WO2013176176A1 - 発泡成形用不織布積層体、該不織布積層体を用いたウレタン発泡成形体複合物、ならびに発泡成形用不織布積層体の製造方法 - Google Patents

発泡成形用不織布積層体、該不織布積層体を用いたウレタン発泡成形体複合物、ならびに発泡成形用不織布積層体の製造方法 Download PDF

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Publication number
WO2013176176A1
WO2013176176A1 PCT/JP2013/064204 JP2013064204W WO2013176176A1 WO 2013176176 A1 WO2013176176 A1 WO 2013176176A1 JP 2013064204 W JP2013064204 W JP 2013064204W WO 2013176176 A1 WO2013176176 A1 WO 2013176176A1
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WO
WIPO (PCT)
Prior art keywords
nonwoven fabric
polyester
fabric laminate
foam molding
fibers
Prior art date
Application number
PCT/JP2013/064204
Other languages
English (en)
French (fr)
Inventor
市川　太郎
Original Assignee
三井化学株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 三井化学株式会社 filed Critical 三井化学株式会社
Priority to CN201380003011.9A priority Critical patent/CN103781955B/zh
Priority to JP2013543073A priority patent/JP5425352B1/ja
Priority to EP13793448.5A priority patent/EP2853628A4/en
Priority to US14/402,010 priority patent/US20150266263A1/en
Publication of WO2013176176A1 publication Critical patent/WO2013176176A1/ja

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C7/00—Parts, details, or accessories of chairs or stools
    • A47C7/02—Seat parts
    • A47C7/18—Seat parts having foamed material included in cushioning part
    • A47C7/20—Seat parts having foamed material included in cushioning part with reinforcement in the foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0076—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised in that the layers are not bonded on the totality of their surfaces
    • B32B37/0084—Point bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/04—Punching, slitting or perforating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
    • B60N2/58—Seat coverings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N2/00—Seats specially adapted for vehicles; Arrangement or mounting of seats in vehicles
    • B60N2/70—Upholstery springs ; Upholstery
    • B60N2/7017—Upholstery springs ; Upholstery characterised by the manufacturing process; manufacturing upholstery or upholstery springs not otherwise provided for
    • 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
    • D04H1/42—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
    • D04H1/4374—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 using different kinds of webs, e.g. by layering 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
    • 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
    • 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
    • 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
    • D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
    • 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
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • 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
    • D04H3/14—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 yarns or filaments produced by welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/04—Punching, slitting or perforating
    • B32B2038/042—Punching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2307/70—Other properties
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
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    • B32B2307/00—Properties of the layers or laminate
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    • B32B2307/726—Permeability to liquids, absorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2479/00—Furniture
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings
    • 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]
    • Y10T442/608—Including strand or fiber material which is of specific structural definition
    • Y10T442/609—Cross-sectional configuration of strand or fiber material is specified

Definitions

  • the present invention relates to a foam molded nonwoven fabric laminate disposed at the bottom of a foam molded product such as polyurethane, a urethane foam molded composite using the nonwoven fabric laminate, and a method for producing a foam molded nonwoven fabric laminate.
  • foamed molded products such as soft polyurethane foam are used.
  • a reinforcing base fabric is disposed at the bottom of such a foam molded product in order to increase the rigidity of the foamed urethane molded product and to prevent urethane from seeping out from the back surface.
  • a combination of cold water and slab urethane or a coarse blanket is used as the reinforcing base fabric, but the rigidity of the urethane molded product is insufficiently improved, and the prevention of seepage from the back of the urethane is insufficient. There was a problem.
  • a method for improving such drawbacks as a reinforcing base fabric, a method of using the basis weight 10 ⁇ 30 g / thin dense layer of m 2 and a basis weight 40 ⁇ 100 g / m 2 of rough bulky layer by integrating the nonwoven (Patent Reference 1), a method using a high-weight nonwoven fabric having a basis weight of 110 to 800 g / m 2 and a fiber diameter of 1 to 16d (see Patent Document 2), and a method using a meltblown nonwoven fabric having a fiber diameter of 10 ⁇ m or less as a dense layer (Patent Document 3).
  • a web (dense layer) made of fibers having a fineness of 1.1 to 2.7 dtex and a web (bulky layer) made of fibers having a fineness of 2.3 to 8.8 dtex are laminated by mechanical entanglement treatment.
  • a method using a non-woven fabric (see Patent Document 4), or a fiber base layer such as a spunbond non-woven fabric and a short fiber layer laminated on at least one surface integrated by the action of high-pressure water flow Foam A method of using as a mold product reinforcement (see Patent Document 5), various methods have been proposed.
  • any of the foam-forming reinforcement base fabrics described in Patent Documents 1 to 5 has been aimed at solving the problem of seepage and impregnation performance during urethane foaming as a problem. It is not a material that can save the manual labor of sewing.
  • the nonwoven fabric obtained by the techniques of Patent Documents 6 and 7 has improved mold following characteristics and saves the labor of sewing, but the nonwoven fabric made of short fibers is stretched when following the mold. However, there was a problem that an extremely thin portion was formed due to insufficient. If urethane foam processing is performed as the next step in this state, bleeding from this thin part to the back of the urethane occurs, resulting in problems such as reduced reinforcement effect and abnormal noise with the metal spring. was there.
  • the present invention is excellent in conformity to a mold at the time of molding of heating, spreading, and compression processing, and can sufficiently maintain a reinforcing effect and urethane exudation preventing performance even after being molded, and a foam molding laminate, and It is an object to provide a urethane foam molded body composite using the same.
  • the nonwoven fabric laminate for foam molding of the present invention is Having a reinforcing layer on at least one side of the dense layer;
  • the dense layer is a nonwoven fabric composed of polyester-based long fibers having a fiber diameter of 10 to 30 ⁇ m, a bulk density of 0.1 g / cm 3 or more, and fibers fused by hot air treatment,
  • the reinforcing layer is a nonwoven fabric made of polyester short fibers having a fiber diameter of 10 to 30 ⁇ m,
  • the dense layer and the reinforcing layer are entangled by needle punch.
  • the dense layer does not have a partial thermocompression bonding portion.
  • the air permeability at a pressure difference of 125 Pa is preferably 25 cm 3 / cm 2 / sec or more and less than 140 cm 3 / cm 2 / sec.
  • the polyester-based long fibers of the dense layer and / or the polyester-based short fibers of the reinforcing layer contain fibers having different melting points on the cross section.
  • the polyester-based long fibers of the dense layer include composite long fibers composed of two or more resins having different melting points, and at least one of the resins constituting the composite long fibers.
  • One is preferably a polyester resin.
  • the polyester-based short fibers of the reinforcing layer include composite short fibers composed of two or more resins having different melting points, and at least the resin constituting the composite short fibers
  • One is preferably a polyester-based resin, and more preferably the melting point of at least one resin constituting the composite short fiber is in the range of 110 to 190 ° C.
  • the basis weight of the dense layer is preferably in the range of 10 to 50 g / m 2
  • the basis weight of the reinforcing layer is preferably in the range of 40 to 150 g / m 2.
  • the basis weight of the nonwoven fabric laminate for foam molding is preferably in the range of 50 to 200 g / m 2 .
  • the urethane foam molded article composite of the present invention is formed by integrating the reinforcing layer of any one of the above-mentioned nonwoven fabric laminates for foam molding of the present invention and the urethane foam molded article.
  • the vehicle seat of the present invention and the chair of the present invention use the urethane foam molded article composite of the present invention.
  • the method for producing the nonwoven fabric laminate for foam molding of the present invention is as follows. A step of obtaining a nonwoven fabric having a fiber diameter of 10-30 ⁇ m and a bulk density of 0.1 g / cm 3 or more by hot air treatment; A step of laminating the non-woven fabric and a non-woven fabric made of polyester short fibers having a fiber diameter of 10 to 30 ⁇ m and entanglement with a needle punch.
  • the polyester-based long fibers include composite long fibers composed of two or more kinds of resins having different melting points, and at least a resin constituting the composite long fibers.
  • One is preferably a polyester resin.
  • the nonwoven fabric laminate for foam molding of the present invention is formed by a dense layer made of a nonwoven fabric made of a specific polyester-based long fiber and a reinforcing layer made of a nonwoven fabric made of a specific polyester-based short fiber being entangled and laminated.
  • Excellent heat resistance can maintain the denseness in the sheet even after heating, spreading, and compression processing, and has excellent compliance with non-woven fabric molds during molding of heating, spreading, and compression. It can be processed into a shape and can be processed into a shape suitable for a mold of a foamed molded article without cutting or by reducing the labor of cutting, and maintains sufficient denseness on the entire surface. be able to.
  • the laminate suitably follows a mold having a desired shape, and the urethane resin oozes out.
  • a urethane foam molded article can be suitably formed on the laminate without any problems.
  • the urethane foam molded article composite of the present invention does not cause the urethane resin to ooze out on the nonwoven fabric laminate side serving as the base fabric, for example, when used in the manufacture of automobile seats, it is caused by rubbing between metal parts and urethane foam. It becomes possible to prevent abnormal noise effectively.
  • the nonwoven fabric laminate for foam molding having the above-mentioned excellent characteristics can be suitably produced.
  • the nonwoven fabric laminate for foam molding of the present invention has a reinforcing layer on at least one surface of the dense layer.
  • the dense layer according to the present invention is a nonwoven fabric composed of polyester-based long fibers
  • the reinforcing layer according to the present invention is a nonwoven fabric composed of polyester-based short fibers, both of which are nonwoven fabrics composed of polyester-based fibers.
  • the short fiber means a fiber having an average fiber length of 200 mm or less.
  • a polyester fiber is a fiber formed from a single polyester alone, a composite fiber formed from two or more polyesters, a composite formed from one or more polyesters and a thermoplastic resin other than polyester. Any of the fibers may be used.
  • the fiber formed only from a single polyester may be a homogeneous fiber, or may have a different melting point on the cross section by a process such as spinning or subsequent heat setting.
  • the composite fiber may have a part with a different melting point on the cross section.
  • the polyester fiber may be a mixed fiber obtained by mixing two or more of these fibers.
  • the melting point of the polyester-based long fibers of the dense layer and / or the polyester-based short fibers of the reinforcing layer is preferably in the range of 110 to 190 ° C., preferably 110 to 140 ° C. Therefore, it is desirable that at least a part of the polyester fiber satisfies such a melting point.
  • the polyester short fibers of the reinforcing layer are composite short fibers, and the melting point of at least one resin constituting the composite short fibers is 110 to 190 ° C., preferably 110 to 140 ° C., particularly preferably 110 to 140 ° C. It is desirable that the temperature be 120 ° C.
  • the polyester-based short fibers of the reinforcing layer are composite short fibers, it is preferable to contain copolymerized polyethylene terephthalate or polyethylene as a fiber component.
  • a non-woven fabric made of polyester fiber when used, it is preferable from the viewpoint of heat resistance at the time of molding processing of heating, spreading, and compression, and formed from a resin having a low melting point resin such as polypropylene resin or polyethylene resin as a single component.
  • a resin having a low melting point resin such as polypropylene resin or polyethylene resin as a single component.
  • transformation at the time of a heating etc. which arises when using the nonwoven fabric made can be prevented.
  • polyester constituting the polyester fiber examples include polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), and polylactic acid (PLA), and copolymers thereof. And combinations thereof.
  • PET polyethylene terephthalate
  • PTT polytrimethylene terephthalate
  • PBT polybutylene terephthalate
  • PLA polylactic acid
  • PET polyethylene terephthalate
  • PET polytrimethylene terephthalate
  • PBT polybutylene terephthalate
  • PBT polylactic acid
  • the resin used when forming the polyester fiber is an antioxidant, a weather stabilizer, a light stabilizer, an anti-blocking agent, a lubricant, a nucleating agent, a pigment, a softening agent, a hydrophilic agent, as long as the object of the present invention is not impaired.
  • Various known additives such as additives, auxiliaries, water repellents, fillers, antibacterial agents, and flame retardants may be added.
  • these additives may be added to the fiber surface by means such as spraying after forming the nonwoven fabric.
  • the dense layer which comprises the nonwoven fabric laminated body for foam molding of this invention is a nonwoven fabric which consists of a polyester-type long fiber among the polyester-type fibers mentioned above.
  • the polyester-based long fibers desirably have a fiber diameter of 10 to 30 ⁇ m, preferably 15 to 25 ⁇ m. If the fiber diameter exceeds 30 ⁇ m, the denseness of the nonwoven fabric is impaired, and the risk of urethane seepage during urethane foaming is increased, which is not preferable. Moreover, when the fiber diameter is less than 10 ⁇ m, the productivity of the polyester long-fiber nonwoven fabric decreases, which is not preferable.
  • the cross-sectional shape of the fiber may be an irregular cross-section such as a trilobal type in addition to a round shape.
  • the dense layer according to the present invention is a nonwoven fabric in which fibers are fused by hot air treatment, and preferably a nonwoven fabric in which fibers are fused by heat treatment such as hot air over the entire portion of the nonwoven fabric. It is desirable that the non-woven fabric of the dense layer does not have a partial thermocompression bonding portion, and it is preferable that the thermocompression bonding such as embossing is not performed.
  • the polyester resin can be obtained by spinning a polyester resin and passing it through a hot air bonding machine (US Pat. No. 3,384). 944, US 3,989,788, Special Table 2010-537068).
  • the obtained non-woven fabric laminate for foam molding has excellent followability to the mold, excellent shape workability, and mold It is preferable because sufficient denseness can be maintained over the entire surface even after processing into a shape.
  • the dense layer according to the present invention has a basis weight of usually 10 to 60 g / m 2 , preferably 10 to 50 g / m 2 , more preferably 15 to 45 g / m 2 .
  • the polyester-based long fibers constituting the non-woven fabric of the dense layer are fibers formed only from a single polyester, composite long fibers formed from two or more polyesters, one or more polyesters and a thermoplastic resin other than the polyester. Any of the formed composite long fibers may be used, and one or more of these polyester fibers can be used.
  • the polyester long fibers constituting the non-woven fabric of the dense layer include composite long fibers composed of two or more resins having different melting points, and at least one of the resins constituting the composite long fibers is a polyester resin. It is preferable. Such polyester-based long fibers also preferably have portions having different melting points on the cross section.
  • polyester-based long-fiber nonwoven fabric examples include “Reimei (R-2 series)” and “Reimei (R-0 series)” manufactured by Fiberweb.
  • “Reimei (R-2 series)” and “Reimei (R-0 series)” are composed of polyester composite continuous fibers having sections with different melting points on the cross section, and hot air bonding treatment is applied to the entire nonwoven fabric. Therefore, it is particularly suitable as a dense layer constituting the nonwoven fabric laminate of the present invention.
  • the dense layer according to the present invention preferably has a bulk density equal to or higher than that of the reinforcing layer, usually 0.1 g / cm 3 or more, preferably 0.1 to 0.3 g / cm 3 , more preferably 0.00.
  • the range of 1 to 0.2 g / cm 3 is desirable.
  • the dense layer according to the present invention may be composed of a single layer of nonwoven fabric, or may be composed of two or more layers of nonwoven fabric. When comprised from a nonwoven fabric of two or more layers, it may be comprised from the same kind of nonwoven fabric, and may be comprised from a different nonwoven fabric. Further, when the dense layer is composed of two or more layers of nonwoven fabric, they may be laminated in advance and entangled or bonded by a known method, or they are formed by laminating at the time of forming the nonwoven fabric laminate for foam molding. May be.
  • the reinforcement layer which comprises the nonwoven fabric laminated body for foam molding of this invention is a nonwoven fabric which consists of a polyester-type short fiber among the polyester-type fibers mentioned above.
  • the polyester short fibers desirably have a fiber diameter of 10 to 30 ⁇ m, preferably 15 to 25 ⁇ m.
  • the average fiber length is usually 200 mm or less, preferably 10 mm to 70 mm, more preferably 30 to 60 mm. The smaller the fiber diameter, the better the performance of preventing or exuding urethane and the performance of reinforcing effect, but it is preferable to be within the above range from the viewpoint of productivity at the time of entanglement.
  • the short fibers forming the reinforcing layer according to the present invention may be single fibers, side-by-side type or core-sheath type composite fibers, or crimped fibers.
  • the cross-sectional shape of the fiber may be an irregular cross section such as a V shape, a cross shape, or a T shape in addition to the round shape.
  • those composed of fibers composed of at least two components of a low melting point resin and a high melting point resin are preferable.
  • a core-sheath composite fiber of a high-melting point PET resin and a low-melting point PET resin or a core-sheath composite fiber of a high-melting point PET resin and a PE resin can be used.
  • the polyester short fibers constituting the nonwoven fabric of the reinforcing layer include composite short fibers composed of two or more resins having different melting points, and at least one of the resins constituting the composite short fibers is a polyester resin. It is preferable. Such polyester short fibers preferably have portions having different melting points on the cross section.
  • the short fibers forming the reinforcing layer As the short fibers forming the reinforcing layer according to the present invention, a mixture of two or more monocomponent polyester short fibers having different melting points can be selected.
  • the melting point of at least one resin constituting the composite short fibers is preferably 110 to 190 ° C, more preferably 110 to 140 ° C, most preferably 110 to 120. It is desirable to be in the range of ° C. In the case of having a resin having a melting point in the above range, it is preferable because the shape retention after the nonwoven fabric laminate is heated, spread and compressed is excellent. Examples of such a resin include copolymerized polyethylene terephthalate or polyethylene.
  • a composite short fiber it is possible to control the shape retention by making it into a mixed fiber state with other short fibers, for example, a single-component polyester short fiber having a high melting point.
  • the blend ratio of the composite polyester short fibers is 10 to 90%, more preferably 20 to 80%, and most preferably 30 to 60%. Below this ratio, shape retention may be inferior. If this ratio is exceeded, the shape retention after heating, spreading, and compression processing is excellent, but the texture of the obtained non-woven fabric becomes hard and may have an adverse effect on the noise prevention effect and riding comfort.
  • fibers exhibiting extensibility can be selected.
  • a high melting point PET resin and a low melting point PET resin or a high viscosity PET resin and a low viscosity can be selected.
  • Examples include side-by-side composite fibers made of PET resin.
  • a method for obtaining a nonwoven fabric from the above polyester short fibers known methods can be used, and preferably, a method of mechanically joining by needle punching or fusing by heat treatment can be adopted.
  • a method of mechanically joining by needle punching or fusing by heat treatment can be adopted.
  • the nonwoven fabric is formed by needle punching.
  • the reinforcing layer according to the present invention preferably has a bulk density equal to or lower than that of the dense layer, and is not particularly limited, but the bulk density is usually 0.01 to 0.1 g / cm 3 , preferably 0. It is desirable that the range be 0.03 to 0.09 g / cm 3 , more preferably 0.05 to 0.08 g / cm 3 .
  • the reinforcing layer according to the present invention has a basis weight of usually 40 to 180 g / cm 2 , preferably 40 to 160 g / cm 2, more preferably 40 to 150 g / cm 2 , further preferably 60 to 150 g / cm 2. Is desirable.
  • the reinforcing layer according to the present invention may be a single layer or two or more layers.
  • the reinforcing layer When the reinforcing layer is a laminate of two or more layers, it may be composed of the same kind of nonwoven fabric or may be composed of different nonwoven fabrics.
  • the reinforcing layer When the reinforcing layer is composed of two or more layers of nonwoven fabric, they may be laminated in advance and entangled or bonded by a known method, or they are formed by laminating at the time of forming the nonwoven fabric laminate for foam molding Also good.
  • the reinforcing layer according to the present invention may be provided only on one side of the dense layer, or may be provided on both sides.
  • the nonwoven fabric laminated body for foam molding of this invention can be manufactured by laminating
  • the dense layer and the reinforcing layer are joined by mechanical entanglement without bias by forming a laminated body in which the dense layer and the reinforcing layer are joined together by an entanglement process by needle punching.
  • the nonwoven fabric laminate for foam molding of the present invention does not interfere with the step of three-dimensionally following the mold for producing the foam molded body, and there is uneven thickness due to stretching when stretching is accompanied by the tracking.
  • the nonwoven fabric laminate for foam molding of the present invention desirably has a performance that prevents foamed resins such as urethane from leaching out at the stage of molding the foam molded body, but has sufficient density and also has air permeability. More preferably, it is retained.
  • the air permeability at a pressure difference of 125 Pa is preferably 20 cm 3 / cm 2 / sec or more and less than 160 cm 3 / cm 2 / sec, and 25 cm 3 / cm 2.
  • the foaming resin such as urethane has better prevention of bleeding, and gas generated by foam molding can be suitably discharged.
  • a foam layer can be formed densely as a result, it is effective in improving the rigidity of the foam.
  • the nonwoven fabric laminate for foam molding of the present invention has a basis weight of usually 20 to 200 g / m 2 , preferably 50 to 200 g / m 2 , more preferably 50 to 160 g / m 2 , and further preferably 50 to 120 g / m 2. More preferably, it is in the range of 50 to 100 g / m 2 .
  • the tensile strength (N / 50 mm) is 50 N / 50 mm or more, preferably 70 N / 50 mm or more, the reinforcing effect and the handleability are improved. It is preferable because it is excellent.
  • Such a nonwoven fabric laminate for foam molding of the present invention may be further laminated with another base material layer and used for foam molding within a range not impairing the effects of the present invention.
  • Specific examples of other base material layers laminated with the nonwoven fabric laminate of the present invention include knitted fabrics, woven fabrics, nonwoven fabrics, films, and paper products.
  • Methods for laminating (bonding) the nonwoven fabric laminate of the present invention and other layers include thermal embossing, thermal fusion methods such as ultrasonic fusion, mechanical entanglement methods such as needle punch and water jet, hot
  • Various known methods such as a method using an adhesive such as a melt adhesive and a urethane-based adhesive, extrusion lamination, and the like can be adopted.
  • nonwoven fabric laminate for foam molding of the present invention may be used after being subjected to secondary processing such as gear processing, printing, coating, laminating, heat treatment, and shaping, as long as the object of the present invention is not impaired.
  • the nonwoven fabric laminate for foam molding of the present invention has a reinforcing layer on at least one surface of the dense layer, and the dense layer usually has a higher bulk density than the reinforcing layer.
  • the reinforcing layer side can be used so as to be the foamed molded body side such as urethane.
  • the urethane foam molded article composite of the present invention is formed by integrating the reinforcing layer of the above-mentioned nonwoven fabric laminate for foam molding of the present invention and the urethane foam molded article.
  • the urethane foam molded body is usually produced by foam molding polyurethane in a mold having a desired shape.
  • the urethane foam molded article composite of the present invention is disposed, for example, by following the above-mentioned nonwoven fabric laminate for foam molding of the present invention on the top or bottom of a mold such as a mold, and a foaming agent is placed in the mold. It can be manufactured by injecting a polyurethane raw material containing and foam-molding it.
  • the nonwoven fabric laminate for foam molding has excellent mold followability and can maintain sufficient denseness on the entire surface even after being followed by the mold, without causing urethane exudation, It is possible to produce a urethane foam molded body composite in which a polyurethane foam is integrated with a molded body that does not ooze out on the surface.
  • the urethane foam molded product composite of the present invention is suitably applied to various uses using a urethane foam molded product, such as seats for vehicles such as automobiles, trains, airplanes, playground equipment, furniture such as chairs and beds, toys, and building materials. can do.
  • the urethane foam molded body composite of the present invention uses the nonwoven fabric laminate for foam molding of the present invention, so that foam molding using a reinforcing material in the mold undergoes complicated processes such as cutting and sewing of the reinforcing material. For example, when used in combination with metal parts, such as for vehicle seats, abnormal noise due to rubbing between the metal parts and urethane foam can be effectively prevented. Also has the effect of.
  • MD length direction of the nonwoven fabric
  • CD direction perpendicular to the length
  • average values were calculated
  • tensile strength and elongation were obtained respectively.
  • Air permeability (cm 3 / cm 2 / sec)
  • a test piece of 200 mm (MD) ⁇ 50 mm (CD) was taken from the nonwoven fabric laminate for foam molding, and was obtained by measuring the flow rate at a pressure difference of 125 Pa using a Frazier air permeability measuring machine according to JISL1096.
  • Molding workability A simple mold having a size of 20 cm square and a height of 10 cm was covered with a 40 cm square foam-molded nonwoven fabric laminate and molded at 200 ° C. with a vacuum / pressure forming machine. The ease of molding at the time of molding, the shape retention of the nonwoven fabric after processing, the texture, etc. were judged by visual and tactile sensation (hand) according to the following criteria.
  • Polyester-based short fiber mixture (low-melting polyester resin (PET copolymer) having a melting point of 110 ° C and high-melting polyester resin (PET homopolymer) having a melting point of 250 ° C, core-sheath composite fiber (manufactured by Unitika Ltd.) Contains 30% “Melty 4080”, average fiber diameter of 16 ⁇ m, average fiber length of 51 mm, 2-component PET in Table 1.
  • High-melting polyester resin having a melting point of 250 ° C.
  • the dense layer As the dense layer, a commercially available polyester-based composite spunbond long-fiber non-woven fabric (“Remay (R-2 series)” circular cross-section type manufactured by Fiber Web Co., Ltd.) is used and laminated with the above-described polyester-based short fiber non-woven fabric for the reinforcing layer,
  • the nonwoven fabric laminate for foam molding was obtained by interlacing and joining with a needle punch machine.
  • the physical properties of the obtained foamed nonwoven fabric laminate were measured by the method described above. The results are shown in Table 1.
  • Examples 2 to 5 A nonwoven fabric laminate for foam molding in the same manner as in Example 1 except that the basis weight of the polyester-based short fiber nonwoven fabric used for the reinforcing layer and the basis weight of the polyester-based long fiber nonwoven fabric used for the dense layer are the basis weight shown in Table 1. Got. The physical properties of the obtained foamed nonwoven fabric laminate were measured by the method described above. The results are shown in Table 1.
  • Example 6 Two layers of the same polyester-based long fiber non-woven fabric used in Example 3 are laminated to form a dense layer, and the same polyester-based short fiber non-woven fabric as in Example 1 is further laminated, and entangled and joined by a needle punch machine. A nonwoven fabric laminate for foam molding was obtained. The physical properties of the obtained foamed nonwoven fabric laminate were measured by the method described above. The results are shown in Table 1.
  • Example 7 As the dense layer, a polyester-based composite spunbond long fiber non-woven fabric (“Reimei (R-0 series)” trilobal cross-sectional type manufactured by Fiber Web Co., Ltd.) was used, and the basis weight shown in Table 1 was used. Thus, a nonwoven fabric laminate for foam molding was obtained. The physical properties of the obtained foamed nonwoven fabric laminate were measured by the method described above. The results are shown in Table 1.
  • Polyester-based short fiber mixture (low-melting polyester resin (PET copolymer) having a melting point of 110 ° C and high-melting polyester resin (PET homopolymer) having a melting point of 250 ° C, core-sheath composite fiber (manufactured by Unitika Ltd.) 50% of “Melty 4080”, average fiber diameter 16 ⁇ m, average fiber length 51 mm, 2-component PET in Table 1.
  • Single fiber of high-melting polyester resin having a melting point of 250 ° C.
  • Example 1 A nonwoven fabric laminate for foam molding was obtained in the same manner as in Example 4 except that a polypropylene spunbond nonwoven fabric having a basis weight of 40 g / m 2 and a fiber diameter of 21 ⁇ m was used as the dense layer. As a result of the dense layer melting and forming the nonwoven fabric into a film during the molding process, a urethane foam test could not be performed. The results are shown in Table 1.
  • Example 2 The polyester short fiber nonwoven fabric for reinforcing layer produced in Example 1 was entangled with a needle punch to obtain a foam molding nonwoven fabric. During the urethane foam test, urethane oozed out from the nonwoven fabric and emerged on the surface, resulting in poor reinforcement effect and noise prevention. The results are shown in Table 1.
  • the nonwoven fabric laminate for foam molding of the present invention can be applied to the production of various foam molded products, and imparts molding auxiliary materials, reinforcements, or rigidity and noise prevention performance for foam molded products made of resins such as urethane. It can be used as a functional material.
  • the present invention can be applied to molding foam molded products for various uses such as vehicle seats such as automobile seats, furniture, office chairs, and beds.

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Abstract

[解決手段] 本発明の発泡成形用不織布積層体は、緻密層の少なくとも片面に補強層を有し、緻密層が、繊維径が１０～３０μｍのポリエステル系長繊維からなり、嵩密度が０．１ｇ／ｃｍ3以上であり、熱風処理によって繊維同士が融着している不織布であり、補強層が、繊維径が１０～３０μｍのポリエステル系短繊維からなる不織布であって、かつ、緻密層と補強層とがニードルパンチにより交絡して積層されてなることを特徴としている。 [効果] 本発明の発泡成形用不織布積層体は、加熱・延展・圧縮加工した後でもシート内の緻密性を維持することが可能で、加熱・延展・圧縮の成形加工時の不織布の鋳型への追従性に優れ、複雑な形状への加工も可能であって、裁断を行うことなく発泡成形体の鋳型等に適した形状に好適に加工できるとともに、全面において十分な緻密性を維持することができる。

Description

発泡成形用不織布積層体、該不織布積層体を用いたウレタン発泡成形体複合物、ならびに発泡成形用不織布積層体の製造方法
　本発明は、ポリウレタンなどの発泡成形品の底部に配設される発泡成形用不織布積層体、該不織布積層体を用いたウレタン発泡成形体複合物、ならびに発泡成形用不織布積層体の製造方法に関する。
　車両用シート等のクッション材として、軟質の発泡ポリウレタン等の発泡成形品が使用されている。このような発泡成形品の底部には、発泡ウレタン成形品の剛性を高める目的及び、ウレタンが裏面に染み出さないようにするために補強用基布が配設されている。補強用基布としては、寒冷紗とスラブウレタンの組合せ、あるいは粗毛布などが用いられているが、ウレタン成形品の剛性の改善が不十分であったり、ウレタンの裏面への染み出し防止が不十分であったりする問題があった。
　かかる欠点を改良する方法として、補強用基布として、目付１０～３０ｇ／ｍ2の薄く緻密な層と目付４０～１００ｇ／ｍ2の粗く嵩高な層とを一体化した不織布を用いる方法（特許文献１参照）、目付１１０～８００ｇ／ｍ2、繊維径１～１６ｄの高目付不織布を用いる方法（特許文献２参照）、緻密層として繊維径が１０μｍ以下のメルトブローン不織布を用いる方法（特許文献３参照）、繊度が１．１～２．７dtexの繊維からなるウェブ（緻密層）と、繊度が２．３～８．８dtexの繊維からなるウェブ（嵩高層）とが、機械的交絡処理により積層された不織布を用いる方法（特許文献４参照）、あるいは、スパンボンド不織布などの繊維質基材層と、少なくとも一方の面に積層した短繊維層とを、高圧水流の作用で一体化したものを、発泡成型品用補強材として用いる方法（特許文献５参照）など、種々の方法が提案されている。
　しかしながら、特許文献１～５に記載されたいずれの発泡成形用補強材基布も、課題としてウレタン発泡時の染み出しや含浸性能の解決をめざしたものばかりで、発泡成形する前の裁断加工や縫製加工の手作業の手間を省くことができる素材とはなっていない。
　近年車両用座席の意匠性や電装化が進むにつれ、ウレタン発泡時の金型形状も複雑となり、この形に合わせるため、補強用基布を手作業で裁断加工し縫製加工していく手間が非常に増えてきている。この手間を軽減する方法として、不織布シートを鋳型に被せ、加熱・延展・圧縮加工して型取りすることで、簡便に発泡前の処理を行う成形加工方法が提案されており、この成形加工で使用される補強材基布として、低融点繊維と高融点繊維とを混合させた不織布シートが例示されている（特許文献６参照）。また、ポリエステル樹脂の高融点成分と低融点成分の配合からなる捲縮性複合短繊維を主材とした不織布をウレタン補強材として用いることにより、裁断加工を必要とせず、発泡ウレタンの成形加工において、成形時に発泡ウレタンの染み出しを防止することが提案されている（特許文献７参照）。
　特許文献６および７の技術で得られる不織布は、鋳型への追従特性が改善され、縫製加工の手間を省けるものであるが、鋳型への追従時には短繊維からなる不織布が引き伸ばされるため、緻密さが不十分で極端に厚みの薄い部分ができてしまうという問題があった。そしてこの状態で次工程であるウレタン発泡加工を行うと、この薄い部分からウレタンの裏面への染み出しが発生してしまい、補強効果の低下や金属バネとの異音などの諸問題を生じる場合があった。
実公昭６２－２６１９３号公報 特開平２－２５８３３２号公報 特開２００４－３５３１５３号公報 特開２００７－１４６３５６号公報 特開２００５－２１２２０２号公報 特開２００６－２８１７６８号公報 特開２０１０－１７４３９３号公報
　本発明は、加熱・延展・圧縮加工の成形加工時に鋳型への追従性に優れ、型取りした後でも補強効果とウレタン染み出し防止性能を十分に維持することのできる発泡成形用積層体、およびそれを用いたウレタン発泡成形体複合物を提供することを課題としている。
　本発明の発泡成形用不織布積層体は、
　緻密層の少なくとも片面に補強層を有し、
　緻密層が、繊維径が１０～３０μｍのポリエステル系長繊維からなり、嵩密度が０．１ｇ／ｃｍ3以上であり、熱風処理によって繊維同士が融着している不織布であり、
　補強層が、繊維径が１０～３０μｍのポリエステル系短繊維からなる不織布であり、
　かつ、前記緻密層と前記補強層とがニードルパンチにより交絡されていることを特徴としている。
　このような本発明の発泡成形用不織布積層体では、前記緻密層が、部分熱圧着部を有さないことが好ましい。
　本発明の発泡成形用不織布積層体では、圧力差１２５Ｐａにおける通気度が、２５ｃｍ3／ｃｍ2／ｓｅｃ以上、１４０ｃｍ3／ｃｍ2／ｓｅｃ未満であることが好ましい。
　本発明の発泡成形用不織布積層体では、緻密層のポリエステル系長繊維および／または補強層のポリエステル系短繊維が、断面上に融点の異なる部分を有する繊維を含むことが好ましい。このような本発明の発泡成形用不織布積層体では、緻密層のポリエステル系長繊維が、融点の異なる２種以上の樹脂からなる複合長繊維を含み、前記複合長繊維を構成する樹脂の少なくとも一つがポリエステル系樹脂であることが好ましい。またこのような本発明の発泡成形用不織布積層体では、補強層のポリエステル系短繊維が、融点の異なる２種以上の樹脂からなる複合短繊維を含み、前記複合短繊維を構成する樹脂の少なくとも一つがポリエステル系樹脂であることが好ましく、前記複合短繊維を構成する少なくとも一つの樹脂の融点が、１１０～１９０℃の範囲であることがより好ましい。
　本発明の発泡成形用不織布積層体では、緻密層の目付が１０～５０ｇ／ｍ2の範囲にあることが好ましく、また、補強層の目付が４０～１５０ｇ／ｍ2の範囲にあることが好ましく、さらにまた、発泡成形用不織布積層体の目付が５０～２００ｇ／ｍ2の範囲にあることが好ましい。
　本発明のウレタン発泡成形体複合物は、前記いずれかの本発明の発泡成形用不織布積層体の補強層と、ウレタン発泡成形体とが一体化して形成されてなる。
　本発明の車両用シート、ならびに本発明の椅子は、前記本発明のウレタン発泡成形体複合物を用いてなる。
　本発明の発泡成形用不織布積層体の製造方法は、
　繊維径が１０～３０μｍのポリエステル系長繊維からなり、嵩密度が０．１ｇ／ｃｍ3以上である不織布を熱風処理により得る工程と、
　前記不織布と、繊維径が１０～３０μｍのポリエステル系短繊維からなる不織布とを積層し、ニードルパンチにより交絡処理する工程とを有する。
　このような本発明の発泡成形用不織布積層体の製造方法では、前記ポリエステル系長繊維が、融点の異なる２種以上の樹脂からなる複合長繊維を含み、前記複合長繊維を構成する樹脂の少なくとも一つがポリエステル系樹脂であることが好ましい。
　本発明の発泡成形用不織布積層体は、特定のポリエステル系長繊維からなる不織布よりなる緻密層と、特定のポリエステル系短繊維からなる不織布よりなる補強層とが交絡して積層されていることにより、耐熱性に優れ、加熱・延展・圧縮加工した後でもシート内の緻密性を維持することが可能で、加熱・延展・圧縮の成形加工時の不織布の鋳型への追従性に優れ、複雑な形状への加工も可能であって、裁断を行うことなく、または裁断の手間を軽減して発泡成形体の鋳型等に適した形状に好適に加工できるとともに、全面において十分な緻密性を維持することができる。
　本発明の発泡成形用不織布積層体上でウレタンなどの発泡成形を行った場合には、発泡成形用樹脂液の透過（滲み出し、または染み出し）を好適に防止することができる。
　また、本発明の発泡成形用不織布積層体を用いてウレタン発泡成形体複合物を製造した場合には、該積層体が所望の形状の金型に好適に追随し、ウレタン樹脂の染み出しを伴うことなく該積層体上にウレタン発泡成形体を好適に形成することができる。
　本発明のウレタン発泡成形体複合物は、基布となる不織布積層体側にウレタン樹脂の染み出しを生じないため、たとえば自動車シートの製造に用いた場合には、金属部品と発泡ウレタンとの擦れによる異音を効果的に防止することが可能となる。
　本発明の製造方法によれば、前記の優れた特性を有する発泡成形用不織布積層体を好適に製造することができる。
　以下、本発明について具体的に説明する。
　＜発泡成形用不織布積層体＞
　本発明の発泡成形用不織布積層体は、緻密層の少なくとも片面に補強層を有する。
　本発明に係る緻密層はポリエステル系長繊維からなる不織布であり、また、本発明に係る補強層はポリエステル系短繊維からなる不織布であって、いずれもポリエステル系繊維からなる不織布である。なお本発明において、短繊維とはおおむね平均繊維長２００ｍｍ以下の繊維を意味する。
　本発明において、ポリエステル系繊維とは、単独のポリエステルのみから形成される繊維、２種以上のポリエステルから形成される複合繊維、１種以上のポリエステルとポリエステル以外の熱可塑性樹脂とから形成される複合繊維のいずれであってもよい。単独のポリエステルのみから形成される繊維としては、均質な繊維であってもよく、紡糸時またはその後のヒートセットなどの工程により、断面上に異なる融点を有するものであってもよい。また複合繊維は断面上に融点の異なる部分を有していてもよい。また、ポリエステル系繊維は、これらの繊維を二種以上混合してなる混合繊維であってもよい。
　本発明では、緻密層のポリエステル系長繊維、および／または補強層のポリエステル系短繊維の融点が、１１０～１９０℃、好ましくは１１０～１４０℃の範囲にあるのが好ましく、複合繊維である場合には、ポリエステル系繊維中の少なくとも一部がこのような融点を満たすことが望ましい。本発明では、補強層のポリエステル系短繊維が複合短繊維であって、該複合短繊維を構成する少なくとも一つの樹脂の融点が１１０～１９０℃、好ましくは１１０～１４０℃、特に好ましくは１１０～１２０℃であるのが望ましい。補強層のポリエステル系短繊維が複合短繊維である場合、繊維成分として共重合ポリエチレンテレフタレートまたはポリエチレンを含むことが好ましい。
　本発明において、ポリエステル系繊維からなる不織布を用いると、加熱・延展・圧縮の成形加工時の耐熱性の観点から好ましく、ポリプロピレン樹脂やポリエチレン樹脂などの低融点樹脂を単一成分とする樹脂から形成される不織布を用いた場合に生じる、加熱時の変形などを防止することができる。
　ポリエステル系繊維を構成するポリエステルとしては、具体的には、ポリエチレンテレフタレート（ＰＥＴ）、ポリトリメチレンテレフタレート（ＰＴＴ）、ポリブチレンテレフタレート（ＰＢＴ）、およびポリ乳酸（ＰＬＡ）、ならびにそれらの共重合体、およびそれらの組合せ等を例示することができる。成形加工性を考慮すると、これらのうち、ポリエチレンテレフタレート（ＰＥＴ）、ポリトリメチレンテレフタレート（ＰＴＴ）、ポリブチレンテレフタレート（ＰＢＴ）等がより好ましい。
　ポリエステル系繊維を形成する際に用いる樹脂には、本発明の目的を損なわない範囲で、酸化防止剤、耐候安定剤、耐光安定剤、ブロッキング防止剤、滑剤、核剤、顔料、柔軟剤、親水剤、助剤、撥水剤、フィラー、抗菌剤、難燃剤等の種々公知の添加剤を加えておいてもよい。また、これらの添加剤は、不織布形成後に噴霧などの手段で繊維表面に添加されてもよい。
　・緻密層
　本発明の発泡成形用不織布積層体を構成する緻密層は、上述したポリエステル系繊維のうち、ポリエステル系長繊維からなる不織布である。ポリエステル系長繊維は、繊維径が１０～３０μｍ、好ましくは１５～２５μｍであることが望ましい。繊維径が３０μｍを超えると、不織布の緻密性が損なわれ、ウレタン発泡時のウレタン染み出しのおそれが高まるので好ましくない。また繊維径が１０μｍ未満では、ポリエステル長繊維不織布の生産性が低下するため好ましくない。また、繊維の断面形状は丸型の他に三葉型などの異型断面であっても良い。
　本発明に係る緻密層は、熱風処理によって繊維同士が融着している不織布であり、好ましくは不織布の全体部分にわたって熱風などの熱処理によって繊維同士が融着している不織布である。緻密層の不織布は、部分熱圧着部を有さないことが望ましく、エンボス加工などの熱圧着が行われていないものであるのが好ましい。
　このようなポリエステル系長繊維不織布からなる不織布としては公知のものを使用することができ、具体的にはポリエステル樹脂を紡糸した後、熱風接合機を通すことにより得ることができる（ＵＳ３，３８４，９４４、ＵＳ３，９８９，７８８、特表２０１０－５３７０６８）。
　緻密層の不織布が、部分熱圧着部を有さない場合には、得られる発泡成形用不織布積層体が、鋳型への追従性に優れるものとなり、形状加工性に優れたものとなるとともに、鋳型形状への加工後にも全面において十分な緻密性を維持することができるため好ましい。
　本発明に係る緻密層は、目付けが通常、１０～６０ｇ／ｍ2、好ましくは１０～５０ｇ／ｍ2、より好ましくは１５～４５ｇ／ｍ2の範囲にある。
　緻密層の不織布を構成するポリエステル系長繊維は、単独のポリエステルのみから形成される繊維、２種以上のポリエステルから形成される複合長繊維、１種以上のポリエステルとポリエステル以外の熱可塑性樹脂とから形成される複合長繊維のいずれであってもよく、これらのポリエステル系繊維を１種以上用いることができる。
　本発明では、緻密層の不織布を構成するポリエステル系長繊維が、融点の異なる２種以上の樹脂からなる複合長繊維を含み、前記複合長繊維を構成する樹脂の少なくとも一つがポリエステル系樹脂であることが好ましい。このようなポリエステル系長繊維は、断面上に融点の異なる部分を有することも好ましい。
　このようなポリエステル系長繊維不織布としては、ファイバーウェブ社製「リーメイ（Ｒ－２シリーズ）」、「リーメイ（Ｒ－０シリーズ）」などがある。「リーメイ（Ｒ－２シリーズ）」および「リーメイ（Ｒ－０シリーズ）」は、断面上に融点の異なる部分を有するポリエステル系複合長繊維から構成されており、かつ、不織布の全体にわたって熱風接合処理によって繊維同士が融着している部分を有する不織布であるため、本発明の不織布積層体を構成する緻密層として特に好適である。
　本発明に係る緻密層は、嵩密度が補強層の嵩密度以上であることが好ましく、通常０．１ｇ／ｃｍ3以上、好ましくは０．１～０．３ｇ／ｃｍ3、より好ましくは０．１～０．２ｇ／ｃｍ3の範囲であるのが望ましい。
　本発明にかかる緻密層は、一層の不織布から構成されていてもよく、また、二層以上の不織布から構成されていてもよい。二層以上の不織布から構成される場合、同種の不織布から構成されていてもよく、また異なる不織布から構成されていてもよい。また緻密層が二層以上の不織布から構成される場合、それらはあらかじめ積層して公知の方法により交絡または接着されていてもよく、また、発泡成形用不織布積層体の形成時に積層して形成されてもよい。
　・補強層
　本発明の発泡成形用不織布積層体を構成する補強層は、上述したポリエステル系繊維のうち、ポリエステル系短繊維からなる不織布である。ポリエステル系短繊維は、繊維径が１０～３０μｍ、好ましくは１５～２５μｍであることが望ましい。また平均繊維長が通常２００ｍｍ以下、好ましくは１０ｍｍ～７０ｍｍ、より好ましくは３０～６０ｍｍの範囲であるのが望ましい。繊維径が細いほど、ウレタンの染み出しあるいは滲み出しの防止や補強効果の性能が向上するため好ましいが、交絡時の生産性などの観点から、上記範囲内とするのが好適である。
　本発明に係る補強層を形成する短繊維は、単繊維であっても、サイド・バイ・サイド型あるいは芯鞘型の複合繊維であっても、あるいは捲縮繊維であってもよい。また、繊維の断面形状は丸型の他にＶ字型、十字型、Ｔ字型などの異型断面であっても良い。特に、成形加工時の鋳型への型取りした後の形状保持性を鑑みると、少なくとも低融点樹脂と高融点樹脂との２成分以上からなる繊維で構成されたものが好ましい。具体的には高融点ＰＥＴ樹脂と低融点ＰＥＴ樹脂との芯鞘複合繊維、あるいは、高融点ＰＥＴ樹脂とＰＥ樹脂との芯鞘複合繊維などがあげられる。
　また、本発明に係る補強層を形成する短繊維としては、二種以上の異なる熱可塑性樹脂からなる繊維を混合してなる混合繊維あるいは、形状が異なる二種以上の繊維を混合してなる混合繊維などの、二種以上の繊維を混合してなる混合繊維であってもよい。
　本発明では、補強層の不織布を構成するポリエステル系短繊維が、融点の異なる２種以上の樹脂からなる複合短繊維を含み、前記複合短繊維を構成する樹脂の少なくとも一つがポリエステル系樹脂であることが好ましい。このようなポリエステル系短繊維は、断面上に融点の異なる部分を有することが好ましい。
　本発明に係る補強層を形成する短繊維として、融点の異なる１成分ポリエステル短繊維を２種以上混繊したものも選択できる。補強層の不織布が複合短繊維から形成される場合、該複合短繊維を構成する少なくとも一つの樹脂の融点が、好ましくは１１０～１９０℃、より好ましくは１１０～１４０℃、最も好ましくは１１０～１２０℃の範囲であることが望ましい。前記範囲の融点の樹脂を有する場合には、不織布積層体を加熱・延展・圧縮加工した後の形状保持性が優れるため好ましい。このような樹脂としては、例えば、共重合ポリエチレンテレフタレートまたはポリエチレン等が挙げられる。複合短繊維を用いる場合は、その他の短繊維、例えば高融点の１成分ポリエステル短繊維と混繊状態にすることで、前記形状保持性を制御することが可能である。複合ポリエステル系短繊維の混繊比率は、１０～９０％、より好ましくは２０～８０％、最も好ましくは３０～６０％である。この比率を下回ると、形状保持性に劣る場合がある。また、この比率を超えると、加熱・延展・圧縮加工した後の形状保持性には優れるが、得られた不織布の風合いが硬くなり、異音防止効果や乗り心地に悪影響を与える場合がある。
　成形加工時の鋳型への追従性を重視する場合は、伸長性を表す繊維を選択することができ、具体的には、高融点ＰＥＴ樹脂と低融点ＰＥＴ樹脂または、高粘度ＰＥＴ樹脂と低粘度ＰＥＴ樹脂とからなるサイドバイサイド複合繊維などがあげられる。
　上記ポリエステル短繊維から不織布を得る方法も公知のものが使用でき、好ましくは、ニードルパンチにより機械的に接合または加熱処理で融着させる方法を採り得る。その後の緻密層との積層をニードルパンチにて行う場合は、ニードルパンチで不織布化しておくことが好ましい。
　本発明に係る補強層は、嵩密度が緻密層の嵩密度以下であることが好ましく、特に限定されるものではないが、嵩密度が通常０．０１～０．１ｇ／ｃｍ3、好ましくは０．０３～０．０９ｇ／ｃｍ3、より好ましくは０．０５～０．０８ｇ／ｃｍ3の範囲であるのが望ましい。
　本発明に係る補強層は、目付が通常４０～１８０ｇ／ｃｍ2、好ましくは４０～１６０ｇ／ｃｍ2より好ましくは４０～１５０ｇ／ｃｍ2、さらに好ましくは６０～１５０ｇ／ｃｍ2の範囲であるのが望ましい。
　本発明に係る補強層は、単層であっても、二層以上であってもよい。補強層が二層以上の積層である場合には、同種の不織布から構成されていてもよく、また異なる不織布から構成されていてもよい。補強層が二層以上の不織布から構成される場合、それらはあらかじめ積層して公知の方法により交絡または接着されていてもよく、また、発泡成形用不織布積層体の形成時に積層して形成されてもよい。
　本発明に係る補強層は、上述したように、緻密層の片面のみに設けられていてもよく、両面に設けられていてもよい。
　・積層体
　本発明の発泡成形用不織布積層体は、上述した緻密層と補強層とを積層し、ニードルパンチにより交絡処理することにより製造することができる。本発明では、ニードルパンチによる交絡処理によって、緻密層と補強層とを一体化するよう接合した積層体とすることにより、偏りのない機械的交絡で緻密層と補強層とが接合される。このため本発明の発泡成形用不織布積層体は、発泡成形体を製造するための鋳型に立体的に追従させる段階を妨げず、かつ、追従により延伸が伴う場合などには延伸による厚さむらが生じにくく、全面において良好な緻密性を維持することができるとともに、得られる発泡成形用不織布積層体に適度な通気性を保持させ、ウレタンなどが発泡成形する際に発生するガスを通過させることができ、ウレタン等の液の含浸をコントロールすることができる。
　本発明の発泡成形用不織布積層体は、発泡成形体を成形する段階で、ウレタンなどの発泡樹脂が染み出さない性能を有することが望ましいが、十分な緻密さを有し、かつ、通気性も保持したものであるのがより好ましい。このような本発明の発泡成形用不織布積層体は、圧力差１２５Ｐａにおける通気度が、２０ｃｍ3／ｃｍ2／ｓｅｃ以上、１６０ｃｍ3／ｃｍ2／ｓｅｃ未満であるのが好ましく、２５ｃｍ3／ｃｍ2／ｓｅｃ以上、１４０ｃｍ3／ｃｍ2／ｓｅｃ未満であるのがより好ましく、３０ｃｍ3／ｃｍ2／ｓｅｃ以上、１２５ｃｍ3／ｃｍ2／ｓｅｃ未満であるのがさらに好ましく、３０ｃｍ3／ｃｍ2／ｓｅｃ以上、１１５ｃｍ3／ｃｍ2／ｓｅｃ未満であるのが特に好ましい。通気度が上記範囲にあると、ウレタン等の発泡樹脂の染み出し防止性がより良好であるとともに、発泡成形で発生する気体を好適に排出することができる。また、結果的に発泡層を密に形成できるため、発泡体の剛性の向上に有効である。
　本発明の発泡成形用不織布積層体は、目付が、通常２０～２００ｇ／ｍ2、好ましくは５０～２００ｇ／ｍ2、より好ましくは５０～１６０ｇ／ｍ2、さらに好ましくは５０～１２０ｇ／ｍ2、更に好ましくは、５０～１００ｇ／ｍ2の範囲にある。
　さらに本発明の発泡成形用不織布積層体では、特に限定されるものではないが、引っ張り強度（Ｎ／５０ｍｍ）が５０Ｎ／５０ｍｍ以上、好ましくは７０Ｎ／５０ｍｍ以上であると、補強効果および取り扱い性に優れるため好ましい。
　このような本発明の発泡成形用不織布積層体は、本発明の効果を損なわない範囲で、さらに他の基材層と積層して、発泡成形に用いてもよい。 本発明の不織布積層体と積層される他の基材層としては、具体的には、例えば、編布、織布、不織布、フィルム、紙製品等を挙げることができる。本発明の不織布積層体と他の層とを積層する（貼り合せる）方法としては、熱エンボス加工、超音波融着等の熱融着法、ニードルパンチ、ウォータージェット等の機械的交絡法、ホットメルト接着剤、ウレタン系接着剤等の接着剤による方法、押出しラミネート等をはじめ、種々公知の方法を採用することができる。
　また本発明の発泡成形用不織布積層体は、本発明の目的を損なわない範囲で、ギア加工、印刷、塗布、ラミネート、熱処理、賦型加工などの二次加工を施して用いてもよい。
　本発明の発泡成形用不織布積層体は、緻密層の少なくとも片面に補強層を有するものであって、緻密層は、通常補強層よりも高い嵩密度を有する。補強層が片面のみに積層されている場合には、補強層側をウレタンなどの発泡成形体側となるように用いることができる。
　＜ウレタン発泡成形体複合物＞
　本発明のウレタン発泡成形体複合物は、上述の本発明の発泡成形用不織布積層体の補強層と、ウレタン発泡成形体とが一体化して形成されてなる。ウレタン発泡成形体は、通常、所望の形状の型内でポリウレタンを発泡成形して製造される。本発明のウレタン発泡成形体複合物は、たとえば、金型等の鋳型内の上部または底部などに上述した本発明の発泡成形用不織布積層体を追従させて配設し、鋳型内に発泡剤を含むポリウレタン原料を注入し、発泡成形させて製造することができる。
　本発明では、発泡成形用不織布積層体が優れた鋳型追従性を有するとともに、鋳型に追従させた後も全面において十分な緻密性を維持することができるため、ウレタンの染み出しを生じることなく、ポリウレタン発泡体が表面に滲み出すことのない成形体と一体となったウレタン発泡成形体複合物を製造することができる。
　本発明のウレタン発泡成形体複合物は、たとえば、自動車、電車、飛行機、遊具などの車両用シート、椅子、ベッドなどの家具、玩具、建材など、ウレタン発泡成形体を用いる各種用途に好適に適用することができる。
　本発明のウレタン発泡成形体複合物は、本発明の発泡成形用不織布積層体を用いることにより、鋳型内に補強材を用いた発泡成形が、補強材の裁断や縫製などの煩雑な工程を経ることなく簡便に製造できるとともに、たとえば車両シート用途などのように、金属部品等と組み合わせて用いる場合には、金属部品と発泡ウレタンとの擦れによる異音を効果的に防止することが可能となるなどの効果も有する。
　以下、実施例に基づいて本発明をさらに具体的に説明するが、本発明はこれらの実施例に限定されるものではない。
　実施例及び比較例における物性値等は、以下の方法により測定した。
（１）目付（ｇ／ｍ2）
　不織布から、機械方向（ＭＤ） １００ｍｍ×横方向（ＣＤ）１００ｍｍで１０点採取し、平均値を算出した。
（２）厚さ（ｍｍ）
　上記目付測定用試料の中央、四隅５点を測定する。５０点の平均値を算出した。荷重は２ｇ／ｃｍ2（荷重面積 ４ｃｍ2）の厚み計を使用した。
（３）嵩密度（ｇ／ｃｍ3）
　不織布の嵩密度は、上記（１）及び（２）で得られた目付及び厚さを用い、次式により求めた。
　嵩密度＝目付（ｇ／ｍ2）／（ 上記厚さ（ｍｍ）／１０×１００×１００）
（４）引張強度（Ｎ／５０ｍｍ）、伸び（％）
　ＪＩＳ Ｌ１９０６に準拠して測定した。発泡成形用不織布積層体から３００ｍｍ（ＭＤ）×５０ｍｍ（ＣＤ）の試験片を採取し、引張試験機（島津製作所：オートグラフＡＧＳ－Ｊ）を用いてチャック間距離２００ｍｍ、ヘッドスピード１００ｍｍ／ｍｉｎでＭＤ（不織布の長さ方向）：５点、ＣＤ（長さに直行する方向）：５点を測定し、平均値を算出して、引張強度および伸びをそれぞれ求めた。
（５）通気度（ｃｍ3／ｃｍ2／ｓｅｃ）
　発泡成形用不織布積層体から２００ｍｍ（ＭＤ）×５０ｍｍ（ＣＤ）の試験片を採取し、ＪＩＳＬ１０９６に準じたフラジール通気度測定機によって、圧力差１２５Ｐａでの流量を測定して求めた。
（６）成形加工性
　２０ｃｍ角、高さ１０ｃｍの簡易鋳型を４０ｃｍ角の発泡成形用不織布積層体で覆い、真空圧空成形機にて２００℃にて成形加工を実施した。成形加工時の型取りのしやすさや、加工後の不織布の形状保持性、風合いなどを下記基準に従い目視と触感（手触り）にて判断した。
　　加工可能で補強材として美麗な外観と風合い： ＡＡ
　　加工可能で補強材として使用可能　　　　　： Ａ
　　加工可であるが補強材としての風合いに劣る： Ｂ
　　溶融したりして加工することが不可　　　　： ＢＢ
（７）ウレタン染み出し評価
　発泡釜へ発泡成形用不織布積層体（４００ｍｍ（ＭＤ）×４００ｍｍ（ＣＤ））を取り付け、ウレタンの染み出しを、以下の基準により目視にて評価した。
　　認められない　　　　 ： ＡＡ
　　ほとんど認められない ： Ａ
　　やや認められる　　　 ： Ｂ
　　かなり認められる　　 ： ＢＢ
　なお、発泡成形は、樹脂材料としてポリウレタン、及び自動車座席シート形状の発泡釜を使用し、通常の自動車座席シート用の発泡ポリウレタン成形条件により行った。
　［実施例１］
　ポリエステル系短繊維混合体（融点が１１０℃である低融点ポリエステル樹脂（PETコポリマー）と、融点が２５０℃である高融点ポリエステル樹脂（PETホモポリマー）との芯鞘複合繊維（ユニチカ（株）製「メルティ４０８０」、平均繊維径１６μｍ、平均繊維長５１ｍｍ。表１の２成分PET。）を３０％含む。融点が２５０℃である高融点ポリエステル樹脂の単独繊維（平均繊維径１６μｍ、平均繊維長５１ｍｍ。表１の１成分PET。）を７０％含む。）を、プレニードルパンチ機にて不織布シート状にして、補強層用のポリエステル系短繊維不織布を得た。
　緻密層として、市販のポリエステル系複合スパンボンド長繊維不織布（ファイバーウェブ社製「リーメイ（Ｒ－２シリーズ）」円形断面タイプ）を用い、前述の補強層用のポリエステル系短繊維不織布と積層し、ニードルパンチ機により交絡させて接合して、発泡成形用不織布積層体を得た。得られた発泡成形用不織布積層体の物性を上記記載の方法で測定した。結果を表１に示す。
　［実施例２～５］
　補強層に用いるポリエステル系短繊維不織布の目付、および緻密層に用いるポリエステル系長繊維不織布の目付を表１に示す目付にしたこと以外は、実施例１と同様にして、発泡成形用不織布積層体を得た。得られた発泡成形用不織布積層体の物性を上記記載の方法で測定した。結果を表１に示す。
　［実施例６］
　実施例３で用いたのと同じポリエステル系長繊維不織布を２層積層して緻密層とし、さらに実施例１と同様のポリエステル系短繊維不織布を積層し、ニードルパンチ機により交絡させて接合して、発泡成形用不織布積層体を得た。得られた発泡成形用不織布積層体の物性を上記記載の方法で測定した。結果を表１に示す。
　［実施例７］
　緻密層として、ポリエステル系複合スパンボンド長繊維不織布（ファイバーウェブ社製「リーメイ（Ｒ－０シリーズ）」三葉断面タイプ）を用い、表１に示す目付にしたこと以外は実施例１と同様にして、発泡成形用不織布積層体を得た。得られた発泡成形用不織布積層体の物性を上記記載の方法で測定した。結果を表１に示す。
　［実施例８］
　ポリエステル系短繊維混合体（融点が１１０℃である低融点ポリエステル樹脂（PETコポリマー）と、融点が２５０℃である高融点ポリエステル樹脂（PETホモポリマー）との芯鞘複合繊維（ユニチカ（株）製「メルティ４０８０」、平均繊維径１６μｍ、平均繊維長５１ｍｍ。表１の２成分PET。）を５０％含む。融点が２５０℃である高融点ポリエステル樹脂の単独繊維（平均繊維径１６μｍ、平均繊維長５１ｍｍ。表１の１成分PET。）を５０％含む。）を用いて、プレニードルパンチ機にて不織布シート状にして、ポリエステル系短繊維不織布を得た。得られたポリエステル系短繊維不織布を補強層として用い、実施例4で用いたのと同じポリエステル系長繊維不織布を緻密層として用いて、これらを積層し、ニードルパンチ機により交絡させて接合して、発泡成形用不織布積層体を得た。得られた発泡成形用不織布積層体の物性を上記記載の方法で測定した。結果を表１に示す。
　［比較例１］
　目付が４０ｇ／ｍ2、繊維径２１μｍのポリプロピレン製スパンボンド不織布を緻密層として用いたことのほかは、実施例４と同様にして発泡成形用不織布積層体を得た。成形加工時に緻密層が溶融し、不織布がフィルム化した結果、ウレタン発泡テストを行うができなかった。結果を表１に示す。
　［比較例２］
　実施例１で製造した補強層用のポリエステル系短繊維不織布についてニードルパンチにて交絡処理を行い、発泡成形用不織布を得た。ウレタン発泡テスト時にウレタンが不織布から染み出して表面に出てしまい、補強効果と異音防止性に劣るものとなった。結果を表１に示す。
Figure JPOXMLDOC01-appb-T000001
産業上の利用の可能性
　本発明の発泡成形用不織布積層体は、各種発泡成形品の製造に適用可能であり、ウレタン等の樹脂からなる発泡成形品の成形補助材、補強材、あるいは剛性や異音防止性能を付与するなどの機能性材料として使用することができる。例えば、自動車シート等の車両座席用シート、家具、事務用椅子、ベッドなどの各種用途の発泡成形品の成形に適用することができる。

Claims (15)

  1. 　緻密層の少なくとも片面に補強層を有し、
    　緻密層が、繊維径が１０～３０μｍのポリエステル系長繊維からなり、嵩密度が０．１ｇ／ｃｍ3以上であり、熱風処理によって繊維同士が融着している不織布であり、
    　補強層が、繊維径が１０～３０μｍのポリエステル系短繊維からなる不織布であり、
    　かつ、前記緻密層と前記補強層とがニードルパンチにより交絡されていることを特徴とする発泡成形用不織布積層体。
  2. 　前記緻密層が、部分熱圧着部を有さない、請求項１に記載の発泡成形用不織布積層体。
  3. 　圧力差１２５Ｐａにおける通気度が、２５ｃｍ3／ｃｍ2／ｓｅｃ以上、１４０ｃｍ3／ｃｍ2／ｓｅｃ未満である、請求項１に記載の発泡成形用不織布積層体。
  4. 　緻密層のポリエステル系長繊維および／または補強層のポリエステル系短繊維が、断面上に融点の異なる部分を有する繊維を含む、請求項１に記載の発泡成形用不織布積層体。
  5. 　緻密層のポリエステル系長繊維が、融点の異なる２種以上の樹脂からなる複合長繊維を含み、前記複合長繊維を構成する樹脂の少なくとも一つがポリエステル系樹脂である、請求項４に記載の発泡成形用不織布積層体。
  6. 　補強層のポリエステル系短繊維が、融点の異なる２種以上の樹脂からなる複合短繊維を含み、前記複合短繊維を構成する樹脂の少なくとも一つがポリエステル系樹脂である、請求項４に記載の発泡成形用不織布積層体。
  7. 　前記複合短繊維を構成する少なくとも一つの樹脂の融点が、１１０～１９０℃の範囲である、請求項６に記載の発泡成形用不織布積層体。
  8. 　緻密層の目付が１０～５０ｇ／ｍ2の範囲にある、請求項１に記載の発泡成形用不織布積層体。
  9. 　補強層の目付が４０～１５０ｇ／ｍ2の範囲にある、請求項１に記載の発泡成形用不織布積層体。
  10. 　発泡成形用不織布積層体の目付が５０～２００ｇ／ｍ2の範囲にある、請求項１に記載の発泡成形用不織布積層体。
  11. 　請求項１～１０のいずれかに記載の発泡成形用不織布積層体の補強層と、ウレタン発泡成形体とが一体化して形成されてなるウレタン発泡成形体複合物。
  12. 　請求項１１に記載のウレタン発泡成形体複合物を用いてなる車両用シート。
  13. 　請求項１１に記載のウレタン発泡成形体複合物を用いてなる椅子。
  14. 　繊維径が１０～３０μｍのポリエステル系長繊維からなり、嵩密度が０．１ｇ／ｃｍ3以上である不織布を熱風処理により得る工程と、
    　前記不織布と、繊維径が１０～３０μｍのポリエステル系短繊維からなる不織布とを積層し、ニードルパンチにより交絡処理する工程とを有する、発泡成形用不織布積層体の製造方法。
  15. 　前記ポリエステル系長繊維が、融点の異なる２種以上の樹脂からなる複合長繊維を含み、前記複合長繊維を構成する樹脂の少なくとも一つがポリエステル系樹脂である、請求項１４に記載の発泡成形用不織布積層体の製造方法。
PCT/JP2013/064204 2012-05-22 2013-05-22 発泡成形用不織布積層体、該不織布積層体を用いたウレタン発泡成形体複合物、ならびに発泡成形用不織布積層体の製造方法 WO2013176176A1 (ja)

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