JP7106605B2 - 不織布積層体 - Google Patents
不織布積層体 Download PDFInfo
- Publication number
- JP7106605B2 JP7106605B2 JP2020119973A JP2020119973A JP7106605B2 JP 7106605 B2 JP7106605 B2 JP 7106605B2 JP 2020119973 A JP2020119973 A JP 2020119973A JP 2020119973 A JP2020119973 A JP 2020119973A JP 7106605 B2 JP7106605 B2 JP 7106605B2
- Authority
- JP
- Japan
- Prior art keywords
- nonwoven
- layer
- layers
- laminate
- copolyester
- Prior art date
- Legal status (The legal status 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 status listed.)
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Images
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Description
不織布積層体は、様々な用途で用いられている。不織布積層体は、例えば自動車用途のアンダーボディシールド材料として使用される。自動車用途のアンダーボディシールド材料は、通常、所与の車両内に配置するのに望ましいアンダーボディシールドを提供するために加熱および成形される。このようなアンダーボディシールドは、通常、多くの厳しい性能仕様を満たす必要がある。そのような仕様を満たすために、様々なアンダーボディシールド材料が当該技術分野で広く提案されてきた。
本発明の目的は、当該技術分野において直面する欠点を少なくとも部分的に克服する不織布積層体を提供することである。
驚くべきことに、本発明の基礎を成す課題は、特許請求の範囲による不織布積層体、成形物品、使用および方法により解決されることが見出された。本発明のさらなる実施形態は、本明細書を通して概説される。
ポリエチレンテレフタレート(PET)およびコポリエステルを含む繊維を含む、スパンボンド不織布層(A)と、
ポリエチレンテレフタレート(PET)およびコポリエステルを含む繊維を含み、かつ不織布層(A)よりもコポリエステル含有量が高い、任意のスパンボンド不織布層(B)と、
ニードリング済みの短繊維不織布層(C)であって、
単成分ポリエチレンテレフタレート(PET)短繊維(c1)と、
少なくとも1つのポリエチレンテレフタレート(PET)成分およびコポリエステル成分を含む多成分短繊維(c2)と
を含むニードリング済みの短繊維不織布層(C)と、
ポリエチレンテレフタレート(PET)およびコポリエステルを含む繊維を含み、かつ不織布層(E)よりもコポリエステル含有量が高い、任意のスパンボンド不織布層(D)と、
ポリエチレンテレフタレート(PET)およびコポリエステルを含む繊維を含む、スパンボンド不織布層(E)と
を(A)~(E)の順序で含む不織布積層体であって、いずれの層も溶融により互いに結合されている、不織布積層体である。
層(A)、(B)、(C)、(D)および(E)、
層(A)、(C)、(D)および(E)、
層(A)、(B)、(C)および(E)、または
層(A)、(C)および(E)
を所与の順序で含むことができ、ここで、層(A)、(C)および(E)が特に好ましい。
ISO 178:2019-04による曲げ強さが、330MPa以上であること、
ASTM 5034:2009による引張強さが、780N以上であること、および/または
DIN EN 29073-3:1992-08による引裂強さが、110N以上であること。
DIN EN ISO 1973:2020-05により決定された繊度が、2~7dTex、より好ましくは3~6dTex、さらにより好ましくは4~6dTexであること、
繊維長が、30~70mm、より好ましくは40~60mm、さらにより好ましくは45~55mmであること、
DIN EN 13844:2003-04により決定された強度が、1~6g/de、より好ましくは2~5g/de、さらにより好ましくは3~4g/deであること、
DIN EN ISO 5079:2020-01により決定された伸びが、20~60%、より好ましくは30~50%、さらにより好ましくは35~55%であること、
JIS L-1074により決定された捲縮数が、4~10個/インチ、より好ましくは5~9個/インチ、さらにより好ましくは6~8個/インチであること、
DIN EN 13844:2003-04により決定された75℃、15分での熱収縮率が、3~7%、より好ましくは4~6%、さらにより好ましくは3.5~4.5%であること、および
融点が、160~200℃、より好ましくは170~190℃、さらにより好ましくは175~185℃であること。
層(A)、(B)、(C)、(D)および(E)のコポリエステルが、ポリエチレンテレフタレートのコポリマーであり、該コポリマーが、160~240℃の融点を有し、
本発明の不織布積層体が、スパンボンド不織布層(B)およびスパンボンド不織布層(D)を含み、該層がいずれもコポリエステルからなり、かついずれもDIN EN 29073-1:1992-08による10~20g/m2の目付を有し、かつ
ニードリング済みの短繊維不織布層(C)が、40~60%の単成分短繊維(c1)および40~60%の多成分短繊維(c2)からなる
ことが好ましい。
本発明の不織布積層体が、スパンボンド不織布層(B)もスパンボンド不織布層(D)も含まず、
層(A)、(C)および(E)のコポリエステルが、ポリエチレンテレフタレートのコポリマーであり、該コポリマーが、160~240℃の融点を有し、かつ
ニードリング済みの短繊維不織布層(C)が、40~60%の単成分短繊維(c1)および40~60%の多成分短繊維(c2)からなる
ことが好ましい。
ニードリングにより、ニードリング済みの短繊維不織布層(C)を製造するステップと、
層(A)~(E)の順序で提供するステップと、
層(A)~(E)を溶融により互いに結合させるステップと
を含む方法も、本発明の主題である。
図1に、本発明による好ましい5層の不織布積層体1を示す。この5層の不織布積層体1は、第1の外層2(層(A)に相当)、第1の接着層3(層(B)に相当)、コア層4(層(C)に相当)、第2の接着層5(層(D)に相当)、および第2の外層6(層(E)に相当)を含む。この積層体のこれらの層は、機械的に結合させたものではない。この積層体のこれらの層は、溶融のみによって互いに結合させたものである。
不織布積層体構成の材料、および該不織布積層体を含むアンダーボディシールドの材料:
短繊維(コア層4用):
50%の単成分短繊維(c1):
材料:r-PET
短繊維長:64mm
繊度:6.7dTex。
構成:シース・コア型
材料:PETシース;融点180℃のコポリエステルコア
短繊維長:51mm
繊度:5dTex。
材料:PET 90%、PETのコポリエステル(CoPET)10%
目付:90g/m2
厚さ:0.33~0.59mm
長繊維径:25~60μm。
PETのコポリエステル(CoPET)100%
目付:16g/m2
厚さ:0.15~0.45mm 長繊維径:25~60μm。
このシートカット済みの材料を、210℃まで加熱したオーブンに3分間(通風オーブンの場合)または1分間(赤外線オーブンの場合)導入した。熱でこの材料が柔らかくなった。次いで、すぐにコールドプレスに移して、この材料を高圧(50トン以上)で成形した。
製造したアンダーボディシールドのサンプルを、アルファキャビン(Alpha-Cabin)と称される機器でその音響特性について試験した。アルファキャビンにおいて、試験サンプルを2mmのエアギャップで壁または床の近傍に置く。次いで、キャビン内の一連のセンサーによってサンプルの吸音率を測定する。成形済みの厚さが3mm、4mmおよび5mmであるサンプルのアルファキャビン試験の結果を、以下の表1に示す。
冷間成形プロセスでは、不織布積層体を、目付に応じて180℃~220℃の温度範囲で1~5分間予熱する。これは、バインダーとして作用する低融点コポリエステルを活性化させることが目的である。バインダーの活性化によってバインダーが溶融して、バージンまたは再生PET繊維間に一種のグルーを形成する。またこれは、短繊維不織布層とスパンボンド不織布層との間のグルーとしても作用する。活性化後、不織布積層体を圧縮金型に配置する。次いで、この圧縮金型は、50トン~200トンのトン数で不織布積層体のすべてまたは一部を圧縮することができる。不織布積層体を、金型内に最大60秒間保持することができる。圧縮した不織布積層体を金型の内部または外部で冷却させて、短繊維におけるおよびスパンボンド構成体におけるコポリエステル繊維をその融点未満に冷却させる。その後、この不織布積層体をその最終形状に変換する。この材料の最終厚さは、目的の用途の要件に応じて2mm~6mmである。次いで、この不織布積層体を必要に応じてトリミングするが、これを、機械的、熱的またはウォータージェットによる切断によって実現することができる。
熱間成形プロセスでは、不織布積層体を一対の高温圧縮金型プレートの間に配置する。次いで、これらのプレートを、材料の厚さ未満の所望の厚さに近づける。例えば、不織布積層体の厚さが6mmの場合には、プレート間の厚さは2mm~5mmである。これらの成形プレートを、180℃~220℃の範囲の温度に加熱する。次いで、不織布積層体を目付に応じて1~3分間圧縮し、これにより低融点コポリエステル(またはバインダー)を活性化させる。バインダーの活性化によってバインダーが溶融して、バージンまたは再生PET繊維間にグルーを形成する。またこれは、短繊維とスパンボンドとの間のグルーとしても作用する。不織布積層体のすべてまたは一部の圧縮を、50トン~200トンのトン数で行うことができる。圧縮した不織布積層体を金型の内部または外部で冷却させて、短繊維におけるおよびスパンボンド構成体におけるバインダー繊維をその融点未満に冷却させる。その後、この不織布積層体をその最終形状に変換する。この材料の最終厚さは、目的の用途の要件に応じて2mm~6mmである。次いで、この不織布積層体を必要に応じてトリミングするが、これを、機械的、熱的またはウォータージェットによる切断によって実現することができる。
1000g/m2、1200g/m2および1400g/m2のさまざまな重量で、厚さ2mmの成形済み不織布積層体サンプルについて機械的特性も試験した。試験結果を表4に示す。
図7a、7bおよび7cは、米国特許出願公開第2016/0288451号明細書によって製造されたニードリング済みの不織布の顕微鏡画像である。それらの繊維層は、ニードリングで機械的に接合されており、すなわちそれらは機械的に互いに結合されている。参照番号14は、ニードリングに起因して繊維密度が比較的低い領域を示す。ある層(コア層)のいくつかの繊維が、隣接する層(スパンボンド外層)へと延び、それを貫通していることが分かる。それにより各繊維の交絡が形成され、これによって2層間の機械的結合が生じる。このような結合は、層状構造のさらなる圧縮および成形時に変形を引き起こすことがあり、波状の外観(象皮状物)を伴う不均一な生成物を招く。
Claims (14)
- ポリエチレンテレフタレート(PET)およびコポリエステルを含む繊維を含む、スパンボンド不織布層(A)と、
ポリエチレンテレフタレート(PET)およびコポリエステルを含む繊維を含み、かつ前記不織布層(A)よりもコポリエステル含有量が高い、任意のスパンボンド不織布層(B)と、
ニードリング済みの短繊維不織布層(C)であって、
単成分ポリエチレンテレフタレート(PET)短繊維(c1)と、
少なくとも1つのポリエチレンテレフタレート(PET)成分およびコポリエステル成分を含む多成分短繊維(c2)と
を含むニードリング済みの短繊維不織布層(C)と、
ポリエチレンテレフタレート(PET)およびコポリエステルを含む繊維を含み、かつ不織布層(E)よりもコポリエステル含有量が高い、任意のスパンボンド不織布層(D)と、
ポリエチレンテレフタレート(PET)およびコポリエステルを含む繊維を含む、スパンボンド不織布層(E)と
を(A)~(E)の順序で含む不織布積層体であって、いずれの層も溶融により互いに結合されている、不織布積層体。 - 層(A)、(B)、(C)、(D)および(E)がいずれも、他の層(A)、(B)、(C)、(D)および(E)のいずれにも機械的に結合されていない、請求項1記載の不織布積層体。
- 前記ニードリング済みの短繊維不織布層(C)が熱収縮している、請求項1または2記載の不織布積層体。
- 前記不織布積層体が、ポリオレフィンを含まず、特にポリプロピレンを含まない、請求項1から3までのいずれか1項記載の不織布積層体。
- 前記不織布積層体が、無機強化材を含まず、特にガラス繊維を含まない、請求項1から4までのいずれか1項記載の不織布積層体。
- 前記不織布積層体が、以下の特性:
ISO 178:2019-04による曲げ強さが、330MPa以上であること、
ASTM 5034:2009による引張強さが、780N以上であること、および/または
DIN EN 29073-3:1992-08による引裂強さが、110N以上であること
のうちの少なくとも1つを有する、請求項1から5までのいずれか1項記載の不織布積層体。 - 前記層(A)、(B)、(C)、(D)および(E)のコポリエステルが、ポリエチレンテレフタレートのコポリマーであり、前記コポリマーが、240℃以下の融点を有する、請求項1から6までのいずれか1項記載の不織布積層体。
- 層(A)および(E)が、10%~70%のコポリエステル、特に少なくとも30%のコポリエステルを含む、請求項1から7までのいずれか1項記載の不織布積層体。
- 前記不織布積層体が、スパンボンド不織布層(B)および/またはスパンボンド不織布層(D)を含み、
スパンボンド不織布層(B)および/またはスパンボンド不織布層(D)が、DIN EN 29073-1:1992-08による1~100g/m2の目付を有する、
請求項1から8までのいずれか1項記載の不織布積層体。 - ニードリング済みの短繊維不織布層(C)が、
10~90%の単成分短繊維(c1)および10~90%の多成分短繊維(c2)からなり、かつ/または
DIN EN 29073-1:1992-08による1700g/m2以下の目付を有する、
請求項1から9までのいずれか1項記載の不織布積層体。 - 前記不織布積層体が、スパンボンド不織布層(B)もスパンボンド不織布層(D)も含まず、
前記層(A)、(C)および(E)のコポリエステルが、ポリエチレンテレフタレートのコポリマーであり、前記コポリマーが、160~240℃の融点を有し、かつ
ニードリング済みの短繊維不織布層(C)が、40~60%の単成分短繊維(c1)および40~60%の多成分短繊維(c2)からなる、
請求項1から6までのいずれか1項記載の不織布積層体。 - 請求項1から11までのいずれか1項記載の不織布積層体を含む、成形物品。
- アンダーボディシールドのための、またはホイールアーチライナーのための、特にアンダーボディシールドのための、請求項1から12までのいずれか1項記載の不織布積層体または成形物品の使用。
- 請求項1から11までのいずれか1項記載の不織布積層体の製造方法であって、
ニードリングにより、ニードリング済みの短不織布層(C)を製造するステップと、
層(A)~(E)の順序で提供するステップと、
層(A)~(E)を溶融により互いに結合させるステップと
を含む、方法。
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ES2969784T3 (es) * | 2020-12-04 | 2024-05-22 | Freudenberg Carl Kg | Tela no tejida gofrada para el habitáculo de vehículos |
EP4241979A1 (en) | 2022-03-10 | 2023-09-13 | Carl Freudenberg KG | Sustainable nonwoven laminate for structural part applications |
JP2024056619A (ja) | 2022-10-11 | 2024-04-23 | カール・フロイデンベルク・カーゲー | 不織布積層体 |
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JP5179558B2 (ja) | 2010-11-09 | 2013-04-10 | 株式会社サンセイアールアンドディ | 遊技機 |
JP2018518382A (ja) | 2015-03-31 | 2018-07-12 | フロイデンベルグ パフォーマンス マテリアルズ エルピー | 成形可能な複合材マット |
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DE102004054299A1 (de) * | 2004-11-09 | 2006-05-11 | Carcoustics Tech Center Gmbh | Akustisch wirksames Teppichformteil für Kraftfahrzeuge und Verfahren zu dessen Herstellung |
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US10981606B2 (en) | 2015-05-12 | 2021-04-20 | Hanwha Azdel, Inc. | Underbody shield compositions and articles that provide enhanced peel strength |
JP6171075B1 (ja) * | 2016-12-01 | 2017-07-26 | 株式会社アクト | 積層シート及びその製造方法 |
JP7191656B2 (ja) | 2017-11-27 | 2022-12-19 | 日本バイリーン株式会社 | 成型用基材不織布及びこれによって得られる成型体 |
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