WO2018110524A1 - 自動車装備材用半製品の製造方法 - Google Patents

自動車装備材用半製品の製造方法 Download PDF

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Publication number
WO2018110524A1
WO2018110524A1 PCT/JP2017/044478 JP2017044478W WO2018110524A1 WO 2018110524 A1 WO2018110524 A1 WO 2018110524A1 JP 2017044478 W JP2017044478 W JP 2017044478W WO 2018110524 A1 WO2018110524 A1 WO 2018110524A1
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WO
WIPO (PCT)
Prior art keywords
core
sheath
component
semi
automobile equipment
Prior art date
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PCT/JP2017/044478
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English (en)
French (fr)
Inventor
花谷　和俊
高橋　達
神ノ門　英明
赤尾　昌哉
裕介 永塚
Original Assignee
ユニチカ株式会社
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Publication date
Application filed by ユニチカ株式会社 filed Critical ユニチカ株式会社
Priority to CN201780076527.4A priority Critical patent/CN110062827A/zh
Priority to US16/466,142 priority patent/US20200063304A1/en
Priority to KR1020197015694A priority patent/KR102351767B1/ko
Publication of WO2018110524A1 publication Critical patent/WO2018110524A1/ja

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    • 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
    • D04H1/42—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
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/20—Floors or bottom sub-units
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
    • B62D29/043—Superstructures
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • D01D5/34—Core-skin structure; Spinnerette packs therefor
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
    • 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
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43825—Composite fibres
    • D04H1/43828—Composite fibres sheath-core
    • 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
    • D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
    • D04H1/43835—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • 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
    • D04H1/48—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 in combination with at least one other method of consolidation
    • D04H1/485—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 in combination with at least one other method of consolidation in combination with weld-bonding
    • 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
    • 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
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
    • 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
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • 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
    • D04H1/542—Adhesive fibres
    • D04H1/55—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
    • D04H1/54—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
    • D04H1/559—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 the fibres being within layered webs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/08—Front or rear portions
    • B62D25/16—Mud-guards or wings; Wheel cover panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/20—Floors or bottom sub-units
    • B62D25/2072—Floor protection, e.g. from corrosion or scratching
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D35/00—Vehicle bodies characterised by streamlining
    • B62D35/02—Streamlining the undersurfaces
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/12—Vehicles
    • 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/80—Technologies aiming to reduce greenhouse gasses emissions common to all road transportation technologies
    • Y02T10/88—Optimized components or subsystems, e.g. lighting, actively controlled glasses

Definitions

  • the present invention relates to a method for producing a semi-finished product particularly suitable for obtaining automobile equipment such as an automobile exterior material, and more particularly to a method for producing a semi-finished product excellent in moldability and hardness after molding.
  • an under cover for covering the lower surface side of an automobile and a cover for covering the inside of a tire house are added.
  • the under cover is intended to improve the fuel efficiency by reducing the air resistance by improving the flow of the air flow passing through the lower surface of the automobile.
  • Another purpose is to prevent the stepping stone from damaging the lower surface of the vehicle during traveling and to reduce the sound of the stepping stone colliding with the lower surface.
  • the tire house cover is used to prevent damage to the inner surface of the tire house due to gravel that the tire entrains during traveling, and to reduce the sound of gravel colliding with the inner surface.
  • Patent Document 1 discloses an undercover formed by heating and compression molding a semi-finished product made of a needle punched nonwoven fabric made of thermoplastic synthetic short fibers as one material (Patent Document 1, Claim 1). ).
  • thermoplastic synthetic short fiber use of polypropylene fiber or polyester fiber is described.
  • the range of heating temperature is narrow, and strict temperature control is required.
  • high rigidity cannot be obtained.
  • the present invention provides a semi-finished product for automobile equipment that can be molded at a relatively wide range of heating temperatures and that can provide a final product with high rigidity.
  • the core component is made of a copolymer composed of ethylene glycol and terephthalic acid
  • the sheath component is made by integrating core-sheath type composite fibers made of a copolymer containing ethylene glycol, adipic acid and terephthalic acid.
  • the present invention relates to a method for manufacturing a semi-finished product for automobile equipment, characterized in that the core-sheath composite fibers are entangled three-dimensionally by needle punching a fiber web.
  • the specific core-sheath type composite fiber is a core component made of a copolymer of ethylene glycol and terephthalic acid, and a sheath component made of a copolymer containing ethylene glycol, adipic acid and terephthalic acid.
  • the copolymer constituting the core component is a polyester obtained by dehydration condensation using ethylene glycol as a diol component and terephthalic acid as a dicarboxylic acid component.
  • the dicarboxylic acid component a very small amount of other dicarboxylic acid components such as isophthalic acid may be mixed.
  • the melting point of the copolymer constituting the core component is about 260 ° C., and the glass transition point is about 70-80 ° C.
  • the copolymer constituting the sheath component is a copolymerized polyester obtained by dehydration condensation using ethylene glycol as a diol component and adipic acid and terephthalic acid as dicarboxylic acid components.
  • the amount of diethylene glycol mixed is about 0.5 to 5.0 mol% in the diol component. Moreover, it is preferable that a small amount of isophthalic acid is mixed as the dicarboxylic acid component. The amount of isophthalic acid mixed is about 2.0 to 5.0 mol% in the dicarboxylic acid component. The reason why a small amount of diethylene glycol or isophthalic acid is mixed is to adjust the rigidity of the resulting fiber as appropriate.
  • the melting point of the copolymer constituting the sheath component is about 200 ° C., and the glass transition point is about 40-50 ° C.
  • the core component and the sheath component may be arranged concentrically or may be arranged eccentrically. However, since it will become easy to produce shrinkage
  • the core-sheath type composite fiber can be obtained by a known method in which a polyester serving as a core component and a copolymer polyester serving as a sheath component are supplied to a spinning device having a composite spinning hole and melt-spun.
  • the core-sheath type composite fiber may be a core-sheath type composite long fiber or a core-sheath type composite short fiber, but the use of the core-sheath type composite long fiber provides a highly rigid automobile equipment material. Therefore, it is preferable.
  • a so-called spunbond method is generally used.
  • the core-sheath type composite continuous fibers obtained by melt spinning can be immediately accumulated in a sheet form to obtain a fiber web.
  • the core-sheath type composite short fibers may be opened through a card machine and accumulated in a sheet form.
  • the weight of the fiber web is about 200 to 2000 g / m 2 . If the weight of the fiber web is too low, it is not suitable for use as an automobile equipment. On the other hand, when the weight of the fiber web is too high, the automobile becomes heavy and the fuel efficiency is deteriorated.
  • the fiber web may be needle punched in a state where the core-sheath composite fibers are not bonded to each other, or may be needle punched in a state where the core-sheath composite fibers are bonded to each other.
  • the former method is preferable because the fibers are not bonded to each other, so that the fiber is less damaged when needle punching is performed, and the strength is not easily lowered due to yarn breakage or the like. Moreover, if it is the latter method, since it is a fiber web with the fibers bonded together, it is easy to handle and transport. Needle punching is performed by a known method, whereby the core-sheath type composite fibers are entangled three-dimensionally to obtain a dense semi-finished product.
  • the punch density is preferably 10 or more / cm 2 .
  • the automobile semifinished product thus obtained is subjected to heating and compression molding to obtain auto equipment.
  • the range of the heating temperature is about 120 to 220 ° C.
  • the pressurization during compression may be arbitrarily selected depending on the degree of compression.
  • the time for heating and compression molding is about 5 to 60 seconds.
  • Such automobile equipment is suitably used as floor materials such as automobile undercovers, tire house covers, ceiling materials, dash silencers, hood silencers, fender liners, and carpet base fabrics for automobiles or various tray materials.
  • floor materials such as automobile undercovers, tire house covers, ceiling materials, dash silencers, hood silencers, fender liners, and carpet base fabrics for automobiles or various tray materials.
  • it can also be used as a filter base material, a transpiration plate for a humidifier, a sound absorbing material (anti-noise material), an interior member, a carpet base fabric, or various plate materials.
  • the semi-finished product for automobile equipment obtained by the method according to the present invention is composed of a core-sheath type composite fiber whose sheath component is made of a copolymer containing ethylene glycol, adipic acid and terephthalic acid. Since the melting point of the sheath component is lowered to about 200 ° C. by using adipic acid as a structural unit, there is an effect that heating and compression molding can be performed in a wide heating temperature range. And since the melting point of the sheath component is low, a highly rigid automobile equipment material is obtained. In particular, when the core-sheath type composite fiber is a long fiber, the melting point of the sheath component is low, and thus the rigidity is more rigid. The effect is that high-quality automotive equipment can be obtained.
  • Example 1 As a core component, a copolymer of ethylene glycol and terephthalic acid (melting point: 250 ° C.) was prepared. As a sheath component, a copolymer of ethylene glycol, diethylene glycol, adipic acid, terephthalic acid and isophthalic acid (melting point: 200 ° C.) was prepared. It should be noted that ethylene glycol as the diol component is 98.8 mol% and diethylene glycol is 1.2 mol%, adipic acid as the dicarboxylic acid component is 18.8 mol%, terephthalic acid is 78.0 mol%, and isophthalic acid. Is 3.2 mol%.
  • Both the core component and the sheath component described above were supplied to a spinning device having a composite spinning hole, and melt spinning was performed to obtain a core-sheath type composite continuous fiber.
  • This fiber web is introduced between a pair of heating rolls, the sheath component is softened and the core-sheath type composite continuous fibers are bonded to each other, and then conveyed to a needle punch device, where the needle density is 90 / cm 2 . Punching was performed to obtain a semi-finished product for automobile equipment having a weight of 525 g / m 2 .
  • Comparative Example 1 As a core component, the copolymer used in Example 1 was prepared.
  • a sheath component a terpolymer (melting point: 230 ° C.) of ethylene glycol, terephthalic acid and isophthalic acid was prepared. Both of these were supplied to a spinning device having a composite spinning hole, and melt spinning was performed to obtain a core-sheath type composite continuous fiber.
  • the core-sheath type composite continuous fiber After obtaining the core-sheath type composite continuous fiber, it is introduced into an air soccer provided below the spinning device, pulled at high speed, and then opened with a known opening device, on a moving screen conveyor The fiber web was obtained by collecting and accumulating. This fiber web is introduced between a pair of heating rolls, the core component is softened and the core-sheath type composite continuous fibers are bonded to each other, and then transported to a needle punch device, where the needle density is 90 / cm 2 . Punching was performed to obtain a semi-finished product for automobile equipment having a weight of 500 g / m 2 .
  • a core-sheath type composite short fiber) was prepared.
  • the core component of the core-sheath-type composite short fiber is the same as the copolymer used in Example 1, and the sheath component is a terpolymer of ethylene glycol, terephthalic acid, and isophthalic acid. However, it has a high mixing ratio of isophthalic acid and has a low melting point.
  • the core-sheath type composite short fibers are opened and collected by a card machine to obtain a fiber web, and immediately conveyed to a needle punch device, and subjected to needle punching at a punch density of 90 pieces / cm 2 , weight 500 g A semi-finished product for automobile equipment of / m 2 was obtained.
  • the semifinished product for automobile equipment obtained in Example 1 and Comparative Examples 1 and 2 was sandwiched between heated metal flat plates, and heated and compression molded under the conditions of a pressure of 30 kPa and a time of 1 minute.
  • the heated metal flat plate was subjected to nine conditions of 120 ° C., 130 ° C., 140 ° C., 150 ° C., 160 ° C., 180 ° C., 200 ° C., 210 ° C. and 220 ° C., and was as follows. That is, the semi-finished product obtained in Example 1 could be molded well at a temperature of 150 ° C. to 210 ° C., and a highly rigid equipment was obtained. Although molding was possible at temperatures of 120 ° C. to 140 ° C.
  • the rigidity was slightly insufficient.
  • the semi-finished product obtained in Comparative Example 1 could not be molded at 120 ° C. to 180 ° C. and could be molded at 200 ° C. to 220 ° C., but had insufficient rigidity.
  • the semi-finished product obtained in Comparative Example 2 was successfully molded at a temperature of 160 ° C. to 180 ° C., and a highly rigid equipment was obtained. Molding was possible at temperatures of 120 ° C. to 150 ° C. and 200 ° C. to 220 ° C., but the rigidity was insufficient.

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Abstract

比較的広い範囲の加熱温度で成型でき、しかも高い剛性を持つ最終製品を得ることができる自動車装備材用半製品の製造方法を提供する。この自動車装備材用半製品の製造方法は、芯鞘型複合繊維が集積されている繊維ウェブに、ニードルパンチを施し、芯鞘型複合繊維相互間を三次元的に交絡させるというものである。芯鞘型複合繊維の芯成分はエチレングリコールとテレフタル酸の共重合体よりなる。芯鞘型複合繊維の鞘成分はエチレングリコールとアジピン酸とテレフタル酸を含む共重合体よりなる。芯鞘型複合繊維中の芯成分と鞘成分の重量比は、芯成分：鞘成分＝１～３：１である。芯成分と鞘成分は、同心に配置されている。繊維ウェブは、芯鞘型複合繊維相互間が鞘成分の軟化又は溶融によって接着されている。

Description

自動車装備材用半製品の製造方法
　本発明は、特に自動車外装材等の自動車装備材を得るのに適した半製品の製造方法に関し、特に、成型性と成型後の硬度に優れた半製品の製造方法に関するものである。
　従来より、自動車には種々の外装材が付加されている。たとえば、自動車の下面側を覆うアンダーカバーや、タイヤハウスの内側を覆うカバー（タイヤハウスカバー）が付加されている。アンダーカバーは、自動車の下面を通過する空気流を流れを良くすることにより、空気抵抗を低下させて燃費の向上を図るためである。また、走行中に飛び石により自動車の下面が損傷するのを防止すると共に、飛び石が下面に衝突する音の低減を図るためでもある。また、タイヤハウスカバーは、走行中にタイヤが巻き込む砂利により、タイヤハウス内面を損傷するのを防止すると共に、砂利が内面に衝突する音の低減を図るために用いられている。
　アンダーカバーやタイヤハウスカバーは、合成樹脂製シートや合成樹脂製布帛等の半製品が、自動車の形状に合致するように成型されてなるものである。たとえば、特許文献１には、熱可塑性合成短繊維よりなるニードルパンチ不織布を一つの素材とする半製品を、加熱及び圧縮成型してなるアンダーカバーが開示されている（特許文献１、請求項１）。熱可塑性合成短繊維としては、ポリプロピレン繊維やポリエステル繊維を用いることが記載されている。しかしながら、かかる繊維では加熱及び圧縮成型する際に、加熱温度の範囲が狭く、厳密な温度管理が必要であった。また、圧縮成型しても、高い剛性のものが得られないということがあった。
ＷＯ２０１２／１６４９７７パンフレット（請求項１）
　本発明は、比較的広い範囲の加熱温度で成型でき、しかも高い剛性を持つ最終製品を得ることができる自動車装備材用半製品を提供するものである。
　本発明は、半製品である不織布を構成している繊維として、特定の繊維を使用することによって、上記課題を解決したものである。すなわち、本発明は、芯成分がエチレングリコールとテレフタル酸からなる共重合体よりなり、鞘成分がエチレングリコールとアジピン酸とテレフタル酸を含む共重合体よりなる芯鞘型複合繊維が集積されてなる繊維ウェブに、ニードルパンチを施すことにより、該芯鞘型複合繊維相互間を三次元的に交絡させることを特徴とする自動車装備材用半製品の製造方法に関するものである。
　本発明では、まず特定の芯鞘型複合繊維を構成繊維とする繊維ウェブを得る。ここで、特定の芯鞘型複合繊維とは、芯成分がエチレングリコールとテレフタル酸の共重合体よりなり、鞘成分がエチレングリコールとアジピン酸とテレフタル酸を含む共重合体よりなるものである。芯成分を構成する共重合体は、エチレングリコールをジオール成分とし、テレフタル酸をジカルボン酸成分として脱水縮合して得られるポリエステルである。なお、ジカルボン酸成分として、ごく少量のイソフタル酸等の他のジカルボン酸成分が混合されていてもよい。芯成分を構成する共重合体の融点は約２６０℃であり、ガラス転移点は約７０～８０℃である。鞘成分を構成する共重合体は、エチレングリコールをジオール成分とし、アジピン酸とテレフタル酸をジカルボン酸成分として脱水縮合して得られる共重合ポリエステルである。ジカルボン酸成分であるアジピン酸とテレフタル酸の混合割合は任意であるが、アジピン酸：テレフタル酸＝１：１～１０（モル比）程度である。ジオール成分として、少量のジエチレングリコールが混合されているのが好ましい。ジエチレングリコールの混合量は、ジオール成分中に０．５～５．０モル％程度である。また、ジカルボン酸成分として、少量のイソフタル酸が混合されているのが好ましい。イソフタル酸の混合量は、ジカルボン酸成分中に２．０～５．０モル％程度である。少量のジエチレングリコールやイソフタル酸を混合するのは、得られる繊維の剛性を適宜調整するためである。鞘成分を構成する共重合体の融点は約２００℃であり、ガラス転移点は約４０～５０℃である。
　芯成分と鞘成分の重量割合は、芯成分：鞘成分＝０．３～３：１（重量比）程度である。芯成分の重量割合が低すぎると、加熱時の形態保持性が低下する傾向となり、また、最終的に得られる自動車装備材の強度や剛性が低下する傾向が生じる。また、芯成分の重量割合が高すぎると、加熱及び圧縮成型で一体化されにくく、表面に毛羽立ちが生じやすくなる。芯成分と鞘成分は、同心に配置されていてもよいし、偏心して配置されていてもよい。しかしながら、偏心に配置されていると、加熱及び圧縮成型時に、収縮が生じやすくなるため、同心に配置されている方が好ましい。
　芯鞘型複合繊維は、芯成分となるポリエステルと、鞘成分となる共重合ポリエステルとを、複合紡糸孔を持つ紡糸装置に供給して、溶融紡糸するという公知の方法で得ることができる。芯鞘型複合繊維は、芯鞘型複合長繊維であっても芯鞘型複合短繊維であってもよいが、芯鞘型複合長繊維を用いた方が、剛性の高い自動車装備材が得られるので、好ましい。芯鞘型複合長繊維を用いて繊維ウェブを得るには、いわゆるスパンボンド法を用いるのが一般的である。すなわち、溶融紡糸して得られた芯鞘型複合長繊維を、直ちにシート状に集積して、繊維ウェブを得ることができる。また、芯鞘型複合短繊維を用いて繊維ウェブを得るには、芯鞘型複合短繊維をカード機に通して開繊し、シート状に集積すればよい。繊維ウェブの重量は、２００～２０００ｇ／ｍ2程度である。繊維ウェブの重量が低すぎると、自動車装備材としての用途に適さない。また、繊維ウェブの重量が高すぎると、自動車が高重量となり、燃費が悪くなる。
　繊維ウェブは、芯鞘型複合繊維相互間が接着されていない状態でニードルパンチを施してもよいし、芯鞘型複合繊維相互間が接着された状態でニードルパンチを施してもよい。前者の方法であれば、繊維相互間が接着されていないため、ニードルパンチを施した際の繊維へのダメージが少なく、糸切れ等による強度低下が起こりにくいため好ましい。また、後者の方法であれば、繊維相互間が接着された状態の繊維ウェブであるため、取扱いしやすく、搬送しやすい。ニードルパンチは周知の方法で行われ、これによって、芯鞘型複合繊維相互間が三次元的に交絡され、緻密な半製品が得られる。なお、芯鞘型複合繊維相互間が接着されていた場合であっても、ニードルパンチによってこの接着は破壊され、芯鞘型複合繊維相互間が三次元的に交絡される。パンチ密度は、１０本以上／ｃｍ2であるのが好ましい。
　このようにして得られた自動車装備材用半製品に、加熱及び圧縮成型が施されて、自動車装備材が得られる。本発明において、加熱温度の範囲は１２０～２２０℃程度である。圧縮する際の加圧は、圧縮の程度により任意に選択しうるのが良い。また、加熱及び圧縮成型する時間は、５～６０秒程度で十分である。以上の加熱及び圧縮成型を施した後、室温中に放置することにより、半製品を構成する芯鞘型複合繊維の鞘成分が溶融固化し、芯鞘型複合繊維相互間が緊密に接着され、剛性のある自動車装備材が得られる。かかる自動車装備材は、自動車のアンダーカバー、タイヤハウスカバー、天井材、ダッシュサイレンサ、フードサイレンサ、フェンダーライナー、自動車用カーペット基布等のフロア材又は各種トレー材等として、好適に用いられる。なお、自動車装備材用ではないが、フィルター基材、加湿器用蒸散板、吸音材（異音防止材）、インテリア部材、カーペット用基布又は各種板材としても用いうるものである。
　本発明に係る方法で得られた自動車装備材用半製品は、鞘成分がエチレングリコールとアジピン酸とテレフタル酸を含む共重合体よりなる芯鞘型複合繊維で構成されており、この共重合体の構成単位としてアジピン酸を用いて、鞘成分の融点を２００℃程度に低下させているので、広い加熱温度の範囲で、加熱及び圧縮成型を行うことができるという効果を奏する。そして、鞘成分の融点が低いので、剛性の高い自動車装備材が得られ、特に芯鞘型複合繊維が長繊維である場合には、鞘成分の融点が低いことと相俟って、より剛性の高い自動車装備材が得られるという効果を奏する。
実施例１
　芯成分として、エチレングリコールとテレフタル酸の共重合体（融点２５０℃）を準備した。鞘成分として、エチレングリコール、ジエチレングリコール、アジピン酸、テレフタル酸及びイソフタル酸の共重合体（融点２００℃）を準備した。なお、ジオール成分としてのエチレングリコールは９８．８モル％でジエチレングリコールは１．２モル％であり、ジカルボン酸成分としてのアジピン酸は１８．８モル％でテレフタル酸は７８．０モル％でイソフタル酸は３．２モル％である。上記した芯成分と鞘成分の両者を、複合紡糸孔を持つ紡糸装置に供給して、溶融紡糸を行い、芯鞘型複合長繊維を得た。芯成分と鞘成分の重量割合は、芯成分：鞘成分＝７：３であった。芯鞘型複合長繊維を得た後、これを紡糸装置の下方に設けたエアーサッカーに導入し、高速で牽引細化した後、公知の開繊装置で開繊させ、移動するスクリーンコンベア上に捕集及び集積させて繊維ウェブを得た。この繊維ウェブを、一対の加熱ロール間に導入し、鞘成分を軟化させて芯鞘型複合長繊維相互間を接着させた後、ニードルパンチ装置に搬送し、パンチ密度９０本／ｃｍ2でニードルパンチを施して、重量５２５ｇ／ｍ2の自動車装備材用半製品を得た。
比較例１
　芯成分として、実施例１で用いた共重合体を準備した。鞘成分として、エチレングリコールとテレフタル酸とイソフタル酸の三元共重合体（融点２３０℃）を準備した。この両者を、複合紡糸孔を持つ紡糸装置に供給して、溶融紡糸を行い、芯鞘型複合長繊維を得た。芯成分と鞘成分の重量割合は、芯成分：鞘成分＝６：４であった。芯鞘型複合長繊維を得た後、これを紡糸装置の下方に設けたエアーサッカーに導入し、高速で牽引細化した後、公知の開繊装置で開繊させ、移動するスクリーンコンベア上に捕集及び集積させて繊維ウェブを得た。この繊維ウェブを、一対の加熱ロール間に導入し、芯成分を軟化させて芯鞘型複合長繊維相互間を接着させた後、ニードルパンチ装置に搬送し、パンチ密度９０本／ｃｍ2でニードルパンチを施して、重量５００ｇ／ｍ2の自動車装備材用半製品を得た。
比較例２
　芯鞘型複合短繊維（ユニチカ株式会社製、品番「２０８０」、繊度が４．４デシテックスで、繊維長：５１ｍｍで、芯成分：鞘成分＝１：１であり、鞘成分の融点が２００℃である芯鞘型複合短繊維）を準備した。なお、この芯鞘型複合短繊維の芯成分は、実施例１で用いた共重合体と同一のものであり、鞘成分は、エチレングリコールとテレフタル酸とイソフタル酸の三元共重合体であるが、イソフタル酸の混合割合の多いものであり、融点が低いものである。この芯鞘型複合短繊維をカード機にて開繊及び集積して、繊維ウェブを得た後、直ちにニードルパンチ装置に搬送し、パンチ密度９０本／ｃｍ2でニードルパンチを施して、重量５００ｇ／ｍ2の自動車装備材用半製品を得た。
　実施例１、比較例１及び２で得られた自動車装備材用半製品を、加熱された金属製平板の間に挟み、圧力３０ｋＰａで時間１分の条件で、加熱及び圧縮成型を行った。加熱された金属製平板は、１２０℃、１３０℃、１４０℃、１５０℃、１６０℃、１８０℃、２００℃、２１０℃、２２０℃の９条件で行ったところ、以下のとおりであった。すなわち、実施例１で得られた半製品は、１５０℃～２１０℃の温度で良好に成型でき、高剛性の装備材が得られた。１２０℃～１４０℃及び２２０℃の温度では成型できるものの、剛性が若干不足しているものであった。一方、比較例１で得られた半製品は、１２０℃～１８０℃では成型できず、２００℃～２２０℃では成型できるものの剛性が不足しているものであった。比較例２で得られた半製品は、１６０℃～１８０℃の温度で良好に成型でき、高剛性の装備材が得られた。１２０℃～１５０℃及び２００℃～２２０℃の温度では成型できるものの、剛性が不足しているものであった。

Claims (9)

  1. 　芯成分がエチレングリコールとテレフタル酸からなる共重合体よりなり、鞘成分がエチレングリコールとアジピン酸とテレフタル酸を含む共重合体よりなる芯鞘型複合繊維が集積されてなる繊維ウェブに、ニードルパンチを施すことにより、該芯鞘型複合繊維相互間を三次元的に交絡させることを特徴とする自動車装備材用半製品の製造方法。
  2. 　鞘成分が、エチレングリコール、アジピン酸、テレフタル酸、イソフタル酸及びジエチレングリコールからなる共重合体である請求項１記載の自動車装備材用半製品の製造方法。
  3. 　芯成分と鞘成分の重量比が、芯成分：鞘成分＝１～３：１である請求項１記載の自動車装備材用半製品の製造方法。
  4. 　芯鞘型複合繊維中において、芯成分と鞘成分とが同心に配置されている請求項１記載の自動車装備材用半製品の製造方法。
  5. 　芯鞘型複合繊維が、芯鞘型複合長繊維又は芯鞘型複合短繊維である請求項１記載の自動車装備材用半製品の製造方法。
  6. 　繊維ウェブ中の芯鞘型複合繊維相互間が、鞘成分の軟化又は溶融によって、接着されている請求項１記載の自動車装備材用半製品の製造方法。
  7. 　自動車装備材が自動車の下面を覆うアンダーカバーである請求項１記載の自動車装備材用半製品の製造方法。
  8. 　芯成分がエチレングリコールとテレフタル酸の共重合体よりなり、鞘成分がエチレングリコールとアジピン酸とテレフタル酸を含む共重合体よりなる芯鞘型複合繊維が集積されてなる繊維ウェブを得る工程、
    　前記繊維ウェブに、ニードルパンチを施すことにより、前記芯鞘型複合繊維相互間を三次元的に交絡させて自動車装備材用半製品を得る工程、
    　及び前記自動車装備材用半製品に加熱及び圧縮を施す工程を具備することを特徴とする自動車装備材の製造方法。
  9. 　鞘成分が、エチレングリコール、アジピン酸、テレフタル酸、イソフタル酸及びジエチレングリコールからなる共重合体である請求項８記載の自動車装備材の製造方法。
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