WO2007018051A1

WO2007018051A1 - Process for production of laminated materials

Info

Publication number: WO2007018051A1
Application number: PCT/JP2006/314956
Authority: WO
Inventors: Hideyuki Suzuki
Original assignee: Nichimen Chemical Industry Co., Ltd.
Priority date: 2005-08-09
Filing date: 2006-07-28
Publication date: 2007-02-15
Also published as: JP4185158B2; JPWO2007018051A1

Abstract

A process for producing laminated materials without a separate step for joining, e.g., a step of applying an adhesive to a joint surface, which comprises the nonwoven fabric production step of mixing and entangling a fiber other than thermoplastic resin fiber (such as vegetable fiber or metal fiber) with 10 to 90% by weight of a thermoplastic resin fiber to form a nonwoven fabric sheet, the lamination step of piling plural nonwoven fabric sheets produced above and heating them to a temperature at which the thermoplastic resin can melt, and the press step of pressing the nonwoven fabric laminate obtained by the lamination step to form a laminated material. In the process, unheated nonwoven fabric sheets and heated nonwoven fabric sheets may be piled alternately in the lamination step and then subjected to the press step to form a laminated material.

Description

Specification

Laminate manufacturing method

Technical field

[0001] The present invention relates to a method for producing a laminated material in which fiber plate-like materials having various properties are laminated and then integrated.

Background art

[0002] Laminates made by integrating hard plate materials such as leather and board made of resin and wood, and fiber plate materials such as non-woven fabric are used as flooring materials and interior materials for automobiles. Widely used. The hard plate material and the fiber plate material are joined using an adhesive. For example, when used in an automobile seat, a thermoplastic elastic resin mesh body, which is a cushion material, and a surface covering material are bonded and bonded using an adhesive (Patent Document 1).

For this reason, a separate process for joining such as applying an adhesive to the joining surface is required, and the manufacturing process is complicated.

[0003] In addition, in order to complement the strength while taking advantage of the excellent heat insulating properties and sound absorption properties of plant fibers, there is one in which thermoplastic fibers and plant fibers are intertwined and then molded (patent text) (Dedication 2, 3)

However, in order to obtain a predetermined thickness, when a plurality of sheets are laminated and integrated, or when this is integrated with a hard plate material or a fiber plate material, the same as described above. In addition, a separate process for bonding is required, such as applying an adhesive to the bonding surface.

Patent Document 1: JP-A-8-56772

Patent Document 2: Japanese Patent Publication No. 63-20936

Patent Document 3: Japanese Patent Laid-Open No. 2004-25857

Disclosure of the invention

Problems to be solved by the invention

[0004] An object of the present invention is to eliminate the above-mentioned drawbacks and to produce a laminated material without a separate process for bonding, such as applying an adhesive to the bonding surfaces.

Means for solving the problem [0005] In order to achieve the above-mentioned object, the present inventor has conducted extensive research, and as a result, laminated non-woven fabric of thermoplastic resin fibers or non-woven fabric containing thermoplastic resin fibers, and heated and pressurized each layer. I found out that I reached the present invention.

[0006] That is, the invention of claim 1 includes a non-woven fabric manufacturing process for manufacturing a non-woven fabric by entanglement of thermoplastic resin fibers,

Next, a plurality of non-woven fabrics manufactured in the non-woven fabric manufacturing process are stacked, and a laminating process for heating to a temperature at which the thermoplastic resin fibers melt,

And a pressurizing step for pressurizing the nonwoven fabric after the laminating step, which is performed in this order.

The invention of claim 2 is a non-woven fabric production process in which a non-thermoplastic fiber is mixed with thermoplastic non-woven fiber at a weight ratio of 10 to 90% and entangled with each other to produce a non-woven fabric. A lamination process in which a plurality of nonwoven fabrics produced in the nonwoven fabric production process are stacked and heated to a temperature at which the thermoplastic resin fiber melts;

Invention of Claim 3 makes the lamination | stacking process of the said Claim 1 or 2 the process of stacking, after heating the nonwoven fabric manufactured at the nonwoven fabric manufacturing process to the temperature which a thermoplastic resin fiber melts. Features.

The invention of claim 4 is characterized in that the laminating step of claim 1 or 2 is a step of alternately stacking a non-heated nonwoven fabric and a nonwoven fabric heated to a temperature at which thermoplastic resin fibers melt. And

The invention of claim 5 is characterized in that the fibers other than the thermoplastic fiber of claim 2 are plant fibers.

The invention of claim 6 is characterized in that the fibers other than the thermoplastic fiber of claim 2 are metal fibers.

The invention of claim 7 is a non-woven fabric production process for producing a non-woven fabric by mixing a thermoplastic fiber in a ratio of 10 to 90% by weight with plant fibers and entwining each other. Next, a plurality of non-woven fabrics manufactured in the non-woven fabric manufacturing process are stacked, a surface covering material is further stacked on the non-woven fabric through a thermoplastic resin sheet, and the lamination process is heated to a temperature at which the thermoplastic resin fiber melts;

[0007] Thermoplastic resin fibers are known in the art, such as polyethylene fibers and polypropylene fibers! /, Either one may be used. However, when mixing plant fibers, it is necessary to melt the plant fibers without denaturing them, so it is preferable to melt them at about 100 to 260 ° C.

The plant fiber may be any known one, but particularly preferred is a material that is inexpensive and can be obtained in large quantities, such as bamboo, kenaf, banana, coconut, hemp, and thinned wood.

Also, the metal fiber may be made of iron, iron alloy, aluminum, aluminum alloy, etc.!

The surface covering material is in the form of a sheet such as cloth, leather, a sheet made of thermoplastic resin, a thin wooden board, bamboo board, or paper.

The invention's effect

[0008] The present invention is a method of stacking a plurality of nonwoven fabrics containing 10% or more of a thermoplastic resin fiber, heating to a temperature at which the thermoplastic resin fiber melts, and then pressurizing or 10% of the thermoplastic resin fiber. After heating the nonwoven fabric containing the above to a temperature at which the thermoplastic resin fibers melt, a plurality of sheets are stacked and pressed. Therefore, in each nonwoven fabric, the melted thermoplastic resin plays the role of an adhesive and is united to be modified into a plate-like laminate.

Therefore, a laminated material can be easily manufactured without a bonding process such as applying an adhesive to the bonding surfaces.

In addition, when stacking a plurality of nonwoven fabrics, a non-heated nonwoven fabric and a nonwoven fabric heated to a temperature at which the thermoplastic resin fiber melts are alternately stacked and then pressed to form a plate-like material and a felt-like material. It can be easily manufactured without a bonding process such as applying an adhesive to the bonding surface.

In addition, when plant fibers are mixed in the production of nonwoven fabric, it becomes a laminated material with excellent effects such as soundproofing, moisture absorption, heat insulation, and deodorization. In addition, when metal fibers are mixed in the production of the nonwoven fabric, the corrosion resistance and weather resistance are improved, and a laminated material having excellent sound absorption characteristics in the high-pitched area is obtained.

Further, when a plurality of non-woven fabrics are stacked and a surface covering material is stacked and heated and pressed via a thermoplastic resin sheet, a laminated material whose surface is coated can be produced without applying an adhesive.

BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, embodiments of the present invention will be described.

First, 10% to 90% by weight of thermoplastic fiber fibers that become noda and vegetable fiber are mixed and entangled by a known one-dollar punching method or carding method to obtain a sheet-like nonwoven fabric (nonwoven fabric manufacturing process) .

Next, a plurality of the nonwoven fabrics are prepared and stacked after being aligned to a predetermined size. Alternatively, after stacking the non-woven fabrics, they are aligned to the desired dimensions. Then, the stacked nonwoven fabric is heated to a temperature at which the thermoplastic resin fiber melts. Alternatively, the nonwoven fabrics having a predetermined size are heated to a temperature at which the thermoplastic resin fibers melt and then stacked. (Lamination process)

Next, this is put into a mold and pressed to form a laminated material (pressurizing step).

Heating conditions and pressurizing conditions vary depending on the thermoplastic resin fibers constituting the nonwoven fabric. The heating temperature is preferably about 100 to 260 ° C. when the plant fiber is mixed, since the plant fiber is not denatured and the thermoplastic resin fiber needs to be melted. Also, when the pressure and heating temperature are high, it becomes a hard plate material, and as it becomes smaller, it becomes a felt-like elastic plate material (cushion material).

[0010] Another embodiment of the present invention will be described below.

First, 10 to 90% by weight of a thermoplastic resin fiber that becomes noda on a plant fiber is mixed and entangled by a known one-dollar punch method or a carding method to obtain a nonwoven fabric (nonwoven fabric manufacturing process).

Next, the non-heated non-woven fabric and the heated non-woven fabric (about 100 to 260 ° C.) are alternately stacked after being aligned to a predetermined size. Or after stacking alternately, it is aligned to the desired dimensions. (Lamination process)

Next, it is put into a mold and pressed to form a laminated material (pressurizing step). The molten thermoplastic resin fiber acts as an adhesive, and the non-heated nonwoven fabric and the heated nonwoven fabric are joined by pressure, and the nonwoven thermoplastic material is joined by the molten thermoplastic resin fiber. It is modified into a plate-like material, and a felt-like material and a hard plate-like material are alternately laminated.

[0011] The laminated material may be manufactured using one non-heated nonwoven fabric and one heated nonwoven fabric. Alternatively, either a non-heated nonwoven fabric or a heated nonwoven fabric may be used as a core, and a sandwich structure may be sandwiched therebetween, or a plurality of non-heated nonwoven fabrics and heated nonwoven fabrics may be stacked alternately.

In the case of flooring (cushion floor), laminate so that a hard plate-like material comes on the surface.

[0012] Still another embodiment of the present invention will be described below.

The difference from the above embodiment is that metal fibers are used instead of plant fibers. That is, 10 to 90% by weight of thermoplastic resin fibers serving as a binder is mixed with metal fibers and entangled by a known one-dollar punching method or carding method to obtain a nonwoven fabric (nonwoven fabric manufacturing process).

Next, the non-heated non-woven fabric and the heated non-woven fabric (about 100 to 230 ° C.) are alternately stacked after being aligned to a predetermined size. Or after stacking alternately, it is aligned to the desired dimensions. (Lamination process)

Next, it is put into a mold and pressed to form a laminated material (pressurizing step).

[0013] By using metal fibers, weather resistance and corrosion resistance are improved as compared with those using the plant fibers. In addition, the sound absorption characteristics in the high sound part are improved.

[0014] In each of the above embodiments, the surface of the laminated material is not covered, but if necessary, such as cloth, leather, a sheet made of thermoplastic resin, a thin wooden board, bamboo board, paper, etc. It may be covered with a surface covering material. In that case, after heating the surface of the stacked non-woven fabric,

Then, it is good to heat and pressurize.

Alternatively, the surface coating material may be stacked and heated and pressed through a thermoplastic resin sheet.

In addition, the surface coating material may be provided with a large number of fine holes to take advantage of the moisture absorption performance of the coated laminated material.

Various functions of the surface coating material can be added to the surface, and the laminated material becomes beautiful. Ma In addition, the surface covering material can be easily joined without using an adhesive.

[0015] The method of laminating the surface covering material is particularly suitable for manufacturing an automobile seat. The surface covering material such as leather or cloth covering the surface and a cushion material (plant fiber and thermoplasticity) are provided. Non-woven fabric in which slagging fibers are entangled with each other) can be joined in a single pressurizing step without an adhesive application step. Also, in this pressurizing step, a predetermined number of laminated nonwoven fabrics can be integrated together. Further, when the surface covering material is made of a material that can easily adhere to the thermoplastic resin fiber used as a cushioning material, the bonding becomes strong.

A nonwoven fabric having a desired thickness may be prepared in advance. However, since the application is limited and the joining is easy as described above, a thin fabric is mass-produced and laminated to a desired thickness. It is cheaper to manufacture and can be used for various products.

In addition, when non-woven fabric is produced by mixing plant fibers, it becomes environmentally friendly in terms of disposal and incineration.

[0016] In the above embodiment, the plant fiber is produced by a known method.

That is, the wood fiber may be pulverized by a pulverizer when the raw material is used paper. Plant fiber materials can be obtained in large quantities at a low price, such as kenaf, banana, coconut, hemp, and thinned wood.

Furthermore, the non-woven fabric is laminated by folding or stacking sheets cut into predetermined dimensions.

[0017] In the above-described embodiment, vegetable fiber or metal fiber and thermoplastic rosin fiber are mixed. However, even if the thermoplastic rosin fiber and other fibers are mixed, only the thermoplastic cocoon fiber is used. There may be.

For example, a non-woven fabric mixed with vegetable fibers and a non-woven fabric mixed with metal fibers may be stacked alternately.

In addition, when a laminated material is used, the stacked nonwoven fabrics are pressed after being put in a mold. However, the present invention is not limited to this, and a method of passing between rollers may be used. Furthermore, in the pressurizing step, the temperature of the mold or roller is not limited to room temperature as long as it is lower than the temperature at which the thermoplastic resin fiber melts. Therefore, you may heat and cool suitably as needed. In addition, the finished laminate may be further cut into predetermined dimensions according to the purpose of use.

S6MC / 900Zdf / X3d L TS0810 / .00Z OAV

Claims

The scope of the claims

[1] A non-woven fabric manufacturing process in which a thermoplastic non-woven fiber is entangled to manufacture a non-woven fabric,

And a pressing step of pressing the nonwoven fabric after the laminating step, which is performed in this order.

[2] A non-woven fabric manufacturing process in which a non-thermoplastic resin is mixed with thermoplastic non-woven fibers at a weight ratio of 10 to 90% and entangled with each other to manufacture a non-woven fabric.

[3] The lamination according to claim 1 or 2, wherein the lamination step is a step of stacking the nonwoven fabric produced in the nonwoven fabric production step after heating to a temperature at which the thermoplastic resin fibers melt. A method of manufacturing the material.

[4] The method according to claim 1 or 2, wherein the laminating step is a step of alternately stacking a non-heated non-woven fabric and a non-woven fabric heated to a temperature at which thermoplastic resin fibers melt. A method for producing a laminated material.

5. The method for producing a laminated material according to claim 2, wherein the fibers other than the thermoplastic fibers are plant fibers.

6. The method for producing a laminated material according to claim 2, wherein the fibers other than the thermoplastic fibers are metal fibers.

[7] A non-woven fabric manufacturing process for manufacturing a non-woven fabric by mixing a thermoplastic fiber in a ratio of 10 to 90% by weight with a vegetable fiber and entwining each other.

Next, a plurality of non-woven fabrics manufactured in the non-woven fabric manufacturing process are stacked, a surface covering material is further stacked on the non-woven fabric through a thermoplastic resin sheet, and the laminate is heated to a temperature at which the thermoplastic resin fiber melts;

It consists of a pressurizing step of pressurizing the nonwoven fabric after the laminating step, and is performed in this order. A method for producing a laminated material.