered from wrinkles and other cosmetic defects.
• a nonwoven fabric having a polyester fiber strength (fineness: 2. Odtex, basis weight: 60 gZm 2 ) obtained by a spun bond method was obtained.
• the nonwoven fabric was pressed with a roll in which needles having a maximum thickness of lmm were randomly arranged.
• the obtained nonwoven fabric 18 holes having a pore diameter of 0.5 mm to 0.8 mm were formed in Zcm 2 . Further, the above nonwoven fabric was impregnated with the phenol-alkylresorcinol-formaldehyde precondensate (solid content: 40% by mass) used in Example 4 so as to have a solid content of 30% by mass. Further, a polyamide hot-melt adhesive having a melting point of 130 ° C. and a particle size passing through 200 mesh was spray-coated on the back surface of the nonwoven fabric. Thereafter, the nonwoven fabric was dried at 150 ° C. for 2 minutes to obtain a stretchable nonwoven fabric having a hot melt powder adhesive.
• a stretchable nonwoven fabric was obtained in the same manner as in Example 5, except that the pore size of the nonwoven fabric in Example 5 was changed to 2.1 to 2.4 mm.
• Non-woven fabric is produced by needle punching using a mixed fiber composed of 90% by mass of the polyester fiber used in Example 5 and 10% by mass of a low melting point polyester fiber (fineness: 2. Odtex, softening point: 110 ° C). (Amount per unit area: 6 OgZm 2 ) was obtained.
• the non-woven fabric was impregnated with the phenol-alkylresorcinol formaldehyde precondensate (solid content: 40% by mass) used in Example 5 so as to have a solid content of 30% by mass.
• the polyamide hot melt adhesive used in 5 was spray applied. Thereafter, the nonwoven fabric was dried at 150 ° C. for 2 minutes to obtain a stretchable nonwoven fabric having a hot melt adhesive.
• Example 5 The stretchable nonwoven fabric obtained in Example 5 and Comparative Examples 3 and 4 was used as a skin material, and the skin material was coated with a phenol-formaldehyde precondensate and precured glass wool (weight per unit area). : LOOOOgZm 2 , thickness 70mm), and hot press-molded into a predetermined shape at 200 ° C for 50 seconds to obtain a molded product. A visual test was performed on the appearance of each of the obtained molded products. The test results are shown in Table 2.
• Comparative Example 3 The skin material was broken at the uneven portion of the molded product. Comparative Example 4 Moldability was good, but thick part
• the nonwoven fabric obtained by the conventional spunbonding method or the like does not stretch in the vertical and horizontal directions, when the nonwoven fabric is adhered to another substrate as a skin material, the surface material of the uneven portion of the other substrate is used. It can be seen that wrinkles are easily formed and poor adhesion (floating) is easily caused.
• the nonwoven fabric obtained by the needle punching method has good stretchability in the vertical and horizontal directions and has good adhesiveness to other base materials. Since the nonwoven fabric has fluff on its surface, the appearance of the obtained molded article can be improved. become worse.
• the appearance of the molded product using the stretchable nonwoven fabric of the present invention as a skin material is good and also excellent in moldability.
• the stretchable nonwoven fabric of the present invention includes, for example, interior materials for automobiles such as door trims, dashboards, ceiling materials, hood insulators, engine covers, heat insulating materials or soundproofing materials, building materials for buildings, wall materials, and heat insulating materials. It can be used as a skin material such as a soundproofing material.
• FIG. 1 is a perspective view of a stretchable nonwoven fabric.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Mechanical Engineering (AREA)
• Laminated Bodies (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
• Nonwoven Fabrics (AREA)
• Reinforced Plastic Materials (AREA)

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• 2003
  • 2003-12-08 JP JP2003408728A patent/JP4071704B2/ja not_active Expired - Lifetime
• 2004
  • 2004-12-01 EP EP04820152A patent/EP1693497A4/de not_active Withdrawn
  • 2004-12-01 CA CA 2548380 patent/CA2548380A1/en not_active Abandoned
  • 2004-12-01 WO PCT/JP2004/017851 patent/WO2005056902A1/ja active Application Filing
  • 2004-12-01 US US10/582,179 patent/US20080026660A1/en not_active Abandoned
  • 2004-12-01 KR KR1020067010323A patent/KR20060132594A/ko not_active Application Discontinuation
  • 2004-12-02 TW TW93137142A patent/TWI292787B/zh not_active IP Right Cessation

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