WO2013047669A1 - Tissu non tissé pour renforcer un article de moulage de mousse - Google Patents

Tissu non tissé pour renforcer un article de moulage de mousse Download PDF

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Publication number
WO2013047669A1
WO2013047669A1 PCT/JP2012/074914 JP2012074914W WO2013047669A1 WO 2013047669 A1 WO2013047669 A1 WO 2013047669A1 JP 2012074914 W JP2012074914 W JP 2012074914W WO 2013047669 A1 WO2013047669 A1 WO 2013047669A1
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Prior art keywords
nonwoven fabric
fiber
stress
layer
reinforcing
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PCT/JP2012/074914
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English (en)
Japanese (ja)
Inventor
坂本　浩之
英夫 磯田
稲富　伸一郎
貴史 恋田
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東洋紡株式会社
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Publication of WO2013047669A1 publication Critical patent/WO2013047669A1/fr

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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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/435—Polyesters
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • 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
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/009—Condensation or reaction polymers
    • D04H3/011—Polyesters
    • 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
    • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/08—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of fibres or yarns

Definitions

  • the present invention relates to a non-woven fabric for reinforcing a foam molded product, which is excellent in handleability and foam moldability. Further, the present invention relates to a non-woven fabric for reinforcing a foam molded product, which is particularly excellent in resistance to bleeding during foam molding, the molded product has excellent functionality and can be reduced in weight.
  • urethane foam molded bodies have been widely used as cushion materials for seats and the like, and generally, a material in which a reinforcing material is integrated at the time of molding a foamed urethane molded body is used.
  • a reinforcing material is located between the urethane foam molded body and the metal spring (hereinafter sometimes referred to as “spring”), and evenly disperses the cushioning action of the metal spring, and from the friction received from the metal spring. It plays a role of protecting the urethane foam molded body.
  • Patent Document 1 proposes a reinforcing material that has a bulky layer and a dense layer, impregnates the bulky layer with urethane, and prevents the urethane from seeping out in the dense layer.
  • This method has a problem that the foam layer reaches the dense layer surface and the dense layer is thin, so that the effect of preventing the seepage is insufficient and the durability of the dense layer is poor due to an increase in scratching sound due to the seepage and insufficient strength of the dense layer.
  • Patent Document 2 and Patent Document 3 propose proposals that increase the basis weight of the bulky layer (base material layer). Even in this method, similarly to Patent Document 1, the foamed layer reaches the dense layer surface, and there is a problem that the effect of preventing the exudation from the dense layer is insufficient and the abrasion noise increases due to the exudation.
  • Patent Documents 4 and 5 propose a method in which one side of a high-weight single-layer nonwoven fabric is thermocompression bonded and the pressure-bonded surface is used as a spring receiving surface.
  • the foamed layer reaches the dense layer surface, and the dense layer is thin, so that the effect of preventing bleeding is insufficient, and there is a problem that durability is inferior due to increase in scratching sound due to bleeding and insufficient strength of the dense layer.
  • deep-drawn urethane foam molding with complex and large irregularities has insufficient followability to the mold and sufficiently prevents the occurrence of undercuts and wrinkles. There remains a problem that can not be.
  • Patent Document 6 proposes a foamed reinforcing material by embossing a crimped polypropylene fiber nonwoven fabric.
  • This method is a method of forming a partial pressure-bonding part by embossing on a crimped bulky layer.
  • the pressure-bonding part improves the bleeding property, but the non-pressure-bonding part has a problem of easy bleeding.
  • the integration of the foamed molded body and the reinforcing material becomes insufficient, and the strength is lowered due to the occurrence of peeling or a flexible material, and there is a problem in durability.
  • Patent Document 7 proposes a method in which a dense layer made of a long-fiber nonwoven fabric subjected to thermocompression bonding and a bulky layer are laminated and subjected to needle punch entanglement and the dense layer is used on the foam layer side.
  • this method suppresses oozing out of the foaming agent, there is a problem that mold followability is lowered due to an increase in rigidity, and it is not possible to sufficiently prevent occurrence of thinning and wrinkles, and bonding with the foam is not possible. The problem remains sufficient and easy to peel off.
  • Patent Document 8 Although the method is the same, a method using a dense layer as an intermediate layer is proposed in Patent Document 8 and Patent Document 9, but has the same problem as Patent Document 7.
  • Patent Document 10 proposes a method for improving the flexibility by laminating and encircling a crimped long fiber nonwoven fabric as a dense layer and a long fiber web as a bulky layer. This method improves the mold followability by providing flexibility, but the entanglement degree of the long fiber web is insufficient, the wear resistance is inferior, and the nonwoven fabric strength is low, so that it is durable as a foam molded article reinforcement. There's a problem.
  • Patent Document 11 proposes a method of using a nonwoven fabric in which a long fiber nonwoven fabric and a short fiber web are laminated and integrated by hydroentanglement to increase the burst strength.
  • the moldability is improved by imparting flexibility by hydroentanglement.
  • a thermal adhesive component is used for the short fiber
  • the rigidity increases but the brittleness is deteriorated and the durability is inferior.
  • the short fiber web is laminated and entangled with the long fiber nonwoven fabric, the abrasion resistance of the short fiber web layer is inferior and the strength of the nonwoven fabric is low.
  • the mold followability is lowered and the finished shape is inferior.
  • Non-woven fabric for reinforcing foam molded products which is excellent in sound-damping functions such as abrasion, bending, refraction, and abrasion resistance, and further can improve the strength of the nonwoven fabric to obtain foam molded products with excellent shape retention durability. It is an issue to provide.
  • the present inventors have made a coating layer serving as a spring receiving surface into a bulky short fiber nonwoven fabric layer having excellent sound damping function and wear resistance function, and a substrate in contact with the foam
  • the layer is composed of a long-fiber nonwoven fabric layer having a dense pressure-bonding part having a foaming agent blocking function, and entangled the covering layer and the base material layer. It has been found that can be made flexible. It was also found that by setting the extension stress in a low elongation range of 30 to 40% within a specific range, it is possible to maintain the handleability and to provide excellent mold followability. Furthermore, it has been found that the durability of the molded product can be improved by strengthening the bonding between the foam and the reinforcing material by the anchor effect of the protruding fiber structure and increasing the strength of the reinforcing material.
  • the present invention is as follows. (1) A short fiber nonwoven fabric layer and a long fiber nonwoven fabric layer partially formed with a dense compression bonded portion are laminated, and the short fiber nonwoven fabric layer and the long fiber nonwoven fabric layer are partially entangled, and the short fiber nonwoven fabric layer Forming a protruding fiber structure through the long-fiber nonwoven fabric layer, the 5% elongation stress (ST5m) in the longitudinal direction is 10 to 30 N / 5 cm, and the 5% elongation stress in the transverse direction.
  • (ST5c) is 5 to 25 N / 5 cm
  • the difference ( ⁇ ST5m ⁇ ST30m) between the 5% elongation stress (ST5m) in the longitudinal direction and the 30% elongation stress (ST30m) in the longitudinal direction and 30% in the longitudinal direction A non-woven fabric for reinforcing a foam molded article, wherein the difference ( ⁇ ST30m ⁇ ST40m) between the stress at stretching (ST30m) and the stress at 40% stretching in the longitudinal direction (ST40m) satisfies the following formula.
  • the fibers constituting the short fiber nonwoven fabric contain at least two types of short fibers, a fiber having a fineness of 1.2 to 3 dtex (fiber A) and a fiber having a fineness of 2 to 4 dtex ( Foam molding according to (1) or (2), which contains fiber B), the fineness difference ( ⁇ D) between fiber A and fiber B, and the mass mixing ratio (A / B) between fiber A and fiber B satisfy the following formula: Non-woven fabric for product reinforcement. Fineness difference ( ⁇ D): 0.5 ⁇ ⁇ D ⁇ 2 (dtex) Formula 3 Mixing ratio (A / B): 80/20 to 30/70 (mass%) Formula 4
  • the present invention is a nonwoven fabric for reinforcing foam molded articles that maintains handleability and satisfies both moldability and a spring receiving function at the same time. That is, the layer (coating layer) that becomes the spring receiving surface is a bulky and dense short fiber nonwoven fabric layer having excellent sound damping function, wear resistance function and easy deformation function, and the layer in contact with the foam (base material layer) is foamed.
  • a long fiber nonwoven fabric layer formed with a dense portion having an agent blocking function and a foaming gas escape function, entangled the coating layer and the base material layer to form a protruding fiber structure on the base material layer surface, Flexibility of the entire structure and expansion of the structure are facilitated when localized stress concentration is applied, and the entire foam structure is integrated and improved durability due to excellent mold tracking and protruding fiber structure anchor effect.
  • This is a non-woven fabric for reinforcing foam-molded articles, which can obtain a foam-molded cushion material excellent in moldability, sound damping and durability.
  • the stress range for drawing out the nonwoven fabric suppresses stretching, lowers the stress in a low elongation region with an elongation of less than 40%, remarkably improves the mold followability during molding, and increases the breaking strength. It is possible to provide a non-woven fabric for reinforcing a foamed molded product having improved durability when formed into a molded product.
  • a short fiber nonwoven fabric layer and a long fiber nonwoven fabric layer partially formed with a dense compression bonded portion are laminated, and the short fiber nonwoven fabric layer and the long fiber nonwoven fabric layer are partially entangled and short fiber nonwoven fabric.
  • the fiber forming the layer penetrates the long-fiber nonwoven fabric layer to form a protruding fiber structure
  • the stress at 5% elongation in the vertical direction (ST5m) is 10 to 30 N / 5 cm
  • the stress (ST5c) is 5 to 25 N / 5 cm
  • the difference ( ⁇ ST5m-ST30m) between 5% longitudinal stress and 30% longitudinal stress (ST30m) is 30% longitudinal stretching
  • a non-woven fabric for reinforcing a foam molded article in which the difference ( ⁇ ST30m ⁇ ST40m) between the stress (ST30m) and the 40% elongation stress (ST40m) satisfies the following formula.
  • the MD direction of the long-fiber nonwoven fabric is the vertical direction
  • the CD direction is the horizontal direction.
  • the arrangement direction of the fibers is the vertical direction.
  • the direction orthogonal to the fiber arrangement direction is the lateral direction.
  • the non-woven fabric for reinforcing foam-molded product of the present invention is composed of a short fiber non-woven fabric layer as a coating layer, so that the degree of freedom of the fibers is increased and the spring shape is easily followed by deformation and friction, and friction with the spring material. The effect of suppressing the generation of sound is given. And the fibers forming the short fiber nonwoven fabric layer penetrate through the long fiber nonwoven fabric layer and are long protruding by being laminated by partial entanglement with the long fiber nonwoven fabric layer formed with the dense crimping portion as the base material layer. It is easy to form a lot of fiber structure. By forming many long protruding fiber structures, the anchoring effect to the foam is enhanced, and the foam and the reinforcing material can be strongly integrated, and the durability against deformation and wear of the foam molded product is enhanced. Yes.
  • the short fiber nonwoven fabric layer that is the coating layer of the present invention is at least partially entangled and integrated with the long fiber nonwoven fabric layer that is the base material layer to form a protruding fiber structure that penetrates the long fiber nonwoven fabric layer.
  • the short fiber nonwoven fabric layer as the coating layer and the long fiber nonwoven fabric layer as the base material layer are easy to peel off, and the durability of the coating function is inferior. Moreover, since the short fiber nonwoven fabric layer collapse
  • the non-woven fabric for reinforcing foam molded products of the present invention uses a long-fiber non-woven fabric layer in which a dense press-bonded portion is partially formed on the base material layer.
  • the long fiber nonwoven fabric layer needs to function as a barrier layer that blocks leakage of the foaming agent to the surface of the reinforcing material during foam molding, as well as ensuring mold followability during molding and outgassing during foaming
  • an independent dot-shaped crimping part is formed, and handling property is maintained by entanglement processing for laminating and integrating with the short fiber nonwoven fabric layer so as not to impair the moldability. It is flexible.
  • the function of the barrier layer at the time of foaming is lost, the foaming agent that has passed through the base material layer reaches the surface of the coating layer, and the foaming agent oozes out, Not only is the quality of the molded product lowered, but it is not preferable because the sound-damping property is lowered due to the generation of frictional noise due to rubbing with the nonwoven fabric for reinforcing a foamed molded product, and the durability is lowered due to the occurrence of damage to the molded product due to wear.
  • the long-fiber nonwoven fabric layer is densely crimped on the entire surface, and when a dense crimping region close to it is formed, the air permeability is insufficient only by the opening by the laminating entanglement process, and the gas escape failure during foaming It is not preferable because the molded product floats due to the above, and it becomes difficult to be deformed due to the increase in rigidity and the mold followability is deteriorated and the moldability is impaired.
  • the dense press-bonded part of the long-fiber nonwoven fabric layer used for the base material layer of the nonwoven fabric for reinforcing foam molded article of the present invention is not particularly limited as long as it satisfies the shielding function of the foaming agent and the mold followability, Preferably, an independent dot-shaped crimping portion that does not hinder mold followability is formed, and the area ratio of the crimping portion is 8 to 25%, more preferably 10 to 20%, so that the shielding function and the mold are Performance that satisfies the following ability can be provided.
  • the nonwoven fabric rigidity becomes high and the mold following ability may be hindered.
  • the area ratio of the independent dot-shaped crimping parts is less than 5%, the mechanical properties as the base material layer are deteriorated and the handling property is inferior, which is not preferable.
  • the foaming agent may have insufficient barrier function and bleeding of the foaming agent may occur, and if the area ratio exceeds 40%, the deformation responsiveness to an extension load may be deteriorated and the mold following property may be inferior. Therefore, it is not preferable.
  • the unit area of the independent dot-shaped crimping part of the partial crimping part of the long-fiber nonwoven fabric layer is too small, the mechanical properties deteriorate due to the strength reduction of the joining point, and the stress at 5% elongation in the longitudinal direction becomes less than 10 N / 5 cm.
  • the strength per unit weight is also less than 1.6 N / 5 cm, which may cause problems in handling and durability. If the unit area of the dot-shaped crimping part is too large, the joining point will be strong, but the difference in local shielding coverage will increase, and bleeding may occur, and the mold followability at the time of deformation will also be uneven. This is not preferable because it may cause oozing, cracking, and jerking, resulting in poor shape quality.
  • the unit area of the independent dot-like crimping part of the partial crimping part of the long-fiber nonwoven fabric in the present invention is preferably 0.01 to 2.5 mm 2 , more preferably 0.02 to 1.0 mm 2 .
  • the method for forming the independent partial crimping portion of the present invention is not particularly limited.
  • known methods such as embossing roller processing can be used.
  • the shape of the crimped fiber assembly part is not particularly limited as long as it is an independent dot, but preferably a texture pattern, diamond pattern, square pattern, turtle shell pattern, ellipse pattern, lattice pattern, polka dot pattern, round pattern Etc. can be exemplified.
  • the independent crimping fiber assembly part functions as a joining point that firmly fixes the constituent long fibers and maintains the mechanical properties, and the other surfaces are flattened only on the surface It has a barrier layer effect, a structure fixing effect, and appropriate air permeability, and is provided with a function that can easily follow deformation caused by foam molding and a deaeration function.
  • the nonwoven fabric for reinforcing foam molded articles of the present invention has a short fiber nonwoven fabric layer as a coating layer and a long fiber nonwoven fabric layer as a base material layer partially entangled, and the fibers forming the short fiber nonwoven fabric layer are long fiber nonwoven fabrics.
  • a protruding fiber structure is formed through the layers.
  • the short fiber nonwoven fabric layer and the long fiber nonwoven fabric layer are entangled and entangled to function as a reinforcing material, and the fibers forming the short fiber nonwoven fabric penetrate the long fiber nonwoven fabric layer to form a protruding fiber structure.
  • the protruding fiber structure is embedded in the foamed layer while holding the short fiber nonwoven fabric layer, so that the foamed molded body is firmly integrated with the foamed layer and the reinforcing material, so that it can also be deformed and structured under external pressure. The deformation of the whole complements each other's functions and improves the durability of the molded body.
  • the fibers constituting the coating layer do not penetrate the base material layer to form a protruding fiber structure, strong integration of the foamed layer and the reinforcing layer due to the anchor effect may be hindered, and the reinforcing layer may be peeled off. It is not preferable. Further, when the fibers constituting the coating layer do not form a protruding fiber structure, even if the foam layer and the base material layer are firmly joined, the coating layer and the base material layer are not firmly joined, The coating layer may be peeled off, and it is not preferable because the entire structure cannot be complemented by the interlocking deformation, and the durability of the molded body is inferior.
  • the protruding fiber structure is not particularly limited as long as the protruding fiber structure is formed on the surface of the long-fiber non-woven fabric layer in contact with the foam, but preferably the protruding number of protruding fiber structures is 50 to 250. / Cm 2 is preferred. If it is less than 50 pieces / cm 2 , the softening effect due to the entanglement treatment effect, the adhesion point to the foamed material such as polyurethane and the anchor effect in the polyurethane may be insufficient, and there may be a case where peeling occurs due to poor bonding.
  • the number of protrusions of the protruding fiber structure in the present invention is also counted as one in which a plurality of fibers protrude from one hole generated by one entanglement process. More preferably, the number of protruding fiber structures of the present invention is 80 to 200 / cm 2 , and most preferably 90 to 150 / cm 2 .
  • the fiber length including a preferable loop formed of the protruding fiber structure in the present invention is 2 to 10 mm. If the fiber length is less than 2 mm, the anchor effect may be insufficient. If the fiber length exceeds 10 mm, there may be a problem in workability during setting to the mold by catching.
  • the more preferable fiber length of the present invention is 3 to 8 mm, and the most preferable fiber length is 4 to 7 mm.
  • the long fiber nonwoven fabric layer and the short fiber nonwoven fabric layer are flexibly integrated by the entanglement entanglement treatment, and the fibers constituting the short fiber nonwoven fabric layer penetrating the long fiber nonwoven fabric layer protrude.
  • a known water entanglement method, a needle punch entanglement method, or the like can be applied.
  • a needle punch method that can easily form a protruding fiber structure can be recommended.
  • Needle punch conditions are not particularly limited, but as a manufacturing method, when a spread web is laminated on a long-fiber nonwoven fabric layer and entangled, the single fiber fineness, cut length, and cross-sectional shape of the laminated short-fiber nonwoven fabric layer Because it is affected by the properties such as fiber mixing state, fabric weight, restrained state of nonwoven fabric, and fabric weight of nonwoven fabric layer, the fabric weight, density, constituent fiber arrangement, single fiber properties, etc., adjustment of barb type and needle punch conditions Is necessary, but it is better to select in the range of 50 to 250 penets / cm 2 .
  • the penetrometer number fifty / cm less than 2 the integration of the short fiber nonwoven fabric layer and the long fiber nonwoven fabric layer is insufficient, there is a case where the coating layer can not be maintained a unitary structure by peeling, penetrometer number 250 lines / cm 2
  • the foaming agent blocking function of the long-fiber nonwoven fabric layer may be lowered, and foaming agent leakage may occur during molding.
  • the stagnation effect due to the entanglement treatment and the non-woven fabric strength may be reduced due to damage.
  • the number of pene is preferably 80 to 150 / cm 2 , more preferably 100 to 130 / cm 2 .
  • the protruding fiber structure forming effect of the needle punch depends on the needle depth, and it is preferable to make it as shallow as possible under the condition that a necessary protruding fiber length can be formed.
  • the needle depth is deep, the opening diameter becomes large and the foaming agent may ooze out, so it is desirable to set the optimum conditions.
  • the needle depth is preferably set to 10 to 16 mm when the thickness of the laminated nonwoven fabric is about 3 mm when measured with a load of 20 g / cm 2 .
  • the nonwoven fabric for reinforcing foam-molded articles of the present invention has a 5% elongation stress (ST5m) in the longitudinal direction of 10 to 30 N / 5 cm.
  • ST5m 5% elongation stress
  • the 5% elongation stress (ST5m) in the vertical direction is 30 N / 5 cm or less, the mold followability during foam molding can be kept good. If it exceeds 30 N / 5 cm, the mold followability at the time of foam molding is deteriorated, and the finished shape of the foam molded product may be inferior.
  • the preferred longitudinal stress at 5% elongation (ST5 m) is 10 to 25 N / 5 cm.
  • the nonwoven fabric for reinforcing foam-molded articles of the present invention has a 5% elongation stress (ST5c) in the transverse direction of 5 to 25 N / 5 cm.
  • ST5c 5% elongation stress
  • the mold followability during foam molding can be kept good. If it exceeds 25 N / 5 cm, the mold followability at the time of foam molding is deteriorated, and the finished shape of the foam molded product may be inferior.
  • the preferred transverse stress at 5% elongation (ST5c) is 10 to 15 N / 5 cm.
  • the non-woven fabric for reinforcing foam-molded articles of the present invention has a difference ( ⁇ ST5-ST30m) between a 5% longitudinal stress (ST5m) and a 30% longitudinal stress (ST30m), and a 30% longitudinal elongation.
  • This is a non-woven fabric for reinforcing foam molded articles in which the difference ( ⁇ ST30m ⁇ ST40m) between the stress at time (ST30m) and the stress at 40% elongation (ST40m) satisfies Expressions 1 and 2.
  • ⁇ ST5m ⁇ ST30m ⁇ 25 (N / 5cm) Formula 1 ⁇ ST30m ⁇ ST40m ⁇ 25 (N / 5cm) Equation 2
  • the non-woven fabric for reinforcing foamed articles of the present invention facilitates uniform deformation with low stress close to plastic deformation until 30% stretch deformation at the initial stage of foam molding, and further low foam stress until 40% stretch deformation.
  • the difference ( ⁇ ST5m) between the 5% longitudinal stress (ST5m) and the 30% longitudinal stress (ST30m) in the vertical direction In order to enable uniform deformation along the mold up to the large deformation part of the mold, the difference ( ⁇ ST5m) between the 5% longitudinal stress (ST5m) and the 30% longitudinal stress (ST30m) in the vertical direction.
  • ⁇ ST30m is 25 N / 5 cm or less satisfying the above formula 1, and the difference ( ⁇ ST30m ⁇ ST40m) between the 30% longitudinal stress (ST30m) and the 40% stretched stress (ST40m) is 25 N /
  • the length 5 cm or less and satisfying the above formulas 1 and 2 at the same time uniform and good foam moldability is imparted.
  • the non-woven fabric for reinforcing foamed articles of the present invention preferably has a ( ⁇ ST5m-ST30m) of 20 N / 5 cm or less, and ( ⁇ ST30 m-ST40 m) of 20 N / 5 cm or less.
  • the polyester in the present invention refers to an aromatic polyester and an aliphatic polyester, and preferably an aromatic polyester having excellent heat resistance and mechanical properties.
  • aromatic polyesters polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polybutylene naphthalate (PBN), polyethylene naphthalate (PEN), polycyclohexanedimethyl terephthalate (PCHT), polytrimethylene terephthalate (PTT) Examples thereof include homopolyesters and copolyesters thereof.
  • polyester having a glass transition temperature of 70 ° C. or lower is preferable, and a polyester having a glass transition temperature of 70 ° C. or lower is more preferable.
  • polyesters include polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), and copolymers and mixtures thereof.
  • PET polyethylene terephthalate
  • modifiers such as an antioxidant, a light-proofing agent, a colorant, an antibacterial agent, a flame retardant, and a hydrophilizing agent can be added as needed without degrading the characteristics.
  • the nonwoven fabric for reinforcing foam-molded articles of the present invention is preferably composed of fibers made of polyester in order to maintain the high strength described below.
  • the non-woven fabric for reinforcing foam-molded products of the present invention can be molded while maintaining mold followability at the time of foam-molding. After becoming a molded product, the non-woven fabric shape is maintained against the external force and exhibits a reinforcing function.
  • the vertical strength per unit weight (DTm) and the horizontal strength (DTc) satisfy 1.6 N / 5 cm (g / m 2 ) or more.
  • the mold followability during foam molding is improved, but the external force of the molded product It is not preferable because the function of retaining the nonwoven fabric form with respect to the resin may deteriorate, resulting in a morphological failure and a molded product having poor durability. If this function is not satisfied in both the vertical direction and the horizontal direction, the form is destroyed from the direction in which the mechanical properties are inferior and the durability is inferior.
  • the non-woven fabric for reinforcing foamed articles of the present invention has a strength per unit weight (DTm) of 1.7 N / 5 cm (g / m 2 ) or more and a transverse strength (DTc) of 1.9 N / 5 cm ( g / m 2 ) or more.
  • the fibers constituting the short fiber nonwoven fabric layer which is a coating layer of the foam molded article reinforcing nonwoven fabric of the present invention, are not particularly limited, but preferably contain at least two types of short fibers and have a fineness of 1.2 to 3 dtex.
  • Fiber (fiber A) having a fineness of 2 to 4 dtex and a fiber having a fineness of 2 to 4 dtex (fiber B), the fineness difference ( ⁇ D) between fibers A and B, and the mass mixture ratio of fibers A and B (A / B) is a non-woven fabric for reinforcing foam-molded articles satisfying the expressions 3 and 4 simultaneously.
  • the preferred fibers constituting the short fiber nonwoven fabric layer that is the covering layer of the nonwoven fabric for reinforcing foam molded product of the present invention are capable of forming a dense structure as the fiber A, and 1.2 to 3 dtex short fibers that are easily deformed, and the fiber B It is preferable that at least two kinds of short fibers of 2 to 4 dtex are mixed in order to impart bulkiness while maintaining the density and ease of deformation. If the fiber A is less than 1.2 dtex, the wear resistance on the spring receiving surface of the molded product is inferior, resulting in a problem of poor durability. If the fiber A exceeds 3 dtex, it becomes difficult to be deformed and the stress at the time of stretching of the nonwoven fabric is increased. There is.
  • the fineness of the fiber A is more preferably 1.5 to 2 dtex, and the fineness of the fiber B is 2.5 to 3.5 dtex.
  • the fineness difference ( ⁇ D) between the fiber A and the fiber B preferably satisfies the expression 3 from the above reason and the migration between the fibers.
  • a more preferred fineness difference ( ⁇ D) in the present invention is 0.5 to 1.5 dtex.
  • the mass mixture ratio (A / B) of the fiber A and the fiber B is expressed by the following formula 4 in order to maintain the ease of deformation at a low stress when a nonwoven fabric for reinforcing foam molded products under a low stress is used. It is preferable to satisfy Mixing ratio (A / B): 80/20 to 30/70 (mass%) Formula 4
  • a more preferable mass mixture ratio (A / B) in the present invention is 60/40 to 40/60 (mass%).
  • the short fiber nonwoven fabric layer in the present invention is formed by mixing the above-mentioned preferred short fibers into a web, and laminating to a desired basis weight by a conventional method, followed by entanglement treatment to form a short fiber nonwoven fabric layer.
  • foam molding was carried out using a nonwoven fabric for reinforcing foam molded products created by entanglement with the long fiber nonwoven fabric layer.
  • the molded article has improved durability because the wear resistance of the coating layer made of short fibers on the spring receiving surface is improved and the structure is hardly broken.
  • the entanglement entanglement treatment in the case of the short fiber nonwoven fabric layer is not particularly limited, but preferably, the nonwoven fabric structure can be maintained, and after the lamination with the long fiber nonwoven fabric layer, the protruding fiber structure can be easily formed by the entanglement entanglement treatment.
  • a degree of entanglement process is preferred. If the entanglement process is excessive, it may be difficult to form a preferable protruding fiber structure, which is not preferable.
  • As a more preferable entanglement method there is a method in which the entanglement process by the needle punch is made into a nonwoven fabric by performing preliminary entanglement and main entanglement process. More preferably, the preliminary entanglement treatment has a number of penetrations of about 20 pieces / cm 2 , and the entanglement treatment has a number of penetrations of about 100 to 150 pieces / cm 2 .
  • the foam molded article reinforcing nonwoven fabric of the present invention is formed in the longitudinal direction.
  • the difference ( ⁇ ST5m-ST30m) between the 5% elongation stress (ST5m) and the 30% elongation stress (ST30m) in the longitudinal direction, and the 30% elongation stress (ST30m) and 40% elongation stress (ST40m) in the longitudinal direction. ) ( ⁇ ST30m ⁇ ST40m) can satisfy Expression 1 and Expression 2.
  • ⁇ ST5m ⁇ ST30m ⁇ 25 (N / 5cm) Formula 1 ⁇ ST30m ⁇ ST40m ⁇ 25 (N / 5cm) Equation 2
  • the basis weight of the non-woven fabric for reinforcing foam-molded products of the present invention is not particularly limited as long as it satisfies the mechanical properties in the preferred form specified, but it is preferably 50 to 180 g / m 2 .
  • the basis weight is less than 50 g / m 2 , the covering function of the foaming agent may be reduced and bleeding may occur, and the mechanical properties may be low, the reinforcing material function may be insufficient, and the durability of the molded product may be inferior. There is.
  • the difference ( ⁇ ST30m ⁇ ST40m) between the stress at 30% elongation (ST30m) and the stress at 40% elongation (ST40m) cannot satisfy the formulas 1 and 2, and the mold followability is deteriorated, and If the basis weight is increased, the weight of the seat is increased, and there is a problem that the weight reduction of the vehicle is hindered.
  • the more preferred basis weight of the nonwoven fabric for reinforcing foam-molded products of the present invention is 60 to 160 g / m 2 , more preferably 80 to 140 g / m 2 .
  • the basis weight of the short fiber nonwoven fabric layer which is a coating layer of the nonwoven fabric for reinforcing foam molded article of the present invention, is not particularly limited as long as it is made of a short fiber nonwoven fabric and has a covering function and a protruding fiber structure. 120 g / m 2 is preferred. If it is less than 50 g / m ⁇ 2 >, there exists a problem that a coating function falls. If it exceeds 120 g / m 2 , the basis weight of the non-woven fabric for reinforcing a foamed molded product may increase, which may cause a problem that impedes weight reduction of the molded sheet. A more preferred basis weight is 60 to 100 g / m 2 .
  • the basis weight of the long-fiber nonwoven fabric layer which is the base material layer of the nonwoven fabric for reinforcing foam molded articles of the present invention, satisfies the shielding function of the foaming agent, grips the protruding fiber structure, and defines the mechanical properties when a laminate is formed.
  • 20 to 60 g / m 2 is preferable. If it is less than 20 g / m 2 , the shielding function of the foaming agent may not be satisfied, and the mechanical properties may be inferior. If it exceeds 60 g / m 2 , the dependency on the extension deformation due to the extension load becomes worse and the mold following ability becomes worse during molding. Therefore, it is desirable to set appropriate conditions. In the present invention, 25 to 45 g / m 2 is more preferable.
  • the basis weight of the uppermost coating layer is particularly preferably a basis weight that can form a protruding fiber structure on the lowermost base material layer surface and can satisfy the spring receiving function of the uppermost coating layer.
  • the non-woven fabric having a basis weight of less than 150 g / m 2, the coating layer 50 g / m 2, it is desirable to set to be less than 100 g / m 2, including the base layer and the intermediate layer.
  • the apparent density of the non-woven fabric for reinforcing a foam molded article of the present invention is not particularly limited as long as it satisfies the requirements of the present invention, but a preferred apparent density is 0.05 to 0.15 g / cm 3 . If the apparent density is less than 0.05 g / cm 3, it is too bulky, which may be inferior in wear resistance and durability, which is not preferable. When the apparent density exceeds 0.15 g / cm 3 , the bulkiness of the coating layer is lost, and the sound damping effect may be deteriorated.
  • a more preferable apparent density of the nonwoven fabric for reinforcing foamed molded products of the present invention is 0.06 to 0.12 g / cm 3 .
  • the apparent density of the short fiber nonwoven fabric layer serving as the covering layer of the nonwoven fabric for reinforcing foam molded products of the present invention is not particularly limited as long as it satisfies the requirements of the present invention, but is preferably 0.02 to 0.07 g / cm 3 , 0 0.02 to 0.06 g / cm 3 is more preferable.
  • the apparent density of the long-fiber nonwoven fabric layer serving as the base material layer of the nonwoven fabric for reinforcing foam molded products of the present invention is not particularly limited as long as it satisfies the requirements of the present invention, but is preferably 0.09 to 0.20 g / cm 3 , More preferably, it is 12 to 0.18 g / cm 3 .
  • the cross section of the fiber constituting the nonwoven fabric for reinforcing a foam molded product of the present invention is not particularly limited as long as it satisfies the requirements of the present invention.
  • the short fiber nonwoven fabric layer serving as the covering layer of the nonwoven fabric for reinforcing foam molded products of the present invention preferably uses a round cross section as a general-purpose short fiber, but can also be mixed with an irregular cross section. When improving the bulkiness, a hollow cross section or an irregular cross section can be mixed.
  • the fiber length of the fibers constituting the short fiber nonwoven fabric layer serving as the covering layer of the foam molded article reinforcing nonwoven fabric of the present invention is not particularly limited, but is preferably 20 to 150 mm.
  • the fiber length of the more preferable short fiber in the present invention is 40 to 110 mm.
  • the fineness of the fibers constituting the long-fiber nonwoven fabric layer serving as the base material layer of the nonwoven fabric for reinforcing foam molded products of the present invention is not particularly limited as long as the requirements of the present invention are satisfied. 6 dtex is preferable, and 1.5 to 4 dtex is more preferable.
  • the long fiber nonwoven fabric layer serving as the base material layer is preferably a round cross section from the viewpoint of productivity in the known spunbonded nonwoven fabric, but an irregular cross section such as a flat cross section, a hollow cross section, and a different fineness blend can be selected as necessary.
  • the nonwoven fabric structure when a heat-bonded nonwoven fabric structure is formed by adding or mixing a heat-bonded fiber component to the short-fiber nonwoven fabric layer and the long-fiber nonwoven fabric layer, the nonwoven fabric structure becomes brittle, resulting in structural failure and poor durability. Is not preferable.
  • the air permeability of the nonwoven fabric for reinforcing foam molded products of the present invention is not particularly limited. However, if the air permeability is less than 50 cc / cm 2 / sec, the expansion air escape during foam molding becomes non-uniform, resulting in the occurrence of missing or resin loss. If it exceeds 350 cc / cm 2 / second, bleeding may occur due to leakage of the foaming agent. In the present invention, it is preferably 50 to 350 cc / cm 2 / sec, and more preferably 80 to 160 cc / cm 2 / sec, as a range that does not cause gas escape failure and foaming agent bleeding during foam molding.
  • the non-woven fabric for foam molded article reinforcement that satisfies the requirements of the present invention is cut into a predetermined shape and set as a foam molding article reinforcing material on the cushion mold so that the protruding fiber structure forming surface is on the foaming agent side.
  • a foaming agent made of urethane foam is obtained by injecting and foaming a foaming agent.
  • foam molding method foam molding is performed by a cold foaming method or a hot foaming method.
  • the molded foam molded body is finished in a good shape, the foaming agent does not bleed out, and as a spring receiving material, it suppresses scratching, bending, and refraction sound, and has excellent shape retention durability and wear resistance. Goods were obtained. Further, the operability of the cutting process to the predetermined shape and the setting to the mold was very good without deformation of the nonwoven fabric.
  • the non-woven fabric for reinforcing foam molded products of the present invention is particularly excellent in handleability and mold followability, and can contribute to cost reduction while minimizing the cost load in the processing process.
  • the nonwoven fabric for reinforcing foam molded articles of the present invention is not limited to foam sheet applications, but as a reinforcing material for foam molded articles, various interior materials for vehicles, building materials, surface foam molded articles of electrical appliances, etc. It is also useful for applications.
  • Apparent density basis weight ⁇ (thickness mm ⁇ 1000)
  • Air permeability (cc / cm 2 / sec) It was carried out with a Frazier permeability tester according to JIS L 1096 8.27.1.
  • Discrimination of non-woven fabric Whether or not the coating layer is a short fiber non-woven fabric layer is obtained by drawing out the constituting fiber and confirming the short fiber form. Whether or not the base material layer is a long-fiber non-woven fabric layer is determined by peeling the other interwoven fiber non-woven fabric layers (including the protruding fiber structure) and visually confirming that it is composed of long fibers.
  • Polyester short fiber made of polyethylene terephthalate with a cut length of 51 mm having a mechanical crimp of 2 dtex in a round cross section as fiber A, and polyester short fiber made of polyethylene terephthalate with a cut length of 51 mm having a mechanical crimp of 3 dtex in a round cross section as fiber B are mixed with cotton blended at a 40/60 mass ratio to form a card web, and laminated with a cross layer so as to be 60 g / m 2, and then entangled with 20 pene / cm 2 as pre-entanglement treatment The treatment was performed, and the entanglement process was continuously performed at a penetrating number of 120 pieces / cm 2 to obtain a short fiber nonwoven fabric having a basis weight of 60 g / m 2 .
  • PET Polyethylene terephthalate
  • embossing is performed at 250 ° C.
  • a polyester continuous fiber non-woven fabric for a base material layer having an apparent density of 0.16 g / m 2 was obtained.
  • a short fiber nonwoven fabric is laminated on the upper surface of the long fiber nonwoven fabric, and from the surface of the short fiber nonwoven fabric, entanglement entanglement treatment is performed by a needle punch at a needle depth of 10 mm at a penetrating number of 120 pieces / cm 2 to reinforce the foam molded product.
  • a nonwoven fabric was obtained.
  • the obtained nonwoven fabric for reinforcing foam-molded articles has a basis weight of 100 g / m 2 , an apparent density of 0.08 g / cm 3 , and a stress at 5% elongation of 17 N / 5 cm in the longitudinal direction, 7 N / 5 cm in the transverse direction, and stress at 30% elongation.
  • the protruding fiber structure is formed on the surface of the non-woven fabric, the protruding fiber length is 7 mm, the number of protruding fiber structures is 115 / cm 2 , and the air permeability is 125 cc / cm 2 / sec.
  • Example 1 which satisfies the requirements of the present invention, has good draw deformation, punchability, and mold setting properties, and exudation, wrinkles, floats, and tears in foam molding. There was no peeling, and the moldability was good. Even in the performance evaluation, the nonwoven fabric for reinforcing foam molded articles has good sound damping properties, wear resistance, and shape retention, and has excellent performance as a reinforcing material for foam molding.
  • Example 2 Except laminated to 80 g / m 2 basis weight of the short fiber nonwoven fabric at cross-layer so as to be 80 g / m 2, the expansion-molded article reinforcing nonwoven fabric obtained in the same manner as in Example 1, basis weight 120 g / m 2, Apparent density 0.09g / cm 3 , 5% elongation stress is 15N / 5cm in the longitudinal direction, 9N / 5cm in the transverse direction, 30% elongation stress is 36N / 5cm in the longitudinal direction, 22N / 5cm in the transverse direction, ⁇ ST5m-ST30m 11N / 5cm, 40% elongation stress is 60N / 5cm in the vertical direction, 38N / 5cm in the horizontal direction, ⁇ ST30m-ST40m is 25N / 5cm, and the strength is 208N / 5cm in the vertical direction (1.7N / 5cm (g / m per unit weight) 2 )
  • Example 2 which satisfies the requirements of the present invention, has good draw deformation, punchability, and mold setting properties, and exudation, wrinkles, floats, and tears in foam molding. There was no peeling, and the moldability was good. Even in the performance evaluation, the nonwoven fabric for reinforcing foam molded articles has good sound damping properties, wear resistance, and shape retention, and has excellent performance as a reinforcing material for foam molding.
  • Example 3 Except laminated to 100 g / m 2 basis weight of the short fiber nonwoven fabric at cross-layer so as to be 100 g / m 2, the expansion-molded article reinforcing nonwoven fabric obtained in the same manner as in Example 1, basis weight 140 g / m 2, Apparent density 0.09g / cm 3 , 5% elongation stress is 20N / 5cm in the longitudinal direction, 10N / 5cm in the transverse direction, 30% elongation stress is 40N / 5cm in the longitudinal direction, 30N / 5cm in the transverse direction, ⁇ ST5m-ST30m At 20N / 5cm, the stress at 40% elongation is 65N / 5cm in the longitudinal direction, 50N / 5cm in the transverse direction, ⁇ ST30m-ST40m is 25N / 5cm, and the strength is 226N / 5cm in the longitudinal direction (1.6N / 5cm (g / g) /
  • the fiber structure was formed on the long fiber nonwoven fabric surface, the protruding fiber length was 6 mm, the number of protruding fiber structures formed was 115 / cm 2 , and the air permeability was 102 cc / cm 2 / sec.
  • Example 3 which satisfies the requirements of the present invention, has good draw deformation, punchability, and mold setting properties, and exudation, wrinkles, floats, and tears in foam molding. There was no peeling, and the moldability was good. Even in the performance evaluation, the nonwoven fabric for reinforcing foam molded articles has good sound damping properties, wear resistance, and shape retention, and has excellent performance as a reinforcing material for foam molding.
  • a web opened using short fibers having a fiber length of 51 mm with a 2 dtex round cross section is laminated on a basis weight of 80 g / m 2 and entangled with a needle punch at a penetrating number of 100 pieces / cm 2 .
  • a short fiber nonwoven fabric serving as a covering layer having a basis weight of 80 g / m 2 was prepared.
  • polypropylene having a melt index of 60 g / 10 min hereinafter referred to as PP
  • a long-fiber non-woven fabric serving as a base material layer having an area of a crimped portion of 0.05 mm 2 and an area ratio of the crimped portion of 16% was obtained.
  • a short fiber nonwoven fabric is laminated on the upper surface of the long fiber nonwoven fabric, and entanglement treatment by needle punching is performed from the surface of the short fiber nonwoven fabric with a needle depth of 10 mm at a penet of 100 pieces / cm 2 , thereby reinforcing a foam molded article reinforcing nonwoven fabric.
  • the obtained non-woven fabric for reinforcing foam-molded articles has a basis weight of 120 g / m 2 , an apparent density of 0.09 g / cm 3 , and a stress at 5% elongation of 24 N / 5 cm in the longitudinal direction, 6 N / 5 cm in the transverse direction, and stress at 30% elongation.
  • protruding fiber structure is formed on the surface of the non-woven fabric, protruding fiber length is 8 mm, the number of protruding fiber structures is 94 / cm 2 , and air permeability is 118 cc / cm 2 / sec.
  • Comparative Example 1 which deviates from the requirements of the present invention was good in drawing deformation, punching property and mold setting property, but ⁇ ST5m-ST30m and ⁇ ST30m- Since ST40m is high, there is a slight difficulty in following the mold in foam molding, and there is no bleeding, tearing, or peeling, but there are wrinkles and the shape of the molded product is somewhat poor.
  • it was a nonwoven fabric for reinforcing foam molded products, which had good points, but had some disadvantages as a reinforcing material for foam molding.
  • ⁇ Comparative example 2> A polyethylene terephthalate (PET) having an intrinsic viscosity of 0.65 is melt-spun at a spinning temperature of 285 ° C. and a single-hole discharge rate of 1.0 g / min, and a web having a basis weight of 80 g / m 2 made of long fibers having a fineness of 2.0 dtex. Got. Next, the same process as in Example 1 was carried out except that a polyester long fiber nonwoven fabric having a slightly weak entire surface pressure-bonding part was obtained by using a calendar roller at 250 ° C. and a linear pressure of 20 kN / m to obtain a coating layer. A nonwoven fabric for reinforcing foam molded articles was obtained.
  • PET polyethylene terephthalate
  • the obtained non-woven fabric for reinforcing foam-molded articles has a basis weight of 120 g / m 2 , an apparent density of 0.14 g / cm 3 , and a stress at 5% elongation of 56 N / 5 cm in the longitudinal direction, 26 N / 5 cm in the transverse direction, and stress at 30% elongation.
  • Comparative Example 2 which deviates from the requirement of the present invention, was good in drawing deformation, punching property, and mold setting property, but had a high stress at 5% elongation and ⁇ ST5m ⁇ Since ST30m is also high, there is a difficulty in following the mold in foam molding, generation of wrinkles, floating, slight breakage, exudation is observed, and the shape of the molded product is poor. It was. In the performance evaluation, the sound damping property is also inferior, the wear resistance is inferior due to wear from the buttocks and the floating part, and the protruding fiber structure is poorly formed, or peeling from the foam layer occurs and the shape retention is good. It was an inferior nonwoven fabric for reinforcing foam-molded products, which is a problem as a reinforcing material for foam molding.
  • Example 3 The nonwoven fabric for reinforcing foam molded articles obtained in Example 2 was evaluated as a nonwoven fabric for reinforcing foam molded articles by adding the protruding fiber structure surface of the nonwoven fabric for reinforcing foam molded articles to a heat roller surface at 185 ° C. and eliminating the protruding fiber structure by fluffing treatment. The nonwoven fabric characteristics did not change except that the protruding fiber structure was lost.
  • the non-woven fabric for reinforcing foam-molded articles has a problem of durability due to peeling and has a problem as a foam-molding reinforcing material.
  • the short fiber nonwoven fabric of Comparative Example 1 was obtained in the same manner as in Example 2 except that the short fiber nonwoven fabric prepared by the same method was used as a base material layer instead of the long fiber nonwoven fabric except that the basis weight was 40 g / m 2.
  • the non-woven fabric for reinforcing foam-molded products having a laminated structure of the short fiber nonwoven fabric has a basis weight of 120 g / m 2 , an apparent density of 0.06 g / cm 3 , and a 5% elongation stress of 1.1 N / 5 cm in the vertical direction and in the horizontal direction.
  • ⁇ ST30m-ST40m is 4 N / 5 cm
  • strength is 151 N / 5 cm in the vertical direction (1.26 N / 5 cm (g / m 2 ) per unit weight)
  • 182 N / 5 cm in the horizontal direction (1.52 N / 5 cm per unit weight (g / m ) Sum) in strength is basis weight per 2.78N / 5cm (g / m 2 )
  • the projecting fiber structure forms a short fiber nonwoven fabric surface of the substrate layer, breathable 250 cc / cm 2 / sec Met.
  • Comparative Example 4 using short fiber non-woven fabric as the base material layer is out of the requirements of the present invention, and is poor in drawing deformation, punching property and mold setting property.
  • the oozing was remarkable, the wrinkles and tears were slightly generated, there was no peeling, and the moldability was somewhat poor due to stretch spots.
  • Even in the performance evaluation the sound damping performance deteriorated due to the oozing of the foaming agent, and the foam molding reinforcement material had a problem that the shape retention was poor in both wear resistance and shape retention.
  • Example 5 The nonwoven fabric for reinforcing foam molded articles obtained in the same manner as in Example 1 except that the basis weight of the short fiber nonwoven fabric is 20 g / m 2 and the basis weight of the long fiber nonwoven fabric is 30 g / m 2 is 50 g / m 2 .
  • Comparative Example 5 which does not satisfy the requirements of the present invention is poor in drawing deformation, punching property, mold setting property, inferior handling property, and exudation in foam molding is very small. Although it occurred, there was no wrinkling, floating, tearing or peeling, and the moldability was acceptable. Even in the performance evaluation, the non-woven fabric for reinforcing foam molded products was poor as a foam molding reinforcing material, with poor sound damping, wear resistance and shape retention.
  • Comparative Example 6 which does not satisfy the requirements of the present invention has no problems with draw deformation, punchability, and mold setting properties, but has good handleability, but exudation in foam molding There was no tearing or peeling, but the moldability was poor and wrinkles and floats were generated.
  • it is a non-woven fabric for reinforcing foam molded products, which remains problematic as a foam molding reinforcement, although it has good noise suppression but slightly inferior in abrasion resistance, and the covering layer collapses due to wear, resulting in poor shape retention. It was.
  • Short fibers are blended with blended cotton at a 40/60 mass ratio to form a card web and laminated to a cross layer of 60 g / m 2, and then pre-entangled with 20 pene / cm 2 penetrants Foaming obtained in the same manner as in Example 1 except that the entanglement treatment was performed continuously, and the short fiber nonwoven fabric having a basis weight of 60 g / m 2 was used by entanglement entanglement treatment with a number of pene of 120 pieces / cm 2 .
  • Comparative Example 7 that does not satisfy the requirements of the present invention is somewhat bulky, so there is a slight problem in the drawing deformation and punchability, and the mold setting property is acceptable. Although handling was acceptable, there was no lifting, tearing or peeling in foam molding, but the moldability was somewhat poor, and bleeding and wrinkles due to side leakage occurred. In the performance evaluation, it was a nonwoven fabric for reinforcing foam molded products, in which sound insulation and abrasion resistance were slightly inferior, and the covering layer was peeled off due to abrasion, so that there was a difficulty in shape retention.
  • the fiber is mixed with a blended cotton at a mass ratio of 40/60 to form a card web, laminated to a cross layer of 60 g / m 2, and then entangled with 20 pens / cm 2 as a pre-entanglement process.
  • Example 2 In the same manner as in Example 1 except that a short fiber nonwoven fabric having a basis weight of 60 g / m 2 obtained by performing an entangling process and continuously entangling with a penetrating number of 120 pieces / cm 2 was used for the coating layer.
  • molded foam reinforcing nonwoven was collected using the basis weight 100 g / m 2, an apparent density 0.09g / cm 3, 5% elongation when the stress longitudinal 23N / cm, transverse direction 11 N / 5 cm, 30% elongation stress is 54 N / 5 cm longitudinal direction, 23 N / 5 cm, ⁇ ST5m-ST30m is 31 N / 5 cm, 40% elongation stress is 86 N / 5 cm longitudinal direction, 32 N transverse direction.
  • ⁇ ST30m-ST40m is 31N / 5cm
  • strength is 236N / 5cm in the vertical direction (2.3N / 5cm / (g / m 2 ) per unit weight)
  • 302N / 5cm in the lateral direction (3.0N / 5cm per unit weight) / (G / m 2 )) and the sum of the strength is 5.3 N / 5 cm / (g / m 2 ) per unit weight
  • the protruding fiber structure is formed on the surface of the long fiber nonwoven fabric, the protruding fiber length is 7 mm, the protruding
  • the number of fiber structures formed was 110 / cm 2
  • the air permeability was 108 cc / cm 2 / sec.
  • Comparative Example 8 which does not satisfy the requirements of the present invention, has excellent handling properties with no problems in drawing deformation, punchability, and mold setting. There was no oozing, floating, tearing or peeling in foam molding, but the moldability was poor and wrinkles were also generated. In the performance evaluation, it was a non-woven fabric for reinforcing foam molded articles, which had good sound-damping properties but slightly inferior in abrasion resistance and had a difficulty in retaining its shape because the coating layer peeled off due to abrasion.
  • the fiber is mixed with a blended cotton at a mass ratio of 92/8 to form a card web, laminated to a cross layer of 80 g / m 2, and then entangled with 20 penes / cm 2 as a pre-entanglement treatment.
  • Example 2 The same procedure as in Example 2 was conducted, except that a short fiber nonwoven fabric having a basis weight of 60 g / m 2 obtained by continuously entanglement treatment at 120 pene / cm 2 was used for the coating layer.
  • ⁇ ST30m-ST40m is 26 N / 5 cm
  • strength is 129 N / 5 cm in the vertical direction (1.1 N / 5 cm / (g / m 2 ) per unit weight)
  • 141 N / 5 cm in the horizontal direction (1.2 N / 5 cm / per unit weight) (G / m 2 )) and the sum of strengths is 2.3 N / 5 cm / (g / m 2 ) per unit weight
  • the protruding fiber structure is formed on the surface of the non-woven fabric, the protruding fiber length is 7 mm, and the protruding fiber is The number of structures formed was 100 / cm 2 and the air permeability was 120 cc / cm 2 / sec.
  • Comparative Example 9 which deviates from the requirement of the present invention, was good in drawing deformation, punching property, and mold setting property, but ⁇ ST5m-ST30m and ⁇ ST30m- Since ST40m is high, there is a slight difficulty in following the mold in foam molding, and there is no bleeding, tearing, or peeling, but there are wrinkles and the shape of the molded product is somewhat poor.
  • it was a nonwoven fabric for reinforcing foam molded products, which had good points, but had some disadvantages as a reinforcing material for foam molding.
  • ⁇ Comparative Example 10> Using polyethylene terephthalate having an intrinsic viscosity of 0.65, spinning and shaking at a spinning temperature of 285 ° C. and a single hole discharge rate of 1.0 g / min, a web having a basis weight of 60 g / m 2 made of long fibers having a fineness of 2.0 dtex is used. Obtained. Next, embossing is performed at 260 ° C. and a linear pressure of 40 kN / m using an embossed roller with a concave texture pattern with a crimping area ratio of 42%, and the crimping area is 38% and the crimping part is not independent.
  • a polyester continuous fiber non-woven fabric having a hanging density of 0.16 g / m 2 was obtained.
  • a nonwoven fabric for reinforcing foam molded articles obtained in the same manner as in Example 1 except that the obtained long fiber nonwoven fabric was used for the base material layer had a basis weight of 120 g / m 2 and an apparent density of 0.10 g / cm 3 , 5 Stress at% elongation is 43N / 5cm in the longitudinal direction, 26N / 5cm in the transverse direction, stress at 30% elongation is 146N / 5cm in the longitudinal direction, 58N / 5cm in the transverse direction, ⁇ ST5m-ST30m is 103N / 5cm, and stress at 40% elongation is Longitudinal direction 204N / 5cm, lateral direction 76N / 5cm, ⁇ ST30m-ST40m is 31N / 5cm, strength is longitudinal direction 298N / 5cm (2.5N /
  • Comparative Example 1 which deviates from the requirements of the present invention was good in drawing deformation, punching property, and mold setting property, but ST5, ⁇ ST5m-ST30m during foam molding and Since ⁇ ST30m-ST40m is high, there is a difficulty in mold followability in foam molding, and there is no tearing or peeling, but wrinkles and floats occur, and bleeding from the outside of the reinforcing material occurs, resulting in the shape of the molded product Was bad.
  • the nonwoven fabric was reinforced with foamed molded article, although the sound-damping property was allowed, but abrasion occurred from the heel part and there were some difficulties in wear resistance and shape retention.
  • the nonwoven fabric for reinforcing foam molded articles of the present invention comprises a base layer that is flexible and has a high shielding function, and a coating layer that is bulky and excellent in sound-damping properties, and the foam molded part and the reinforcing material are integrated by an anchor effect due to a protruding fiber structure.
  • foam molding with good moldability which maintains the handleability by suppressing the elongation at the time of initial stretching, and is easy to stretch and deform when the local shear stress is applied during molding to improve uniform mold followability
  • This is a non-woven fabric for reinforcing foam molded products that is optimal for reinforcing material applications.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention porte sur un tissu non tissé pour renforcer un article de moulage de mousse, lequel tissu non tissé est caractérisé en ce qu'une structure à fibres saillantes est formée par mise en couches d'une couche de tissu non tissé à fibres courtes et d'une couche de tissu non tissé à fibres longues partiellement formées avec une minuscule partie sertie, la couche de tissu non tissé à fibres courtes et la couche de tissu non tissé à fibres longues étant partiellement entremêlées transversalement, et la fibre qui forme la couche de tissu non tissé à fibres courtes traversant la couche de tissu non tissé à fibres longues, et la contrainte à 5 % d'allongement (SR5m) dans la direction longitudinale étant de 10 à 30 N/5 cm, la contrainte à 5 % d'allongement (ST5c) dans la direction latérale étant de 5 à 25 N/5 cm, et la différence (ΔST5m - ST30m) entre la contrainte à 5 % d'allongement (ST5m) dans la direction longitudinale et la contrainte à 30 % d'allongement (ST30m) dans la direction longitudinale et la différence (ΔST30m - ST40m) entre la contrainte à 30 % d'allongement (ST30m) dans la direction longitudinale et la contrainte à 40 % d'allongement (ST40m) dans la direction longitudinale satisfaisant aux formules suivantes. Formule (1) : ΔST5m - ST30m ≤ 25 (N/5 cm) Formule (2) : ΔST30m - ST40m ≤ 25 (N/5 cm)
PCT/JP2012/074914 2011-09-30 2012-09-27 Tissu non tissé pour renforcer un article de moulage de mousse WO2013047669A1 (fr)

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JP2011215960A JP2013076179A (ja) 2011-09-30 2011-09-30 発泡成形品補強用不織布

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JP2018518382A (ja) * 2015-03-31 2018-07-12 フロイデンベルグ パフォーマンス マテリアルズ エルピー 成形可能な複合材マット

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JP6482335B2 (ja) * 2015-03-13 2019-03-13 七王工業株式会社 防草シート及びその使用方法
JP6745635B2 (ja) * 2016-04-19 2020-08-26 フタムラ化学株式会社 起毛状組織を有する複層不織布
JP6862717B2 (ja) * 2016-08-22 2021-04-21 東洋紡株式会社 ウレタン発泡成形用補強材の製造方法
JP7444408B2 (ja) 2021-10-14 2024-03-06 株式会社ＡＥＴＥＣ－α 発泡成形品用補強材に用いられる不織布、発泡成形品用補強材、及び発泡成形品用補強材に用いられる不織布の製造方法

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JPH0625391U (ja) * 1992-09-09 1994-04-05 千代田株式会社 不織布
JPH08142245A (ja) * 1994-11-18 1996-06-04 Matsushita Electric Works Ltd 積層不織布、その積層不織布を用いた電気カーペット、及びその積層不織布の製造方法
JP2002363849A (ja) * 2001-06-01 2002-12-18 Toyobo Co Ltd 積層不織布及びニードルパンチカーペット基布
JP2005212204A (ja) * 2004-01-28 2005-08-11 Daiwabo Co Ltd 発泡成形品用補強材

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2018518382A (ja) * 2015-03-31 2018-07-12 フロイデンベルグ パフォーマンス マテリアルズ エルピー 成形可能な複合材マット

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