JP4185158B2 - Laminate manufacturing method - Google Patents

Laminate manufacturing method Download PDF

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JP4185158B2
JP4185158B2 JP2007529484A JP2007529484A JP4185158B2 JP 4185158 B2 JP4185158 B2 JP 4185158B2 JP 2007529484 A JP2007529484 A JP 2007529484A JP 2007529484 A JP2007529484 A JP 2007529484A JP 4185158 B2 JP4185158 B2 JP 4185158B2
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laminated
thermoplastic resin
fibers
nonwoven fabric
woven fabric
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JPWO2007018051A1 (en
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英幸 鈴木
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NICHIMEN CHEMICAL INDUSTRY CO.,LTD.
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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
    • 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
    • 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
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • 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
    • B32B2262/0207—Elastomeric fibres
    • B32B2262/0215—Thermoplastic elastomer fibers
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B32B2307/102—Insulating
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/712—Weather resistant
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
    • 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
    • B32B2471/00—Floor coverings
    • 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
    • B32B2601/00—Upholstery
    • 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

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)

Description

本発明は、種々の性質を持った繊維製の板状材を、積層した後、一体にする積層材の製造方法に関する。   The present invention relates to a method of manufacturing a laminated material in which fiber plate-like materials having various properties are laminated and then integrated.

樹脂製の皮革や板や木製の板などの硬質の板状材と、不織布などの繊維製の板状材とを一体にした積層材は、床材や自動車の内装材などに広く使用されている。
この硬質の板状材と繊維製の板状材との接合は、接着剤を使用して行っている。例えば、自動車の座席に使用する場合、クッション材である熱可塑性弾性樹脂網状体と表面の被覆材とを接着剤を使用し接着している（特許文献１）。
そのため、接合面に接着剤を塗布するなどの接合のための別工程が必要となり、製造工程が繁雑である。Laminates that integrate rigid plate materials such as resin leather and boards and wooden boards and fiber-made plate materials such as non-woven fabrics are widely used in flooring materials and automotive interior materials. Yes.
The hard plate material and the fiber plate material are joined using an adhesive. For example, when used for an automobile seat, a thermoplastic elastic resin mesh body as a cushion material and a surface covering material are bonded using an adhesive (Patent Document 1).
Therefore, a separate process for joining such as applying an adhesive on the joining surface is required, and the manufacturing process is complicated.

また、植物繊維の持つ、優れた断熱性、吸音性を生かしつつ、強度を補完するために、熱可塑性繊維と植物繊維とを絡み合わせた後、成形するものがある（特許文献２，３）
しかし、所定の厚さを得るために、複数枚を積層し一体にする場合や、このものと硬質の板状材や繊維製の板状材とを一体にする場合には、前記と同様に接合面に接着剤を塗布するなどの接合のための別工程が必要である。
特開平８−５６７７２号公報 特公昭６３−２０９３６号公報 特開２００４−２５８５７号公報 In addition, in order to complement strength while taking advantage of the excellent heat insulating properties and sound absorption properties of the plant fiber, there is one in which the thermoplastic fiber and the plant fiber are intertwined and then molded (Patent Documents 2 and 3).
However, in order to obtain a predetermined thickness, when a plurality of sheets are laminated and integrated, or when this is integrated with a hard plate material or a fiber plate material, the same as described above. A separate process for bonding, such as applying an adhesive to the bonding surface, is required.
JP-A-8-56772 Japanese Patent Publication No. 63-20936 JP 2004-25857 A

本発明は、上記欠点を解消し、接合面に接着剤を塗布するなどの接合のための別工程なしに積層材を製造することを目的とする。   An object of the present invention is to eliminate the above-mentioned drawbacks and to produce a laminated material without a separate process for joining, such as applying an adhesive to a joining surface.

上記目的を達成するために本発明者は鋭意研究の結果、熱可塑性樹脂繊維の不織布、あるいは熱可塑性樹脂繊維を含む不織布を積層し、各層を加熱、加圧すればよいことを知見し本発明に至った。   In order to achieve the above-mentioned object, the present inventor has found that it is only necessary to laminate a nonwoven fabric of thermoplastic resin fibers or a nonwoven fabric containing thermoplastic resin fibers and to heat and press each layer as a result of intensive studies. It came to.

すなわち請求項１の発明は、熱可塑性樹脂繊維を絡ませて不織布を製造する不織布製造工程と、
前記不織布を熱可塑性樹脂繊維の溶融温度に加熱した後、複数枚積重ねる積層工程と、
前記積層工程により積層した積層不織布を加圧する加圧工程とからなり、各工程をこの順に行うことを特徴とする。
請求項２の発明は、植物繊維及び／又は金属繊維に、重量比１０〜９０％の割合で熱可塑性樹脂繊維を混合して互いに絡ませて不織布を製造する不織布製造工程と、
前記不織布を熱可塑性樹脂繊維の溶融温度に加熱した後、複数枚積重ねる積層工程と、
前記積層工程により積層した積層不織布を加圧する加圧工程とからなり、各工程をこの順に行うことを特徴とする。
請求項３の発明は、熱可塑性樹脂繊維を絡ませて不織布を複数枚製造する不織布製造工程と、
前記複数枚のうち一部の不織布を熱可塑性樹脂繊維の溶融温度に加熱し、この加熱した不織布と加熱しない不織布を交互に積重ねる積層工程と、
前記積層工程により積層した積層不織布を加圧する加圧工程とからなり、各工程をこの順に行うことを特徴とする。
請求項４の発明は、植物繊維及び／又は金属繊維に、重量比１０〜９０％の割合で熱可塑性樹脂繊維を混合して互いに絡ませて不織布を製造する不織布製造工程と、
前記複数枚のうち一部の不織布を熱可塑性樹脂繊維の溶融温度に加熱し、この加熱した不織布と加熱しない不織布を交互に積重ねる積層工程と、
前記積層工程により積層した積層不織布を加圧する加圧工程とからなり、各工程をこの順に行うことを特徴とする。 That is, the invention of claim 1 is a non-woven fabric manufacturing process for manufacturing a non-woven fabric by entwining thermoplastic resin fibers,
After heating the nonwoven fabric to the melting temperature of the thermoplastic resin fiber, a plurality stacked Ru lamination process,
And a pressurizing step of pressurizing the laminated nonwoven fabric laminated by the laminating step, and performing each step in this order.
The invention of claim 2 is a non-woven fabric manufacturing process in which a non-woven fabric is manufactured by mixing thermoplastic resin fibers at a ratio of 10 to 90% by weight with plant fibers and / or metal fibers and entwining each other.
After heating the nonwoven fabric to the melting temperature of the thermoplastic resin fiber, a plurality stacked Ru lamination process,
And a pressurizing step of pressurizing the laminated nonwoven fabric laminated by the laminating step, and performing each step in this order.
The invention of claim 3 is a non-woven fabric manufacturing process for manufacturing a plurality of non-woven fabrics by entwining thermoplastic resin fibers,
A lamination process in which some of the plurality of non-woven fabrics are heated to the melting temperature of the thermoplastic resin fibers, and the heated non-woven fabric and the non-heated non-woven fabric are alternately stacked, and
And a pressurizing step of pressurizing the laminated nonwoven fabric laminated by the laminating step, and performing each step in this order .
The invention of claim 4 is a non-woven fabric manufacturing process for manufacturing non-woven fabric by mixing thermoplastic resin fibers in a proportion of 10 to 90% by weight with plant fibers and / or metal fibers and entangled with each other.
A lamination process in which some of the plurality of non-woven fabrics are heated to the melting temperature of the thermoplastic resin fibers, and the heated non-woven fabric and the non-heated non-woven fabric are alternately stacked, and
And a pressurizing step of pressurizing the laminated nonwoven fabric laminated by the laminating step, and performing each step in this order.

熱可塑性性樹脂繊維は、ポリエチレン繊維、ポリプロビレン繊維などの公知のいずれのものであってもよい。ただし、植物繊維を混合する場合には、植物繊維を変性しないで溶融する必要があるので、約１００〜２６０℃で溶融するものがよい。
植物繊維は、公知のいずれのものであってもよいが、竹、ケナフ、バナナ、ココナツ、麻、間伐材など原料が安価で大量に入手できるものが特によい。
また、金属繊維は、鉄製、鉄合金製、アルミニウム製、アルミニウム合金製などの公知のいずれのものであってもよい。
また、表面被覆材は、布、皮革、熱可塑性樹脂製のシート、薄い木の板や竹の板、紙などのシート状のものである。The thermoplastic resin fibers may be any known ones such as polyethylene fibers and polypropylene fibers. However, when mixing plant fibers, it is necessary to melt the plant fibers without denaturing them.
The plant fiber may be any known one, but is particularly preferably one that can be obtained in a large amount at a low cost, such as bamboo, kenaf, banana, coconut, hemp, and thinned wood.
The metal fiber may be any known one such as made of iron, iron alloy, aluminum, or aluminum alloy.
The surface covering material is in the form of a sheet such as cloth, leather, a sheet made of a thermoplastic resin, a thin wooden board, a bamboo board, or paper.

本発明は、熱可塑性樹脂繊維を１０％以上含む不織布を熱可塑性樹脂繊維が溶融する温度まで加熱した後、複数枚積重ね、加圧する。各不織布は溶融した熱可塑性樹脂が接着剤の役割を担い一体となり板状の積層材に変性する。
よって、接合面に接着剤を塗布するなどの接合のための工程なしに簡単に積層材を製造できる。
また、不織布を複数枚積重ねる際に、非加熱の不織布と、熱可塑性樹脂繊維が溶融する温度に加熱した不織布とを交互に積重ね、その後加圧すると、板状のものとフェルト状のものとが積層した積層材を接合面に接着剤を塗布するなどの接合のための工程なしに簡単に製造できる。
さらに、不織布を製造する際に植物繊維を混入すると、防音、吸湿、断熱、脱臭などの効果の優れた積層材になる。
また、不織布を製造する際に金属繊維を混入すると、耐食性、耐候性が向上すると共に、高音部での吸音特性の優れた積層材になる。 The present invention, after the non-woven fabric containing a thermoplastic resin fiber by 10% or more thermoplastic resin fibers is heated to a temperature to melt, stacked plurality pressurized. In each non-woven fabric, a molten thermoplastic resin plays a role of an adhesive and is integrated into a plate-like laminated material.
Therefore, a laminated material can be easily manufactured without a bonding process such as applying an adhesive to the bonding surface.
In addition, when stacking a plurality of nonwoven fabrics, the non-heated nonwoven fabric and the nonwoven fabric heated to a temperature at which the thermoplastic resin fibers melt are alternately stacked, and then pressed to form a plate-like one and a felt-like one. Can be easily manufactured without a bonding process such as applying an adhesive to the bonding surface.
Furthermore, when a vegetable fiber is mixed when manufacturing a nonwoven fabric, it will become the laminated material excellent in effects, such as sound insulation, moisture absorption, heat insulation, and deodorizing.
In addition, when metal fibers are mixed in the production of the nonwoven fabric, the corrosion resistance and weather resistance are improved, and a laminated material having excellent sound absorption characteristics in the high-pitched part is obtained .

以下本発明の実施の形態について説明する。
まず、植物繊維にバインダになる熱可塑性樹脂繊維を重量比で１０〜９０％混合し、公知のニードルパンチ法、カーディング法などにより絡ませ、シート状の不織布を得る（不織布製造工程）。
次に、この不織布を複数枚用意し、これを所定の寸法に揃え、熱可塑性樹脂繊維が溶融する温度まで加熱した後積重ねる。（積層工程）
次に、これを金型に入れて加圧し積層材にする（加圧工程）。
加熱条件、加圧条件は、不織布を構成する熱可塑性樹脂繊維により異なる。加熱温度は、植物繊維を混合する場合には、植物繊維を変性せず、かつ熱可塑性樹脂繊維を溶融する必要があるので、約１００〜２６０℃がよい。また、圧力、加熱温度が大であると硬質の板状材になり、小になるに従いフェルト状の弾力のある板状材（クッション材）になる。 Embodiments of the present invention will be described below.
First, 10 to 90% by weight of thermoplastic resin fibers serving as a binder is mixed with plant fibers and entangled by a known needle punch method, carding method or the like to obtain a sheet-like nonwoven fabric (nonwoven fabric manufacturing process).
Next, a plurality of the nonwoven fabrics are prepared, and the nonwoven fabrics are aligned to a predetermined size, heated to a temperature at which the thermoplastic resin fibers melt, and then stacked. (Lamination process)
Next, this is put into a mold and pressed to form a laminated material (pressurizing step).
Heating conditions and pressure conditions vary depending on the thermoplastic resin fibers constituting the nonwoven fabric. When the plant fiber is mixed, the heating temperature is preferably about 100 to 260 ° C. because the plant fiber is not denatured and the thermoplastic resin fiber needs to be melted. Further, when the pressure and heating temperature are high, a hard plate-like material is formed, and as the pressure and the heating temperature are reduced, a felt-like elastic plate-like material (cushion material) is obtained.

以下本発明の別の実施の形態について説明する。
まず、植物繊維にバインダになる熱可塑性樹脂繊維を重量比で１０〜９０％混合し、公知のニードルパンチ法、カーディング法などにより絡ませ、不織布を得る（不織布製造工程）。
次に、非加熱の不織布と、加熱（約１００〜２６０℃）した不織布を、所定の寸法に揃えた後交互に積重ねる。或いは、交互に積重ねた後、所望の寸法に揃える。（積層工程）
次に、金型に入れて加圧し積層材にする（加圧工程）。
溶融した熱可塑性樹脂繊維が接着剤の役割をして、非加熱の不織布と加熱した不織布とが加圧により接合し、さらに不織布は、溶融した熱可塑性樹脂繊維が接合して硬質の板状材に変性し、フェルト状のものと硬質の板状のものとが交互に積層したものになる。Hereinafter, another embodiment of the present invention will be described.
First, 10 to 90% by weight of thermoplastic resin fibers serving as a binder is mixed with plant fibers and entangled by a known needle punch method, carding method or the like to obtain a nonwoven fabric (nonwoven fabric production process).
Next, the non-heated non-woven fabric and the heated (about 100 to 260 ° C.) non-woven fabric are alternately stacked after having a predetermined size. Alternatively, after stacking alternately, it is aligned to a desired dimension. (Lamination process)
Next, it puts into a metal mold and pressurizes it to make a laminated material (pressurization process).
The molten thermoplastic resin fiber acts as an adhesive, and the non-heated non-woven fabric and the heated non-woven fabric are joined by pressure, and the non-woven fabric is joined to the molten thermoplastic resin fiber to form a hard plate-like material. It becomes a laminate in which felt-like ones and hard plate-like ones are alternately laminated.

前記積層材は、非加熱の不織布と加熱した不織布をそれぞれ１枚ずつ使用し製造してもよい。また、非加熱の不織布又は加熱した不織布のいずれかを芯にして、それを挟むサンドイッチ構造にしたり、非加熱の不織布と加熱した不織布を交互に複数枚積重ねてもよい。
床材（クッションフロア）の場合には、表面に硬質の板状のものが来るよう積層する。The laminate material may be manufactured using one non-heated nonwoven fabric and one heated nonwoven fabric. Alternatively, either a non-heated nonwoven fabric or a heated nonwoven fabric may be used as a core, and a sandwich structure may be sandwiched therebetween, or a plurality of non-heated nonwoven fabrics and heated nonwoven fabrics may be stacked alternately.
In the case of floor materials (cushion floors), they are laminated so that a hard plate-like material comes to the surface.

以下本発明のさらに別の実施の形態について説明する。
前記実施形態との違いは、植物繊維の代わりに金属繊維を使用したことである。
すなわち、金属繊維にバインダになる熱可塑性樹脂繊維を重量比で１０〜９０％混合し、公知のニードルパンチ法、カーディング法などにより絡ませ、不織布を得る（不織布製造工程）。
次に、非加熱の不織布と、加熱（約１００〜２３０℃）した不織布を、所定の寸法に揃えた後交互に積重ねる。或いは、交互に積重ねた後、所望の寸法に揃える。（積層工程）
次に、金型に入れて加圧し積層材にする（加圧工程）。Hereinafter, still another embodiment of the present invention will be described.
The difference from the above embodiment is that metal fibers are used instead of plant fibers.
That is, 10 to 90% by weight of thermoplastic resin fibers serving as a binder is mixed with metal fibers and entangled by a known needle punching method or carding method to obtain a nonwoven fabric (nonwoven fabric manufacturing process).
Next, the non-heated nonwoven fabric and the heated (about 100-230 degreeC) nonwoven fabric are laminated | stacked alternately, after aligning to a predetermined dimension. Or after stacking alternately, it is aligned to the desired dimensions. (Lamination process)
Next, it puts into a metal mold and pressurizes it to make a laminated material (pressurization process).

金属繊維を使用することにより、前記植物繊維を使用したものより耐候性、耐食性が向上する。また、高音部での吸音特性が向上する。   By using metal fibers, weather resistance and corrosion resistance are improved as compared with those using the plant fibers. In addition, the sound absorption characteristics in the high sound part are improved.

以上の各実施形態では、積層材の表面を被覆していないが、必要に応じて布、皮革、熱可塑性樹脂製のシート、薄い木の板や竹の板、紙などの表面被覆材で被覆してもよい。その場合、積重なった不織布の表面を加熱した後、表面被覆材を積層して、その後加熱加圧するとよい。
また、熱可塑性樹脂シートを介して表面被覆材を重ね加熱加圧してもよい。
また、表面被覆材は、微細孔を多数穿設して、被覆した積層材の吸湿性能などを生かしてもよい。
表面に表面被覆材のもつ各種機能を付加できると共に、積層材が美麗になる。また、接着剤の使用なしに表面被覆材の接合を簡便に行える。In each of the above embodiments, the surface of the laminated material is not covered, but if necessary, it is covered with a surface covering material such as cloth, leather, a sheet made of thermoplastic resin, a thin wooden board, bamboo board, or paper. May be. In that case, after heating the surface of the laminated nonwoven fabric, it is good to laminate | stack a surface coating material and to heat-pressurize after that.
Further, the surface covering material may be stacked and heated and pressed through a thermoplastic resin sheet.
In addition, the surface covering material may be provided with a large number of fine holes to take advantage of the moisture absorption performance of the coated laminated material.
Various functions of the surface coating material can be added to the surface, and the laminated material becomes beautiful. Further, the surface covering material can be easily joined without using an adhesive.

上記表面被覆材を積層する方法は、特に自動車の座席を製造するのに適しており、表面を被覆する皮革や布などの表面被覆材と内装されたクッション材（植物繊維と熱可塑性樹脂繊維が相互に絡まった不織布）とを、接着剤の塗布工程なしに、一度の加圧工程で接合できる。また、この加圧工程で、同時に、不織布を所定枚数積層したもの同士を一体にできる。また、表面被覆材は、クッション材として使用する熱可塑性樹脂繊維と密着しやすい素材を使用すると接合が強固になる。
不織布は、予め所望の厚さのものを用意してもよいが、用途が限定されること、及び上記のとおり接合が容易であることから、薄いものを大量生産し、積層して所望の厚さにするほうが安価に製造できると共に、多様な製品に使用できる。
また、植物繊維を混合して不織布を製造すると、廃棄や焼却の点で環境に優しいものになる。The above-mentioned method of laminating the surface covering material is particularly suitable for manufacturing an automobile seat. The surface covering material such as leather or cloth covering the surface and a cushion material (plant fiber and thermoplastic resin fiber are included). The non-woven fabric entangled with each other can be joined in a single pressurizing step without an adhesive application step. Further, in this pressurization step, a predetermined number of laminated nonwoven fabrics can be integrated at the same time. Further, when the surface covering material is made of a material that is easily adhered to the thermoplastic resin fiber used as a cushioning material, the bonding becomes strong.
A nonwoven fabric having a desired thickness may be prepared in advance. However, since the application is limited and joining is easy as described above, a thin fabric is mass-produced and laminated to a desired thickness. It is cheaper to manufacture and can be used for various products.
Moreover, when vegetable fibers are mixed to produce a nonwoven fabric, it becomes environmentally friendly in terms of disposal and incineration.

なお、前記実施形態において、前記植物繊維は、公知の方法にて製造する。
すなわち、木質繊維は、原料が古紙の場合は、粉砕機により粉砕すればよい。
植物繊維の材料は、前記のほかケナフ、バナナ、ココナツ、麻、間伐材など安価で大量に入手できるものであればよい。
さらには、不織布の積層は、折り重ねたり、所定寸法に切断したシート状のものを積重ねたりする。In addition, in the said embodiment, the said plant fiber is manufactured by a well-known method.
That is, the wood fiber may be pulverized by a pulverizer when the raw material is used paper.
The plant fiber material may be any material that can be obtained in large quantities at a low price such as kenaf, banana, coconut, hemp, and thinned wood.
Furthermore, the lamination of the non-woven fabrics is performed by folding or stacking sheet-like products cut into predetermined dimensions.

前記実施形態では、植物繊維又は金属繊維と、熱可塑性樹脂繊維を混合したが、熱可塑性樹脂繊維と他の繊維を混合したものであっても、熱可塑性樹脂繊維だけであってもよい。
積層するものも同じ材質の不織布でなく、例えば、植物繊維を混合した不織布と、金属繊維を混合した不織布を交互に積層してもよい。
また、積層材にする際に、積重ねた不織布を金型に入れた後加圧しているが、これに限るものではなく、金型に入れずローラ間を通す方法であってもよい。さらに加圧工程では、金型やローラの温度は、熱可塑性樹脂繊維が溶融する温度より低い温度であればよく、常温に限らない。よって、金型やローラを必要に応じ適宜加熱したり冷却したりしてもよい。
また、出来上がった積層材は、さらに、使用目的に応じ所定の寸法に切断してもよい。


In the embodiment, vegetable fiber or metal fiber and thermoplastic resin fiber are mixed, but the thermoplastic resin fiber and other fibers may be mixed, or only the thermoplastic resin fiber may be used.
What is laminated is not a nonwoven fabric of the same material, for example, a nonwoven fabric mixed with plant fibers and a nonwoven fabric mixed with metal fibers may be alternately laminated.
In addition, when a laminated material is used, the stacked nonwoven fabrics are pressed after being put into a mold, but the present invention is not limited to this, and a method of passing between rollers without entering the mold may be used. Furthermore, in the pressurizing step, the temperature of the mold or roller may be any temperature that is lower than the temperature at which the thermoplastic resin fibers melt, and is not limited to room temperature. Therefore, the mold and the roller may be appropriately heated or cooled as necessary.
Moreover, you may cut | disconnect the completed laminated material to a predetermined dimension further according to the intended purpose.


Claims (4)

熱可塑性樹脂繊維を絡ませて不織布を製造する不織布製造工程と、
前記不織布を熱可塑性樹脂繊維の溶融温度に加熱した後、複数枚積重ねる積層工程と、
前記積層工程により積層した積層不織布を加圧する加圧工程とからなり、各工程をこの順に行うことを特徴とする積層材の製造方法。Non-woven fabric manufacturing process for manufacturing non-woven fabric by entwining thermoplastic resin fibers;
After heating the nonwoven fabric to the melting temperature of the thermoplastic resin fiber, a plurality stacked Ru lamination process,
A method for producing a laminated material comprising: a pressurizing step of pressurizing the laminated nonwoven fabric laminated by the laminating step, and performing each step in this order. 植物繊維及び／又は金属繊維に、重量比１０〜９０％の割合で熱可塑性樹脂繊維を混合して互いに絡ませて不織布を製造する不織布製造工程と、
前記不織布を熱可塑性樹脂繊維の溶融温度に加熱した後、複数枚積重ねる積層工程と、
前記積層工程により積層した積層不織布を加圧する加圧工程とからなり、各工程をこの順に行うことを特徴とする積層材の製造方法。A non-woven fabric manufacturing process in which a non-woven fabric is manufactured by mixing thermoplastic resin fibers in a ratio of 10 to 90% by weight with plant fibers and / or metal fibers and entwining each other.
After heating the nonwoven fabric to the melting temperature of the thermoplastic resin fiber, a plurality stacked Ru lamination process,
A method for producing a laminated material comprising: a pressurizing step of pressurizing the laminated nonwoven fabric laminated by the laminating step, and performing each step in this order. 熱可塑性樹脂繊維を絡ませて不織布を複数枚製造する不織布製造工程と、
前記複数枚のうち一部の不織布を熱可塑性樹脂繊維の溶融温度に加熱し、この加熱した不織布と加熱しない不織布を交互に積重ねる積層工程と、
前記積層工程により積層した積層不織布を加圧する加圧工程とからなり、各工程をこの順に行うことを特徴とする積層材の製造方法。 A nonwoven fabric manufacturing process for manufacturing a plurality of nonwoven fabrics by entwining thermoplastic resin fibers;
A lamination process in which some of the plurality of non-woven fabrics are heated to the melting temperature of the thermoplastic resin fibers, and the heated non-woven fabric and the non-heated non-woven fabric are alternately stacked, and
A method for producing a laminated material comprising: a pressurizing step of pressurizing the laminated nonwoven fabric laminated by the laminating step, and performing each step in this order . 植物繊維及び／又は金属繊維に、重量比１０〜９０％の割合で熱可塑性樹脂繊維を混合して互いに絡ませて不織布を製造する不織布製造工程と、
前記複数枚のうち一部の不織布を熱可塑性樹脂繊維の溶融温度に加熱し、この加熱した不織布と加熱しない不織布を交互に積重ねる積層工程と、
前記積層工程により積層した積層不織布を加圧する加圧工程とからなり、各工程をこの順に行うことを特徴とする積層材の製造方法。 A non-woven fabric manufacturing process in which a non-woven fabric is manufactured by mixing thermoplastic resin fibers in a ratio of 10 to 90% by weight with plant fibers and / or metal fibers and entwining each other.
A lamination process in which some of the plurality of non-woven fabrics are heated to the melting temperature of the thermoplastic resin fibers, and the heated non-woven fabric and the non-heated non-woven fabric are alternately stacked, and
A method for producing a laminated material comprising: a pressurizing step of pressurizing the laminated nonwoven fabric laminated by the laminating step, and performing each step in this order .
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