JPH01104868A - Production of fibrous laminate - Google Patents

Abstract

PURPOSE: To produce a fibrous laminated body suitable for deep-drawing forming and having excellent shape keeping properties after forming by laminating a binder nonwoven fabric of a thermoplastic resin fiber having a specific melting point on the surface of a fiber mat having a higher melting point, subjecting the laminated body to a needing process, subsequently placing a surface-finishing material on the needled laminated body, and heating and fusing them. CONSTITUTION: A binder nowoven fabric A of a thermoplastic resin fiber having a melting point of 60-200 deg.C is laminated on the surface of a fiber mat B consisting of a synthetic fiber or a natural fiber having a melting point higher than the melting point of the fibrous-binder nonwoven fabric by 40 deg.C or more, needling is applied on the laminated body from the side of the binder nonwoven fabric A of the thermoplastic resin to obtain a laminated-body mat C in which binder fibers of the nonwoven fabric A and fibers of the fiber mat B are entangled with each other. Subsequently, a surface- finishing material D is placed on the side of the nonwoven fabric A, and subsequently heating them up to a temperature at which the fibers of the surface-finishing material D and the fiber mat B are not fused, while the binder fiber of the nonwoven fabric A is fused to obtain the objective laminated body in which the surface finishing material D and the fiber mat B are finally integrally fused.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method for manufacturing a fibrous laminate, and in particular, to a method for manufacturing a fibrous laminate, which can be used as an interior material for automobiles and other vehicles by chestnut drawing and has good shape retention. The present invention relates to a method for producing a quality laminate.

[Conventional technology]

Automotive interior materials include, for example, moldable fiber mats prepared by coating or impregnating needle-punched nonwoven fabric with an aqueous emulsion of thermoplastic resin with a softening point of 100 to 10°C and drying them, and high-melting-point fibers such as polyethylene terephthalate. Carpets are known that are made by heating and press-molding a non-woven fabric mat made of mixed fibers of carbon dioxide and a thermoplastic resin fiber binder having a melting point of 100 to 130° C. to match the shape of an automobile floor.

However, these carpets lack luxury by themselves and are unsatisfactory in terms of rigidity, elasticity, moldability, etc., so tufted carpets or needle punch carpets are used as covering materials on the surface of these carpets. Attempts have been made to bond using adhesives or hot melt agents, or to back it with resin sheets or foam sheets.

The present inventor has previously developed a method for prefabricating carpets without reducing the air permeability of the carpet. Yoshimo proposed a carpet lining method in JP-A-61-135614, in which a felt layer made by needling a felt layer mixed with fibers having a melting point higher than 40°C is molded under heat and pressure via a fiber binder nonwoven fabric. did.

[Problem that the invention seeks to solve]

The carpet lining method proposed in JP-A No. 61-135614 differs from the conventional method in which a film of hot melt adhesive is continuous, and an adhesive layer (non-woven fabric binder) is used.
Since it is discontinuous with voids, it is excellent in that it does not impair breathability and flexibility. However, with this method, there is a problem with uniformity when mixing the fiber binder with the fiber mat used for lining.
By sufficiently mixing the fiber binder and other fibers, moldability and fiber fixation are achieved as evenly as possible. 0
0 In order to ensure more secure adhesion between the covering material and the fiber mat, a water-permeable nonwoven fabric made of thermoplastic fiber binder is sandwiched between the two and bonded under heat. In this way, a hot melt adhesive (nonwoven fabric binder, thermoplastic resin film, thermoplastic resin powder, etc.) is required for adhesion to other materials.

It should be noted that if needling alone is used, the surface of the facing material will be rough and the adhesive strength will be insufficient, and even if a hot melt adhesive and needling are used together, the surface of the facing material will be rough.

[Means for solving problems]

The present invention further improves the carpet lining method proposed above, and provides a fibrous laminate that is simple, inexpensive, and capable of producing a carpet lining that is highly decorative and has excellent moldability and shape retention. It provides a manufacturing method.

That is, the present invention applies a thermoplastic resin fiber binder nonwoven fabric (A) having a melting point of 60 to 2001 to the surface of a fiber mat made of synthetic fibers or natural fibers having a melting point 40° C. or more higher than the melting point of the fiber binder nonwoven fabric. Laminated on
Needling is performed from the thermoplastic resin binder nonwoven fabric (A) side of this laminate to obtain a laminate mat (D) in which the binder fibers of the nonwoven fabric (A) and the fibers of the fiber mat [) are intertwined with each other. Place the surface material (D) on a rotating rack, then heat the surface material ■ and the fiber mat to a temperature where the fibers of the surface material ■ and the fiber mat (B) do not melt, but the binder fibers of the nonwoven fabric (A), and the surface material ◎ and the fiber mat ■ The present invention provides a method for producing a fibrous laminate in which the fibrous laminate is integrally fused.

[Detailed description of the invention]

(1) Fibrous laminate The fibrous laminate obtained by the method for producing a fibrous laminate of the present invention, as shown in FIG.
) on the surface of the fiber binder nonwoven fabric (A),
Then, on the surface of the needled laminate mat (Q) having a two-layer structure, for example, a needle-punched carpet is layered as the upper r/peripheral carpet (D) of the facing material, and heated and compressed to form the fiber binder non-woven material. It has a structure in which the facing material and fiber mat are welded together by melting.

Fiber binder nonwoven fabric The fiber binder nonwoven fabric (A) used in the method for producing a fibrous laminate of the present invention is a nonwoven fabric made of thermoplastic resin fibers, such as polyethylene, polypropylene, linear polyester, polyamide, composite fibers thereof, etc. melting point is 6
Spun bend the resin fibers at a temperature of 0 to 200 C, preferably 90 to 170 C, and the resin fibers may be thick or thin depending on the purpose, but are usually 3 denier or more and the fiber length is preferably 8 days or more in terms of entanglement. It can be obtained by intertwining the fibers by a method such as a method or a needle punch method, or it can be in the form of a fiber web obtained by carding or the like, or it can be fixed with a binder, and it can be air permeable. Generally, the basis weight is 15~g o o
t/- is preferred.

In addition, the fiber binder nonwoven fabric (the Bureau uses an extruder to melt pellets of resin such as polypropylene, low-melting point polyester, and low-melting point polyamide, extrudes them into a solid shape through a goo with many thin holes, and blows them in the wind) It may also be produced by placing the fibers on the fibers, pulling them out so that the individual fibers do not converge, depositing them on a screen below the die, and then taking them off with a winder.

Such non-woven fabrics made of fiber binders have many gaps through which water can pass, and are available under the trade name of Diabond Kogyo Yosho Meltron W, and the polyamide-based ones are called PAY-2.
00, PAS-200-Polyester type is KS-
500, the ethylene/acetic acid copolymer type is grade name Y-7, and the polypropylene type from Mikata Petrochemical Industry ■ is Syntex PK-103, PK-1.
06, PK-404, PK-408, etc., polyethylene-based products are manufactured by Admel, and similar nonwoven fabrics are manufactured by Guigen Seni ■ under the product names of DYNAC, such as I, MS-0000, and LNS-. 2000, ES-00S
It is commercially available with grade names such as B-1000, B-2000, and 3-3000.

The fiber binder nonwoven fabric (A) preferably has a melting point that is 40° C. or more lower than the melting point of the fibers that are the main component of the fibers of the fiber mat (B). This is because the heating to melt the nonwoven right gyrus is usually done at a degree of contraction 20 to 30° C. higher than the melting point of the binder fibers of the nonwoven fabric Q.

In addition, this nonwoven fabric (A) has a fiber mat of 10 to 200%
It is used in proportions of % by weight.

Further, the fiber binder nonwoven fabric does not have to be made of a single fiber, but may be a mixed fiber of polypropylene and polyamide, for example. In other words, the melting point of the fiber mat (B) is 40℃
As long as it is lower than that, it may be a mixed fiber or a laminated structure of six of these fibers. Roughly, slightly (30%
The following high melting point fibers may be mixed. In the case of recovered fibers, they are well mixed.

(B) Fiber Mat Synthetic fibers or natural fibers are used as the fibers for constituting the fiber mat (6) used in the method for producing a fibrous laminate of the present invention.

Examples of synthetic fibers include polyethylene terephthalate, polyamide, polyacrylonitrile, etc., which are 40°C or higher, preferably 70°C or higher than the melting point of the fiber binder nonwoven fabric (A).
A thermoplastic resin having a high melting point of 0.degree. C. or higher (specifically, 200 to 280.degree. C.) is used.

Further, as the natural fiber, cotton, hemp, wool, miscellaneous felt, scrap poly fiber, etc. are used.

This fiber mat (B) may contain a fiber binder having a melting point of 60 to 200°C in a proportion of 5 to 50% by weight.

The fiber mat (B) of the present invention is produced by intertwining and integrating the fibers of the fiber binder nonwoven fabric (A) and the fiber binder nonwoven fabric (A) laminated on the surface thereof by needling. It is not necessary to provide sufficient shape retention to the fiber binder itself, and even if the fibers are not necessarily of high quality, a web of waste fibers can be used to achieve the purpose, and the melting point of the fiber binder Q A fiber mat is used in which fibers having a melting point higher than 40°C, preferably 70°C or more higher than that of the fibers, such as wool, nylon, polyacrylonitrile, polyacetate, polyethylene terephthalate, etc., are made into a web using a card. .

■ Upholstery As the covering material, use a tufted carpet material made of a primary base fabric knitted from polypropylene flat yarn with erected piles made of polyamide or polyethylene terephthalate, or use the above-mentioned needle punch carpet as the primary base fabric. Raw tufted carpet with piles on it, knee)' Lupante carpet, woven fabric, paper, etc. are used.

(2) Production of Iso fibrous laminate In order to produce a fibrous laminate by the method of the present invention, the laminate mat 0 that has been subjected to the needling and intertwined,
It is necessary to stack, heat and compress the top layer carpet 0).

Needling is carried out in such a way that the fiber binder of the nonwoven fabric (to) is vertically inserted into the fiber mat (B) and the needles pass through this fiber mat (6).

This allows the non-woven fabric (
The fiber binder of A) will be present in an amount of 5 to 100%. However, if the fiber mat (B) layer contains 5 to 50 vt% of fiber binder before needling (
11, there is no need to insert the needle until it completely passes through the mat (B).

Father, the fiber binder of the nonwoven fabric (A) is the fiber mat (□
5-80% inserted into □□ and always (B)
95 to 20% of the fiber binder layer (A) and (6) remain in contact with the surface of the fiber, and the two-layer structure of the fiber binder layer (A) and (6) is clearly defined, and the binder fiber (8) is present in the fiber binder layer (A) and (6). do.

The surface layer material is placed on top of the fiber binder and is finally thermally bonded, but it is also possible to intertwine the surface layer material by light needling and then heat bond it to the fiber binder during thermoforming. This method involves losses due to roughening of the surface of the covering material and an additional step.

It is particularly important that the heating is carried out at a temperature higher than the temperature at which the fiber binder non-woven right-layer melts, and at a temperature at which the upper layer carpet υ and the fiber mat do not melt.

For only thermal bonding, a pressure roll of about IA 9/m is sufficient, and when molding and mat density are controlled simultaneously with thermal bonding, a roll pressure of 5 #/cIi to 50 m/-j is required. If only thermal bonding is used, the heating and compression can be carried out continuously using a roll or the like. Needling is non-woven fabric (A)
5-100% of the binder fibers are fiber mats (CB)
It is preferable to do this so that the fibers are intertwined with each other.

The fibrous laminate of the present invention can be thermoformed to match the shape of the floor on which it is installed. This molding can be done at the same time as the above-mentioned upper layer carpet is adhered, or even after the upper layer carpet is adhered, it can be molded into the required shape depending on the application.

〔effect〕

In the fibrous laminate of the present invention, the fibers of the nonwoven fiber binder enter the fiber mat (B) through needling, and the fibers of the papermaking partner are entangled with each other. Provides strength, hardness and shape retention.

Even after needling, the surface of this base layer Ω is mainly made of binder fibers (fiber binder non-woven fabric), so it has the advantage that adhesives such as maid cloth, powder, hot melt, etc. are not required for adhesion to the upper layer carpet ■. There is.

Further, due to the presence of this fiber binder nonwoven fabric, the moldability by heat molding is excellent, and it is particularly suitable for deep drawing, and the shape retention after molding is good.

Further, since the fiber mat and the fiber binder are stacked and entangled by needling, there is no need to uniformly mix the meat fibers as in the conventional method, and the process is simplified.

〔Example〕

Example 1 As the fiber binder nonwoven fabric (A), 16 denier, 5
0m length of polypropylene (melting point 164℃) fiber-2s
ot/rr? A web version of the following was used.

Combine this (A) with Howa Seni ■'s phenol felt (B).
1 felt tube 10t” (product name, 10m! 11 thickness,
Layer it on the surface of a 7-piece type, fabric weight s o t/m"), and in that state, use a 15-18-32-3RB needle to needle at a rate of 150 needles per square inch to obtain a wall thickness of approximately 13 -1 A laminate mat (C) with an apparent density of 0.062 t/crti was obtained.

Plain type needle punch carpet made of 300 f/- fiber mat made of randomly stacked colored polyethylene terephthalate (M point 264°C) fiber cards of 6 denier and fiber length 85 to 12'Ow+ (
D) was superimposed on the upper surface of the above laminate matte rono fiber binder, this laminate was heated to 190°C through a suction dryer to melt the polypropylene iR fiber binder, and then immediately 1
Pressure molding was carried out at a pressure of 0 #/- to obtain a molded carpet for laying that was faithful to the mold and had a thickness of 6 m and 3 cm.

150m x 5 from this 6- and 3ms+ thick carpet
A sample piece of 011IK was cut out and the adhesion strength of the surface layer material was measured using an Instron type tester, and the I/crisp strength was determined to be 5.5 #15cfn width.

Example 2, Comparative Example 1 In Example 1, there is a case where the fiber binder nonwoven fabric (A) is not used (Comparative Example 1), and a case where the nonwoven fabric has a melting point of 119
A fibrous laminate was obtained in the same manner as in Example 2, except that a nonwoven polyethylene fabric of 100° C. manufactured by Mikata Petrochemical Industry Co., Ltd. (trade name "Admel", basis weight 100 y/rr) (Example 2) was used.

Example 3 A fibrous laminate was prepared in the same manner as in Example 1 except that Fine Needle 650L (trade name, felt containing 20% fiber binder. 650?/ff/) manufactured by Seishaku Sangyo ■ was used as the fiber mat (B). I got a body.

Example 4 A fibrous laminate was obtained in the same manner as in Example 1, except that Kansai Felt ■ polyester miscellaneous felt (Dorfelt 8cm thickness, basis weight j1 asof/m'') was used as the fiber mat.

Comparative Example 2 A fibrous laminate was obtained in the same manner as in Example 2, except that the needling operation was not performed.

Representative physical properties of these fibrous laminates are shown below.

(Margin below)

[Brief explanation of the drawing]

FIG. 1 is a cross-sectional view of a fibrous laminate obtained by the method of the present invention, in which needling was applied to a two-layer structure in which a fiber binder nonwoven fabric (6) was superimposed on the surface of a fiber mat (B). Carpet for upper layer as covering material on laminate mat 0◎
This shows a state in which (D) and (D) are welded together by overlapping them, heating and compressing them, and melting the fiber binder. Patent applicant Mitsubishi Yuka Perdice Co., Ltd. Agent
Patent attorney Masahisa Hase Agent Patent attorney Takashi Yamamoto Purity of the drawing; (no change in high language) Procedural amendment (method) % formula % 1. Indication of the case 1988 Patent Application No. 260557 2. Invention Name: Manufacturing method for fibrous laminates 3, relationship with the case of the person making the amendment Patent applicant address: 1000 Yojiri-cho, Yokkaichi City, Mie Prefecture Name: Mitsubishi Yuka Verdice Co., Ltd. 4, Agent address: 2 Marunouchi, Chiyoda-ku, Tokyo No. 5-2 Mitsubishi Yuka Co., Ltd. December 24, 1988 (Delivery date: January 26, 1983)
6. Subject of correction

Claims (3)

[Claims] (1). A thermoplastic resin fiber binder nonwoven fabric (A) having a melting point of 60 to 200°C is laminated on the surface of a fiber mat (B) made of synthetic fiber or natural fiber having a melting point 40°C or more higher than the melting point of the fiber binder nonwoven fabric, A laminate mat (C) in which binder fibers of the nonwoven fabric (A) and fibers of the fiber mat (B) are intertwined with each other by needling from the thermoplastic resin binder nonwoven fabric (A) side of the laminate.
After that, the surface material (D) is placed on the side of the nonwoven fabric (A), and then the temperature is reached such that the fibers of the facing material (D) and the fiber mat (B) do not melt, but the binder fibers of the nonwoven fabric (A) melt. A method for producing a fibrous laminate in which a surface layer material (D) and a fiber mat (B) are fused together by heating. (2). 2. The method according to claim 1, wherein the weight of the thermoplastic resin binder nonwoven fabric (A) is 10 to 200% by weight of the weight of the fiber mat (B). (3). 2. The method according to claim 1, wherein 5 to 100% of the fiber binder of the nonwoven fabric is intertwined with the fibers of the fiber mat (B).