201207176 六、發明說明： 【發明所屬之技術領域】 本發明是有關質輕且體積高，同時’通氣性、隔熱性、 耐久性、成形性、回收再利用性優良的不織纖維成形體， 以及該不織纖維成形體的製造方法。 【先前技術】 作為質輕材料的發泡苯乙稀(Styrol ;聚苯乙稀發泡體） 一直以來都被廣泛地使用著。發泡苯乙烯是輕質、隔熱性、 成形性、衝擊吸收性優異，係作為緩衝或梱綁包裝材，或 是必要物的保溫或保冷之隔熱材使用。然而，當發泡苯乙 烯的局部負重時就成為凹陷之形狀而不會回復原形，或是 受到彎曲應力時就容易折斷，而耐久性低。又，作為頭盔（安 全帽）之衝擊緩衝材等使用的情形，由於沒有通氣性，故容 易悶熱。 作為緩衝材者，由於軟質聚胺脂發泡體(urethane foam) 之觸感與視覺的風味良好並且形態安定性優異而被廣泛使 用。然而，一般軟質聚胺脂發泡體由於是獨立發泡，故沒 有通氣性而容易悶熱。又，容易引起耐候劣化或黃變，故 财久性也低。在回收再利用方面，由於燃燒時會發生有毒 害的NOx、CO氣體，而成為不適合熱回收的材料。作為 材料回收者’雖然有利用將聚胺脂發泡體廢料經破碎後之 聚胺脂小片加以再成形的方法，但必需要添加為了將破碎 後之聚胺脂互相連結的黏著劑。 在此，已知作為質輕，且通氣性、耐久性、隔熱性、 4 322972 201207176 耐折性優異的材料者，係將含有濕熱接著性纖維的不織纖 維網[本文中的『網web』表示不規則的纖維團，有稱為棉 * 網的情形並不是net]加以積層，再藉由高溫水蒸氣加熱， 、 而成為有不織纖維結構，且在厚度方向以均勻之接著率融 著濕熱接著性纖維的硬質成形體（專利文獻1 :國際公開 WO2007/116676號公報）。然而，在此成形體，將梳棉網 (card web)以蒸氣濕熱接著之際，由於纖維集合體之表觀密 度會上昇，而得不到0.05 g/cm3以下的成形體。又，由 於是在2台的皮帶輸送機之間將網挾住成形的方法，故有 可能作成板形狀的成形體者，要作成複雜的3次元結構物 就有困難。 作為纖維集合體的3次元結構物之方法，已知有將纖 維材料與黏著劑充填到模具内的熱成形方法（專利文獻2 : 曰本特開2000-238057號公報）。然而，此方法，為了接著 纖維，有必要將黏著劑一起充填，又將黏著劑均勻地付著 在纖維中是很困難的 工作。 [先前技術文獻] (專利文獻） 專利文獻1 :國際公開WO2007/116676號公報 專利文獻2:日本特開2〇〇〇_238〇57號公報 【發明内容】 [發明欲解決之課題] 因此，本發明之目的是提供有不織纖維結構，質輕且 體積高，同時，成形性優，即使複雜的三次元形狀也可以 322972 5 201207176 簡單地成形的不織纖維成形體及其製造方法。 本發明之另一目的是提供回收利用性優的不織纖維 成形體及其之製造方法。 本發明之另外之目的是提供通氣性、隔熱性、财久性 優異的不織纖維成形體及其之製造方法。 本發明之別的目的是提供質輕且吸音性優，同時，形 態安定性也優異的不織纖維成形體及其之製造方法。 [解決課題之手段] 本發明人等為了達成前述課題經過精心研究之結 果，顯現，將含有濕熱接著性纖維之複數之不織纖維集合 體藉由前述濕熱接著纖維的融著及固定，可以有不織纖維 結構，質輕且體積高，同時，成形性優，即使複雜的三次 元形狀，也可以簡單地形成，遂而完成本發明。 亦即，本發明的不織纖維成形體，係以複數的不織纖 維集合體所形成的不織纖維成形體，前述不織纖維集合體 為含有濕熱接著性纖維，且前述不織纖維集合體相互間為 藉由前述濕熱接著性纖維的融著而固定。此成形體的表觀 密度也可以有0.01至0.7 g/cm3。前述不織纖維集合體藉 由濕熱接著性纖維的融著也可以固定纖維。本發明的不織 纖維成形體中，前述不織纖維集合體為不定形狀，並且， 集合體表面中濕熱接著性纖維的根數比率也可以為50 % 以上。又，前述不織纖維集合體為各向異性形狀，且各不 織纖維集合體也可以為在不規則之方向配向。前述不維集 合體也可以由藉由濕熱接著性纖維的融著所固定織纖的不 6 322972 201207176 織纖維集合體或該不織纖維集合體而得到成形體的廢料。 前述不織纖維集合體的體積也可以有〇 〇1至3〇〇 cm3左 • 右。 、 本發明的不織纖維成形體，其表觀密度為0.01至0.05 g/cm3左3右，藉由Frazir Type法的通氣度也可能為Q1 至300 cm /cm •秒鐘）程度，並且熱傳導率為〇 至〇」 W/m _ k程度。 則述不織纖維集合體可以用濕熱接著性纖維單獨形 成，也可以由濕熱接著性纖維/非濕熱接著性纖維=1〇/ 90至100/0的範圍選擇。前述不織纖維集合體也可以復 二接者性纖維’濕熱接著性纖維與非濕熱接著性 二4 質量比）也可以是濕熱接著性纖維/非濕埶接 著性纖維=1〇/9〇至99/1。 /非I"接 。/的熱接著性纖維係以乙埽單元含量至6〇莫耳 =二=共聚合Γ與非濕熱接著性樹脂所形 比率(f量比)為前者Λ系：:二與至非^^ 乙烯一乙烯醇系丑 /90，並且前述 前述濕熱接著性纖維表面的至少一部份。態佔有 = = == = =脂所構成：是: 組中之至少—種類的非濕;接著群 成的芯鞘複合纖維。 7耩成的芯部 水蒸; 本發明的不織纖維成形體，也可以是使用高况 322972 7 201207176 將前述不織纖維集合體相互間熱接著。 本發明中也包含前述成形體的製造方法，係含有將複 數的不織纖維集合體熱接著的步驟。前述熱接著也可以是 使用高溫水蒸氣來熱接著。 [發明效果] 本發明由於將含有濕熱接著性纖維的複數之不織纖 維集合體藉由前述濕熱接著性纖維的融著而固定，而有不 織纖維結構，質輕且體積高，同時，成形性優，即使複雜 的三次元形狀也可以簡單地成形。又，作為不織纖維集合 體者，由於可以將不織纖維集合體的廢材，例如，在製造 過程等發生的切割末端，或廢棄物或使用過之不織纖維集 合體，加以破碎或切斷處理之集合體等加以利用，故回收 利用性方面也優異。又，由於有不織纖維結構，故可以提 高通氣性、隔熱性、财久性。又，質輕在吸音性方面優異， 同時，形態安定性（或是自立性）方面也可以提高。 【實施方式】 [實施發明之最佳形態] [不織纖維集合體] 在本發明中，由於複數的不織纖維集合體（不織纖維集 合體單元或粒狀不織纖維集合體），係在各不織纖維集合體 所含之濕熱接著性纖維為在集合體相互間的接觸部分形成 接著點，故可以製造全體為體積高且質輕的成形體。 (濕熱接著性纖維） 濕熱接著性纖維至少是以濕熱接著性樹脂所構成。濕 8 322972 201207176 熱接著性樹脂係藉由高溫水蒸氣在容易可實現之溫度中， 只要可能流動或容易變形並能顯現接著機能就可以。具體 i 上，以熱水（例如：80至12(TC，尤其是95至100°C程度） v 軟化後自己接著或是在其他纖維上可以接著的熱可塑性樹 脂’例如’可列舉：纖維素系樹脂（甲基纖維素等之Ci ^ 炫基纖維素、羥基甲基纖維素等之羥基Cii3烷基纖維素、 竣基曱基纖維素等之羧基Cm烷基纖維素或其鹽等）、聚 伸烧基一醇樹脂（聚伸乙基氧化物、聚伸丙基氧化物等之聚 伸C2 i 4烧基氧化物等）、聚乙烯系樹脂（聚乙烯基0比咯烷 酮、聚乙烯基鱗、乙烯醇系聚合物、聚乙稀基縮酿等）、丙 烯酸系共聚物及其鹽[含有（甲基）丙烯酸、（曱基）丙烯醯胺 等丙稀酸系單體所構成的單元之共聚物或其鹼金屬鹽 等]、改質乙烯系共聚物（異丁烯、苯乙烯、乙烯、乙烯基 醚等之乙烯基系單體，與馬來酸酐等之不飽和羧酸或其酸 酐的共聚物或其鹽等）、導入親水性取代基之聚合物（導入 磺酸基或羰基、羥基等之聚酯、聚醯胺、聚笨乙烯或其鹽 等）、脂肪族聚酯系樹脂（聚乳酸系樹脂等）等。又，也包含 聚烯烴系樹脂、聚酯系樹脂、聚醯胺系樹脂、聚胺酯系樹 脂、熱可塑性彈性體或橡膠（苯乙烯彈性體等）等之中，也 包含在熱水（高溫水蒸氣）之溫度中軟化後能顯現接著機能 的樹脂。 此等濕熱接著性樹脂’可以單獨使用，也可以組合2 種以上而使用。濕熱接著性樹脂通常是以親水性高分子或 水溶性樹脂所構成。此等濕熱接著性樹脂之中，以乙嫦_ 322972 9 201207176 乙烯醇共聚物等之乙烯醇系聚合物、聚乳酸等之聚乳酸系 樹脂、含（曱基）丙烯醯胺單元之（曱基）丙烯酸系共聚物，尤 其是含乙烯或丙烯等之a —C2至10烯烴單元的乙烯醇系聚 合物、特別是以乙烯一乙烯醇系共聚物為佳。 乙稀一乙烯醇系共聚物中，乙烯單元的含量（共聚合比 率），例如是10至60莫耳％，以20至55莫耳％為佳，更 佳是30至50莫耳％程度。由於乙烯單元在此範圍内，可 以得到雖然有濕熱接著性，但無熱水溶解性之特異性質。 乙烯單元的比率太少時，乙烯一乙烯醇系共聚物在低溫之 蒸氣（水）中容易膨脹濕潤或凝膠化，在水中只暫時濕濡就 容易形態變化。另一方面，乙烯單元的比率過多時，吸濕 性降低，由於濕熱而難顯現纖維融著，故變成難以確保實 用性的強度。乙烯單元的比率，尤其是在30至50莫耳％ 的範圍時，加工性特別優異。 乙烯一乙烯醇系共聚物中，乙烯醇單元之鹼化度，例 如是90至99.99莫耳％左右，以95至99.98莫耳％為佳， 更佳是96至99,97莫耳％程度。鹼化度太少時，熱安定性 下降，由於熱分解或凝膠化而安定性降低。另一方面，鹼 化度太多時，纖維本身之製造會變困難。 乙烯一乙烯醇系共聚物的黏度平均聚合度，因應需要 是可以選擇，例如是200至2500,而以300至2000為佳， 更佳是400至1500程度。聚合度在此範圍時，紡絲性與濕 熱接著性的平衡優異。 濕熱接著性纖維的橫截面形狀（與纖維的長度方向成 10 322972 201207176 垂直的截面开>狀），不限S為圓型戴面或異型截面[偏平 狀、橢圓狀、多角形狀、3至14片葉狀、τ字狀、H字狀、 -V字狀、狗骨(1字形狀）等]’也可以是中空截面狀等。 ' ^濕熱接著性纖維也可以是至少由含有濕熱接著性樹 月曰的複數祕脂所構成之複合纖維。複合纖維、濕熱接著性 ^維’、要疋在至少纖維表面的—部分有濕熱接著性樹脂就 可乂由接著性之觀點而言，以長度方向連結之形態佔有 表面的至乂冑分濕熱接著性樹脂者為佳。濕熱接著性樹 脂的被覆率，彻 幻如疋在50%以上，而以80%以上為佳，以 90%以上為更佳。 社 為.’、熱接著性纖維佔有表面的複合纖維之橫截面 ° 可以列舉如：同芯芯鞘型、偏芯芯賴型、邊靠邊 (side by Side、刑〃 您罪理 、卜 、海島型、多層黏貼型、放射狀黏貼型、 :見丨複。型等。此等之橫截面結構中，從接著性高的結 有全表面 濕熱接著性樹脂以長度方向連結之形態佔 之結構的芯鞘型（即，鞘部為以濕熱接薯性樹脂所 構成㈣鞘型結構)為佳。 人，纖1維之情形，雖也可以將濕熱接著性樹脂相互組 性樹r去了 =與非濕熱接著性樹脂組合。作為非濕熱接著 系樹月:、二曰非水溶性或疏水性樹脂’可以列舉：聚稀烴 糸榭=基）丙烯酸系樹脂、氯化乙烯系樹脂、苯乙烯 系樹脂、聚酯系椒sa 个Q邱 聚胺醋系樹脂、叙曰、聚酿胺系樹脂、聚碳酸醋系樹脂、 樹脂，可以單獨^塑性彈性體等。此等之非濕熱接著性 却便用亦可以組合2種以上而使用。 322972 11 201207176 此等非濕熱接著性樹脂之中，從财熱性及尺寸安定性 之觀點而言’融點為比濕熱接著性樹脂（尤其是乙烯一乙烯 醇系共聚物）更高的樹脂 ，例如，聚丙烯系樹脂、聚酯系樹 脂、聚酿胺系樹脂，尤其是從耐熱性或纖維形成性等之平 衡優之觀點而言，以聚酯系樹脂、聚醢胺系樹脂為佳。 作為聚醋系樹脂者，以聚c 2至4伸烷基芳香族酸酯系 樹脂等的芳香族聚酯系樹脂（聚對苯二曱酸乙二酯（PET)、 聚對苯二甲酸三甲S旨、聚對笨二甲酸丁二醋、聚萘二曱酸 乙二酯等），尤其是以PET等之聚對苯二甲酸乙二酯系樹 脂為佳。聚對笨二曱酸乙二S旨系職，係在對苯二曱酸乙 二酯單元以外，亦可以含有其他之二羧酸(例如：間苯二曱 I萘2,6——羧酸、鄰苯二曱酸、4,4，一二苯基二羧酸、 雙(幾基笨基）乙燒、5 一納硫代間苯二甲酸等），或二醇(例 如.二乙二醇、丙二醇、14-丁二醇、1，6-己二醇、 新戍二ϋ、環己烷—二甲醇、聚乙二醇、聚四甲基二醇等) 所構成單元在2〇莫耳％以下程度的比率。 作為聚酿胺系樹脂者，以聚醯胺6、聚酿胺的、聚酿 :〇、聚酿胺1Q、聚醯胺12、聚醯胺6—12等之脂肪族 =胺及此之共聚物、由芳香族二_與脂肪族二酿胺所 :成二半料族聚醯胺等為佳。在此等之聚酿胺系樹脂 肀，也可以含有可以共聚合的其他單元。 著性樹脂與㈣熱接魏樹脂（纖維形成性聚 =)的比率（質量比）’可以因應結構(例如，抑型 選擇’濕熱接著性樹脂只要在表面存在著即可，而無特 322972 12 201207176 別限定’例如，濕熱接著性樹脂/非濕熱接著性樹脂=90 / 至 1〇/9〇 ’ 而以 8〇/2〇 至 15/85 為佳，以 60/40 至2〇/ 80程度為更佳。濕熱接著性樹脂之比率過多時， •很^續保纖維之強度’濕熱接著性樹脂之比率過少時，則 在纖維表面之長度方向連結並存在濕熱接著性樹脂變成有 困難’濕熱接著性會下降。此傾向係與將濕熱接著性樹脂 在非扁熱接著性樹脂之表面塗布之情开)相同。 濕熱接著性纖維的平均纖度，因應用途，例如，可以 自0.01至100 dtex程度之範圍選擇，而以〇」至5〇 dtex 為佳，以0.5至30 dtex(尤其是1至10 dtex)程度為更佳。 當平均纖度在此範圍時，纖維的強度與濕熱接著性的顯現 之平衡優異。 濕熱接著性纖維的平均纖維長，例如是可以自至 100 mm程度的範圍選擇，而以2〇至8〇 mm為佳，以25 至75 mm(尤其是35至55 mm)程度為更佳。當平均纖維長 在此範圍時，由於纖維有充分的糾纒，而可以提高纖維集 合體的機械強度。又，當纖維長太長時，就變成很難形成 均勻的單位面積重量的不織纖維集合體。 濕熱接著性纖維的捲縮率，例如是1至50%，而以3 至40°/。為佳，以5至3〇%(尤其是1〇至2〇%)程度為更佳。 又’捲縮數’例如是1至1〇〇個/25 mm，而以5至5〇個 /25 mm為佳，以1〇至3〇個/25 mm程度為更佳。加熱 後之捲縮數’例如是5個/25 mm以上(例如是，5至2〇〇 個/25 mm)，而以5至150個/25 mm為佳，以1〇至1〇〇 322972 13 201207176 個/25 mm程度為更佳。本發明藉由濕熱接著性纖維的捲 縮可以提高集合體單元相互間的接著性。 在不織纖維集合體中，除了此等纖維之外，在不損及 前述纖維的特性範圍内，也可以含有其他之纖維。作為其 他之纖維者，例如，除了在濕熱接著性纖維項中所例示的 非濕熱接著性樹脂之外，也可以使用：纖維素纖維[例如， 天然纖維(木綿、羊毛、絲、麻等）、半合成纖維（三醋酸酯 纖維等之醋酸酯纖維等）、再生纖維（嫘縈、高濕模量黏膠 纖維（Polynosic)、cupra(日本人造纖維之一種）、Lyocell(例 如，註冊商標「Tencel」纖維等）等]、無機纖維（例如，碳 纖維、玻璃纖維、金屬纖維等）。其他纖維的平均纖度及平 均纖維長是與濕熱接著性纖維同樣。此等其他之纖維，可 以單獨使用也可以組合2種以上而使用。 此等其他纖維之中，以嫘縈等再生纖維、醋酸酯等之 半合成纖維、聚丙烯或聚乙烯等之聚烯烴系纖維、聚酯纖 維、聚醯胺纖維等為佳。尤其，濕熱接著性纖維為聚酯系 纖維時，其他纖維也可以是聚酯系纖維。 濕熱接著性纖維的比率，相對於不織纖維集合體全 體，例如是10質量％以上，而以3 0質量％以上為佳。尤 其是從不織纖維集合體單元相互間的接著觀點而言，集合 體表面中濕熱接著性纖維的根數比率也可以是在30%以 上，例如是50%以上，以70%以上為佳，更佳是90%以上。 不織纖維集合體，也可以進一步含有慣用的添加劑， 例如：安定劑（銅化物等之熱安定劑、紫外線吸收劑、光安 14 322972 201207176 定劑、抗氧化劑等）、抗菌劑、消臭劑、香料、著色劑（染 料、顏料等）、充填劑、帶電防止劑、難燃劑、可塑劑、潤 滑劑、結晶化速度延緩劑等。此等添加劑，可以單獨使用 也可以組合2種以上而使用。此等添加劑，可以在纖維表 面擔持，也可以在纖維中含有。 (不織纖維集合體的特性） 前述不織纖維集合體（粒狀或塊狀不織纖維集合體）至 少是有以濕熱接著性纖維所形成的不織纖維結構。 又，本發明之不織纖維成形體中，由於具備高體積性 與通氣性之不織纖維結構，在前述不織纖維集合體的内部 形狀中，藉由濕熱接著性纖維的融著而有必要適度調整纖 維的接著狀態。 詳細而言，不織纖維集合體係以濕熱接著性纖維相互 間或與其他纖維之交叉點（即，濕熱接著性纖維相互間之交 接點，濕熱接著性纖維與其他纖維之交接點）融著為佳。在 本發明，不織纖維集合體中，構成不織纖維結構的纖維， 係藉由濕熱接著性纖維在各個之纖維的接觸點接著，為了 儘可能以少接點數保持纖維集合體的形態，該接著點為自 集合體的表面附近以在橫跨整個内部大致均勻地分布為 佳。 當接著點為集中在表面或内部等時，接著點少的部分 之形態安定性會降低。例如，以熱黏接法所得之高體積的 不織纖維集合體，雖是接近熱源部分為過度接著以致表面 硬化，但離熱源遠的内部是接著點少而形態不安定。又， 15 322972 201207176 因形成接著點，由於將過剩之熱經歷會賦與纖維，而變成 不能再度將不織纖維集合體互相接著。 相對於此，不織纖維集合體，自集合體的表面附近在 橫跨内部全體大致均勻地分布接著點，為了能效率佳地固 定纖維，不管藉由濕熱接著性纖維融著點數少也可以顯現 形態安定性，也可以兼具體積高性及通氣性。又，藉由濕 熱接著性纖維，由於融著各纖維，故可以抑制纖維的脫落， 故不易引起結構的破壤。又，由於以100至120°c程度的 水蒸氣軟化後接著，故濕熱接著性纖維不會受到過剩的熱 經歷，也不會受到為了在製造不織纖維集合體的暫時熱處 理，而有可能再度互相接著不織纖維集合體。 又，不織纖維集合體，藉由濕熱接著性纖維不僅融著 為均一地分散而成為點接著，且此等之點接著為短融著點 距離（例如是數十至數百// m)故能密緻的網路結構掛滿四 周。藉由有如此結構之不織纖維集合體形成成形體，本發 明的成形體即使有外力作用，也有對不正的追從性變高， 同時，在微細地分散的纖維之各融點由於外力的分散變 小，可以推定能顯現高的形態安定性。 不織纖維集合體的表觀密度，可以因應用途而選擇， 例如是0.05至0.7 g/cm3，而以0.08至0.5 g/cm3為佳， 更佳是0.1至0.4 g/cm3程度。尤其是製作硬質的成形體 的情形，表觀密度也可以是0.2至0.7 g/cm3，而以0.25 至0.65 g/cm3為佳，更佳是0.3至0.6 g/cm3程度。又， 製作軟質的成形體的情形，表觀密度也可以是0.05至0.5 g 16 322972 201207176 /cm3，而以0.08至0.4 g/cm3為佳，更佳是0.1至0.35 g /cm3程度。密度過小時，以現狀之製造方法製造是有困 . 難，而生產性下降。另一方面，密度太大時，質輕性或通 _ 氣性會下降。 不織纖維集合體的單位面積重量，例如是可以由50 至10000 g/m2程度的範圍中選擇，而以100至8000 g/ m2為佳，更佳是200至6000 g/m2程度。單位面積重量 太小時，很難確保硬度，又，單位面積重量太大時，纖維 網（web)變得太厚因而在濕熱加工中，高溫水蒸氣不能充分 進入網的内部，而在厚度方向有困難作成均勻的結構體。 藉由不織纖維集合體的Frazir Type法形成通氣度是 0.1cm3/(cm2·秒）以上[例如是 0.1 至 300 cm3/(cm2·秒）]， 而以1至250 cm3/(cm2 ·秒）為佳，更佳是5至200 cm3 /(cm2 ·秒)程度。通氣度太小時，高溫水蒸氣或熱風很難 到達内部，就變得很困難製造成形體。另一方面，通氣度 太大時，通氣性變高，但集合體内部的纖維空隙變得過大， 形態安定性會下降。 在不織纖維集合體中，構成不織纖維結構的纖維藉由 前述濕熱接著性纖維的融著，纖維接著率是可以自1至85 %程度的範圍選擇，硬質的成形體例如是10至85 %，而 以20至80 %為佳，更佳是30至75 %程度。又，軟質的 成形體，例如是1至60 %，而以2至50 %為佳，更佳是3 至35 %(特別是3至30 %)程度。又,不織纖維集合體在厚 度方向，三等分之各個領域中，相對於纖維接著率的最大 17 322972 201207176 值，最小值的比率（最小值/最大值）(纖維接著率為相對於 最大的領域之最小領域的比率），例如，5〇%以上（例如是 50至1〇〇%)，而以55至99 %為佳，以60至98%(特別是 70至97%)程度為更佳，在厚度方向中也可以均勻地接著。 纖維接著率及此之均勻性，在不織纖維截面中，相對於全 纖維截面數，可以根據2根以上接著的纖維截面數之比率 而算計出來，而可以在國際公開w〇2〇〇7 /116676號公 報（專利文獻1)所記载的方法測定。 不織纖維集合體的體積是可以自〇 〇1至300 cm3的範 圍選擇’而以0.1至l〇〇cm3為佳，更佳是〇 5至5〇项3。 不織纖維集合體的體積比〇〇1 cm3小時，密度很難作戍 0.05g/cm3以下的低密度成形體，比3〇〇cm3大時，模具 中充填集合體成开> 之際，就變成不能均勻地充填。 、 不織纖維集合體的形狀，也可以是球狀、骰子狀等的 等方形狀、棒狀（四方形狀、圓柱狀等）、板狀或薄片狀、 圓錐狀、角錐狀、塊狀、不定形狀等的各向異性形狀等。 此等形狀之中，從成形體的安定性等的觀點而言，以不定 形狀、棒狀、板狀或薄片狀等的各向異性形狀為佳。又， 各集合體的形狀，可以為相同的，亦可以為相異的。 不織纖維集合體的大小，可以因應目的的成形體而選 擇，例如是可以自平均徑1至500 mm程度的範圍選擇， 而以2至100 mm為佳，以3至5〇 mm(尤其是5至3〇坩功） 程度為更佳。 尤其是棒狀的情形，例如，長徑是3至1〇〇 mm，而 322972 18 201207176 以5至80 mm為佳，以l〇至50 mm(尤其是15至40 mm) 程度為更佳，截面的平均徑是0.1至50 mm，而以0.5至 .30 mm為佳，以1至20 mm(尤其是3至10 mm)程度為更 v 佳。 板收或薄片狀的情形，例如，平均形狀的平均徑是5 至300 mm，而以1〇至200 mm為佳，以15至100 mm(尤 其是20至80 mm)程度為更佳，厚度是0.1至30 mm，而 以0.3至20 mm為佳，以0.5至15 mm(尤其是1至10 mm) 程度為更佳。 各集合體的大小、形狀也都是一樣，可以是相同，亦 可以是相異。 不織纖維集合體中，濕熱接著性纖維與非濕熱接著性 纖維的比率（質量比），係濕熱接著性纖維/非濕熱接著性 纖維=10/90至100/0(例如是10/90至99/1 )，而以 30/70至100/0 (例如是30/70至95/5 )為佳，以50 /50至100/0(例如是50/50至90/10)程度為更佳。濕 熱接著性纖維的比率太小時，纖維集合體的形態容易崩 潰。從可以提高不織纖維集合體單元相互間的接著之觀點 而言，也可以是濕熱接著性纖維/非濕熱接著性纖維=70 /30 至 100/0，而以 80/20 至 100/0 為佳，以 90/10 至100/0程度為更佳，也可以濕熱接著性纖維單獨來形 成。 不織纖維集合體，進一步也可以含有捲縮纖維。捲縮 纖維也可以是熱收縮率不同的複數樹脂形成相分離結構的 19 322972 201207176 複合纖維。例如，可以利用在日本特開2009—97133號公 報、日本特開2009- 183363號公報、日本特開2010 — 84284號公報等所揭示的捲縮纖維。捲縮纖維的比率，相 對於不織纖維集合體全體，係在50質量％以下，而以1至 40質量％為佳，以5至30質量％程度為更佳。 [不織纖維成形體] 本發明之不織纖維成形體是以組合複數的前述不織 纖維集合體單元而形成，將前述不織纖維集合體單元相互 間藉由濕熱接著而形成成形體。各不織纖維集合體的配向 (尤其是各向異性形狀之集合體的配向），並無特別限定， 也可以是規則配向，也可以是無規則配向。本發明之不織 纖維成形體，也可以是在各不織纖維集合體之間有空隙 部，雖然也可以特別有貫通成形體之空隙部，但各不織纖 維集合體相互間以相互密接者為佳，尤其是在硬質的成形 體，各單元為相互密接接著，無貫通成形體之空隙部為佳。 第1圖是將不織纖維集合體規則地配向的本發明之不 織纖維成形體的一個'例子的模示圖。該不織纖維成形體1 係將截面略為長方形狀的棒狀不織纖維集合體以複數組合 而形成，主要的不織纖維集合體2為將長度方向與面方向 平行配向並配列，關於所定之間隔，不織纖維集合體3為 將長度方向與面方向垂直配向並配列。該成形體，相對於 將長度方向與面方向平行配向的棒狀集合體，係將長度方 向與面方向垂直配向的棒狀集合體因為是有適當的間隔地 存在，故棒狀集合體是面方向及厚度方向中平衡良好地接 20 322972 201207176 著，成形體是有均勻的強度。 第2圖是將不織纖維集合體不規則地配向的本發明 之不織纖維成形體的一個例子的概略斜視圖。該不織纖維 成形體11係將截面略為正方形狀的棒狀不織纖維集合體 12以複數組合而形成，各不織纖維集合體12是在不規則 的方向配向而配設。該成形體，由於各向異性形狀的不織 纖維集合體為在不規則的方向配向，故各不織纖維集合體 為藉由各個方向的配列，集合體相互間的接著點有適度間 隔隔開而均勻地分散，在成形體内部形成適度空隙部。因 此，如此之成形體，質輕性及通風性優異，並且，藉由棒 狀集合體的無規則配向，可以顯現也有均勻的強度及耐折 性。 第3圖是表示使不織纖維集合體在不規則方向配向的 本發明不織纖維成形體之其他例子的概略斜視圖。該不織 纖維成形體21是將平面形狀為不定形狀的板狀之不織纖 維集合體22以複數組合而形成，各不織纖維集合體22是 在不規則的方向配向而配列。該不織纖維集合體是軟質 者，在不織纖維集合體之中，也包含以折疊狀態與其他集 合體接著的集合體。在該成形體，由於板狀的不織纖維集 合體為面接觸，並不限定是柔軟的，作為成形體的一體性 都優異，如此之成形體，緩衝性優異，同時，不容易分離， 由於可以保持一體性，故適合作為棉被的綿等之用途。 此等之成形體之中，不織纖維集合體的形狀為各向異 性形狀的情形，從生產性高，並且質輕性或成形體的強度 21 322972 201207176 之均勻性也高的觀點而言，各不織纖維集合體以在無規則 的方向配向之成形體為佳。 (不織纖維成形體的特性） 進一步，為了將本發明之不織纖維成形體製作成具備 高體積性、通氣性、耐久性、與成形性的成形體，在成形 體的内部形狀中，藉由不織纖維集合體相互間的融著，接 著狀態有必要適當地調整。 本發明之不織纖維成形體，係以與前述不織纖維集合 體單元相互間或與其他結構單元（不含濕熱接著性纖維的 纖維集合體或粒狀物等）的交點（即，不織纖維集合體的交 點，不織纖維集合體與其他結構單元的交點）融著後而接著 為佳。由於各不織纖維集合體單元相互間融著，故也可以 抑制不織纖維集合體的脫落，不易引起結構的破壤。又， 由於以100至120°c程度的水蒸氣軟化後而接著，因為不 織纖維集合體不會受到過剩熱經歷，故可能再度相互間接 著不織纖維集合體，且回收再利用性優。 不織纖維集合體相互間的接著點面積（1個的不織纖維 集合體單元是與鄰接之不織纖維集合體單元，或其他結構 單元以複數處所接著的情形，各接著點面積）是有0.1至 100 cm2，而以1至10 cm2為佳，以1至5 cm2為更佳。比 0.1 cm2的接著面積小時，受到外力時結構就容易破壌，又 大於100cm2時，因為會失去成形性而不可能成形複雜的3 次元結構物。 本發明之不織纖維成形體的密度，具體上，表觀密度 22 322972 201207176 例如，可以自001至0.7 g/cm3程度之範圍選擇，例如是 0.02 至 0.4 g/cm3，而以 0.05 至 0.4 g/cm3 為佳，以 0.07 . 至0.3 g/cm3為更佳。表觀密度過低時，固然通氣性會提 高，但形態安定性會下降，相反的，太高時，雖然形態安 定性是可以確保，但通氣性會下降，而損及質輕性。在本 發明藉由均勻性高的融著，一方面有比較的低密度，一方 面可以保持成形體的形態。 又，如前述，各不織纖維集合體，由製造上的限制， 調製0.05 g/cm3以下成形體是有困難，相對於此，在本 發明中，藉由組合複數的不織纖維集合體單元而成形，可 以調製以往的不織纖維集合體不能達到的低密度的成形 體。即，本發明的不織纖維成形體之表觀密度，例如，也 可以是0.01至0.05 g/cm3程度的低密度。 本發明的不織纖維成形體，由於有不織纖維結構，而 在纖維間產生有空隙。此等空隙是與如海綿般的樹脂發泡 體不同，由於不是各自獨立的空隙而是連續的，故有通氣 性。本發明的成形體的通氣度，藉由Frazir Type法的通氣 度有0.1 cm3/(cm2·秒）以上（例如是0.1至300 cm3/ (cm2 ·秒）），而以0.5至250 cm3/(cm2 ·秒）(例如是1至 250 cm3/(cm2 ·秒))為佳，以 5 至 200 cm3/(cm2 ·秒）程 度為更佳，通常有1至100cm3/(cm2 ·秒)程度。通氣度 太小時，在成形體中為了使空氣通過而必需自外部加入壓 力，導致自然的空氣出入變成困難。另一方面，通氣度過 大時，則通氣性是變高，致成形體内的纖維空隙會變得過 23 322972 201207176 大，形態安定性會下降。 本發明的不織纖維成形體的隔熱性也高，熱傳導率低 到0.1 W/m.K以下，例如是0.03至0.1 W/m.K，而以 0.05至0.08 W/m.K程度為佳。 本發明的不織纖維成形體除了不織纖維集合體之 外，在不損及前述不織纖維集合體的特性範圍内，也可以 含有其他結構谷或結構材料（或粒狀物）。作為其他結構單 元者，係不含濕熱接著性纖維，可列舉，以非濕熱接著性 纖維所形成的纖維集合體（例如是不織纖維集合體等）等。 其他結構單元的比率，相對於成形體全體，也可以是在10 重量％以下（尤其是5重量％以下）。本發明的不織纖維成形 體，也可以將在前述不織纖維集合體項中所例示的慣用之 添加劑同時摻配在不織纖維集合體中。 本發明的不織纖維成形體的形成，由於是組合複數的 不織纖維集合體而形成，故不限定薄片狀或板狀等的二次 元形狀，可以形成各種的三次元形狀。 [不織纖維成形體的製造方法] 本發明的不織纖維成形體的製造方法，包含將複數的 不織纖維集合體熱接著的步驟。本發明的方法，進一步也 包含形成不織纖維集合體的成形步驟。 (不織纖維集合體的成形步驟） 在不織纖維集合體的成形步驟中，首先，將含有前述 濕熱接著性纖維的纖維網狀化。作為形成網的方法者，可 以利用慣用的方法，例如是：絲織黏接法（spunbond)、溶 24 322972 201207176 融流動法（meltblow)等的直接法、使用熔融流動纖維或短 絲纖維（staple fibre)等的梳棉法(card method)、充空氣法等 . 的乾式法等。此等方法之中，使用熔融流動纖維或短絲纖 維的梳棉法’尤其是以使用短絲纖維的梳棉法最為廣泛。 使用短絲纖維而得之網者，例如可列舉：無規則網、半無 規則網、同方向的網、交聯重疊網等。 其次，所得纖維網是藉由輸送帶送到其次的步驟去’ 以高溫水蒸氣加熱處理，進而濕熱接著性纖維互相融著。 在本發明中作為加熱的方法，藉由使用以高溫水蒸氣處理 方法’由纖維集合體的表面橫跨内部全部，可以顯現均勻 的融著。又’作為融著步驟的前步驟者’從抑制纖維飛散 的觀點而言，也可以經過將所得纖維網的一部分纖維，藉 由喷射低壓力水(例如是〇.1至1 5 MPa，較佳是〇·5至1 MPa程度的水）等喷霧或喷射（喷灑）而交纒的方法等能輕 度地交纒的步驟。 具體上，所得之纖維網是藉由輸送帶運送到其次的步 驟去，然後藉由過熱或高溫純（高壓蒸氣）流的喷灑，而 得到有不織纖維結構的纖維集合體。即，以輪送帶搬運的 纖維網通過自蒸氣喷射裝置的喷嘴所喷出的高速高溫水蒸 氣流之中時，藉由喷吹的高溫水蒸氣，而融著濕熱接著性 纖維。尤其是本發明中，由於纖維網有通氣性，故高溫水 蒸氣可以浸透到内部，可以得到有略為均句組織的纖維集 合體。 〃 使用的輸送帶’只要基本上不會將在加工中使用的纖 322972 25 201207176 維網形態變亂而可以古、、σ 定，適合使用環:二蒸=即:，而無特別的限 田了 般的單獨輸送帶’ 間:住網之;另外一台之輸送帶機，以在兩皮帶之 之f運。藉由如此之搬運，在處理纖維網 動ΐ之外力理中使㈣水、高溫水蒸氣、輸送帶的振 動等之外力，可以抑制所搬運的纖_形態之變形。又， 藉=整該輸送帶的間隔，而可以抑制處理後的不織纖維 的密度或厚度。 為了供應水蒸氣到纖維網，可以使用慣用的水赛氣喷 射裝置。作為該水蒸氣喷射裝置者，以所期望的壓力與量， 在全部網全寬中以可以概略地均勻地吹付水錢的裝置為 宜。組合2台輸送帶的情形，在—邊的輸送帶内裝置，經 由通水性的輸送帶，或是通過在輸送帶上所载置的輸送網 供給水錢到網上。在另—邊的輸送帶也可以裝置吸水箱 (SUCti〇n b〇X )。藉由吸水箱，可以吸引排出通過纖維網的 過剩水蒸氣。X，纖維網的表及裡的兩側為了暫時水蒸氣 處理，進—步在裝著錢水蒸氣噴射裝置的輸送帶之錢 的輸送帶中，在比裝置前述水蒸㈣射裝置部位 游 部的輸送㈣也可以設置其他的錢㈣射駿置 2的蒸氣喷射裝置及財箱之情形，蒸氣處理纖維網的 表及裡的情形，也可以將暫時經處理的纖維網 而通過再度處理裝置内來代替。 裡反轉 在輸送帶使用環狀帶，只要不妨礙纖維網的搬運或高 溫水蒸氣處理即可，而無特別限定。但是，在進行高溫水 322972 26 201207176 時隨著其條件在纖維網表面因有轉印皮帶表面 矣 '月形故以因應用途而適當選擇為佳。尤其是在得 • 1 ®平坦的纖維集合體時’只要使用網眼…細的網 網二II日又卩9〇網眼左右為上限，A概比90網眼粗的 絪，’、々是10至50網眼程度的網）為佳。此以上網眼的細 料通，I1 生低水蒸氣通過變困難。網眼皮帶的材質，從 、於水蒸氣處理的耐熱性等之觀點而言，以金屬、經财熱 處理的聚醋系樹脂、聚伸苯基硫化物系樹脂、聚芳香酸醋 系樹月曰（全芳香族系聚酯系樹脂）、芳香族聚醯胺系樹脂等 的耐熱性樹脂等為佳。 由水蒸氣喷射裝置所喷射的高溫水蒸氣，由於是氣流 之故，與水流纒結處理或穿孔處理不同，被處理體的纖維 網中的纖維並未有大的移動而進入纖維網内部。藉由對此 纖維網中的水蒸氣流的進入作用及濕熱作用，水蒸氣流能 有效地覆在纖維網内存在的各纖維表面而成濕熱狀態，被 "心為可以變成均勻的熱接著。又，與乾熱處理相比較，對 纖維内部由於可以充分地熱傳導，故表面及厚度方向中捲 縮的程度變得大致略為均勻。 用以噴射高溫水蒸氣的喷嘴，可以使用所定噴孔為在 寬方向連續地並列板或擠壓模具，只要將此在所供給的纖 維、祠的寬方向喷孔為並列配置即可，喷孔列是只要1列以 上即可’也可以複數列並行配列。又，也可以將有1列的 喷孔列之喷嘴設置成複數台並列。 使用在板上打開喷孔型式的喷嘴時，板的厚度也可以 27 322972 201207176201207176 VI. [Technical Field] The present invention relates to a nonwoven fabric molded article which is light in weight and high in volume, and which is excellent in air permeability, heat insulation property, durability, moldability, and recycling property. And a method of producing the nonwoven fabric molded body. [Prior Art] Foamed styrene (Styrol; polystyrene foam) which is a light-weight material has been widely used. The foamed styrene is excellent in light weight, heat insulation, moldability, and impact absorption, and is used as a heat-insulating material for heat preservation or cold preservation of a buffer or a tied package. However, when the foamed styrene is partially loaded, it becomes a concave shape without returning to the original shape, or is easily broken when subjected to bending stress, and has low durability. Further, when it is used as an impact cushioning material for a helmet (safety cap), it is suffocating because it has no air permeability. As a cushioning material, soft urethane foam is widely used because of its good touch and visual flavor and excellent form stability. However, since the general soft polyurethane foam is independently foamed, it is not ventilated and is easily sultry. Moreover, it is easy to cause weathering deterioration or yellowing, so the long-term durability is also low. In terms of recycling, toxic and NOx and CO gases are generated during combustion, which makes them unsuitable for heat recovery. As a material collector, there is a method of reshaping a small piece of polyurethane which has been crushed by the polyurethane foam waste, but it is necessary to add an adhesive for bonding the broken polyurethanes to each other. Here, it is known that it is a material that is lightweight, and has excellent air permeability, durability, heat insulation, and 4 322972 201207176. It is a non-woven web containing wet heat-bonding fibers. 』Indicative irregular fiber clusters, which are called cotton* meshes, are not nets. They are layered and heated by high-temperature steam to form a non-woven fiber structure, which is melted in a uniform direction in the thickness direction. A hard molded body of a wet heat-bonding fiber (Patent Document 1: International Publication WO2007/116676). However, in this formed body, when the card web is wetted by steam, the apparent density of the fiber assembly rises, and 0. A molded body of 05 g/cm3 or less. Further, since the net mesh is formed between the two belt conveyors, it is possible to form a plate-shaped molded body, and it is difficult to form a complicated three-dimensional structure. As a method of the ternary structure of the fiber assembly, a thermoforming method in which a fiber material and an adhesive are filled in a mold is known (Patent Document 2: JP-A-2000-238057). However, in this method, in order to adhere the fibers, it is necessary to fill the adhesive together, and it is difficult to uniformly apply the adhesive to the fibers. [Prior Art Document] (Patent Document) Patent Document 1: International Publication No. WO2007/116676 (Patent Document 2) Japanese Laid-Open Patent Publication No. Hei No. Hei. SUMMARY OF THE INVENTION An object of the present invention is to provide a nonwoven fabric molded article which has a nonwoven fabric structure, is light in weight, high in volume, and excellent in formability, and can be easily molded even at a complicated three-dimensional shape of 322972 5 201207176, and a method for producing the same. Another object of the present invention is to provide a nonwoven fabric molded article excellent in recyclability and a method for producing the same. Another object of the present invention is to provide a nonwoven fabric molded article excellent in air permeability, heat insulating property, and long-lasting property, and a method for producing the same. Another object of the present invention is to provide a nonwoven fabric molded article which is lightweight, excellent in sound absorbing property, and excellent in shape stability, and a method for producing the same. [Means for Solving the Problems] As a result of intensive studies to achieve the above-mentioned problems, the inventors of the present invention have found that a plurality of nonwoven fabric aggregates containing wet heat-bonding fibers can be fused and fixed by the wet heat and then the fibers. The non-woven fiber structure is light in weight and high in volume, and at the same time, the formability is excellent, and even a complicated three-dimensional shape can be easily formed, and the present invention is completed. In other words, the nonwoven fabric molded article of the present invention is a nonwoven fabric molded body formed of a plurality of nonwoven fabric aggregates, wherein the nonwoven fabric aggregate is a wet heat-bonding fiber, and the nonwoven fabric aggregate is used. They are fixed to each other by the fusion of the aforementioned wet heat bonding fibers. The apparent density of the shaped body may also be 0. 01 to 0. 7 g/cm3. The aforementioned nonwoven fabric assembly can also fix the fibers by the fusion of the wet heat bonding fibers. In the nonwoven fabric of the present invention, the nonwoven fabric aggregate has an indefinite shape, and the ratio of the number of the wet heat-bonding fibers in the surface of the aggregate may be 50% or more. Further, the nonwoven fabric aggregate has an anisotropic shape, and each of the nonwoven fabric aggregates may be aligned in an irregular direction. The non-dimensional assembly may also be obtained from a woven fabric assembly or a nonwoven fabric assembly in which the woven fabric is fixed by the fusion of the wet heat-bonding fibers to obtain a waste of the molded body. The volume of the aforementioned nonwoven fabric aggregate may also be 〇1 to 3〇〇 cm3 left/right. The nonwoven fabric molded article of the present invention has an apparent density of 0. 01 to 0. 05 g/cm3 left 3 right, the air permeability by the Frazir Type method may also be Q1 to 300 cm / cm • second), and the thermal conductivity is 〇 to 〇 W/m _ k degree. The nonwoven fabric assembly may be formed separately from the wet heat-bonding fibers, or may be selected from the range of the wet heat-bonding fibers/non-wet heat-bonding fibers = 1 〇 / 90 to 100 / 0. The foregoing non-woven fabric assembly may also be a double-bonded fiber 'wet heat-bonding fiber and a non-wetting heat-bonding ratio of 4 to 4 mass ratios) or a wet heat-bonding fiber/non-wetting adhesive fiber = 1〇/9〇 to 99/1. /Non-I" / The thermal adhesive fiber is in the form of acetonitrile unit content to 6 〇 mol = two = copolymerized yttrium and non-wet heat adhesive resin (f ratio) is the former lanthanide:: two and to non-^^ ethylene A vinyl alcohol is ugly/90 and at least a portion of the surface of the aforementioned wet heat bonding fiber. State possession = = == = = fat consists of: yes: at least the type of non-wet; followed by a group of core-sheath composite fibers. The core of the present invention is steamed; the nonwoven fabric of the present invention may be thermally bonded to each other using the high-grade 322972 7 201207176. The present invention also includes a method for producing the molded article, which comprises the step of thermally heating a plurality of nonwoven fabric aggregates. The aforementioned heat may then be followed by heat using high temperature steam. [Effect of the Invention] In the present invention, a plurality of nonwoven fabric aggregates containing wet heat-bonding fibers are fixed by the fusion of the wet heat-bonding fibers, and have a non-woven fiber structure, which is light in weight and high in volume, and is formed at the same time. Excellent, even complex three-dimensional shapes can be easily formed. Moreover, as a nonwoven fabric aggregate, it is possible to crush or cut the waste material of the nonwoven fabric aggregate, for example, the cut end which occurs in a manufacturing process, or the waste or the used nonwoven fabric aggregate. Since the aggregate of the breaking treatment is used, it is also excellent in recycling property. Moreover, since there is a non-woven fiber structure, it is possible to improve air permeability, heat insulation, and longevity. Moreover, the lightness is excellent in sound absorbing properties, and the form stability (or self-reliance) can also be improved. [Embodiment] [Best Mode for Carrying Out the Invention] [Non-woven Fabric Aggregate] In the present invention, a plurality of nonwoven fabric aggregates (non-woven fabric aggregate units or granular nonwoven fabric aggregates) are used. Since the wet heat-bonding fibers contained in the respective nonwoven fabric aggregates form a contiguous point in the contact portion between the aggregates, it is possible to manufacture a molded body which is high in volume and light in weight. (Wet Thermal Adhesive Fiber) The wet heat adhesive fiber is composed of at least a wet heat adhesive resin. Wet 8 322972 201207176 Thermal adhesive resin is used in high temperature water vapor at an easily achievable temperature, as long as it may flow or be easily deformed and can exhibit subsequent functions. Specifically, in the case of hot water (for example, 80 to 12 (TC, especially 95 to 100 ° C) v, the thermoplastic resin which can be followed by itself or on other fibers, for example, can be exemplified: cellulose a resin (such as Ci^cell cellulose such as methyl cellulose, hydroxy Cii3 alkyl cellulose such as hydroxymethyl cellulose, or carboxy Cm alkyl cellulose such as mercapto fluorenyl cellulose or a salt thereof), Poly-resin-based alcohol resin (poly-extension ethyl oxide, poly-extension propyl oxide, etc., C2 i 4 alkyl oxide, etc.), polyethylene resin (polyvinyl 0-pyrrolidone, poly Vinyl scale, vinyl alcohol polymer, polyethylene condensate, etc., acrylic copolymer and salt thereof [containing (meth)acrylic acid, (mercapto) acrylamide, etc. a copolymer of a unit or an alkali metal salt thereof, a modified vinyl copolymer (a vinyl monomer such as isobutylene, styrene, ethylene or vinyl ether, or an unsaturated carboxylic acid such as maleic anhydride or a copolymer of an acid anhydride or a salt thereof, or a polymer into which a hydrophilic substituent is introduced (introduction of a sulfonate) An acid group, a carbonyl group, a polyester such as a hydroxyl group, a polyamine, a polystyrene or a salt thereof, an aliphatic polyester resin (such as a polylactic acid resin), and a polyolefin resin or a polyester. A resin, a polyamide resin, a polyurethane resin, a thermoplastic elastomer, or a rubber (styrene elastomer, etc.) may also exhibit a function of adhesion after softening at a temperature of hot water (high temperature water vapor). Resin. These wet heat conductive resins may be used singly or in combination of two or more. The wet heat adhesive resin is usually composed of a hydrophilic polymer or a water-soluble resin. Among these wet heat bonding resins,嫦 嫦 322972 9 201207176 A vinyl alcohol polymer such as a vinyl alcohol copolymer, a polylactic acid resin such as polylactic acid, or a (fluorenyl) acrylic copolymer containing a (fluorenyl) acrylamide unit, especially ethylene. Or a vinyl alcohol-based polymer of a-C2 to 10 olefin units such as propylene, particularly preferably an ethylene-vinyl alcohol-based copolymer. In the ethylene-vinyl alcohol-based copolymer, the content of the ethylene unit (copolymerization) The ratio) is, for example, 10 to 60 mol%, preferably 20 to 55 mol%, more preferably 30 to 50 mol%. Since the ethylene unit is within this range, although wet heat bonding can be obtained, However, there is no specificity of solubility in hot water. When the ratio of ethylene unit is too small, the ethylene-vinyl alcohol copolymer is easily swollen or gelled in low-temperature steam (water), and it is easy to be wet only in the water. On the other hand, when the ratio of the ethylene unit is too large, the hygroscopicity is lowered, and it is difficult to visualize the fiber fusion due to moist heat, so that it is difficult to ensure practical strength. The ratio of ethylene units, especially at 30 to 50 mol% In the range of the range, the workability is particularly excellent. In the ethylene-vinyl alcohol copolymer, the alkalinity of the vinyl alcohol unit is, for example, 90 to 99. 99% of the moles, from 95 to 99. 98% of the moles is preferred, and more preferably 96 to 99,97 moles. When the degree of alkalization is too small, the thermal stability is lowered, and the stability is lowered due to thermal decomposition or gelation. On the other hand, when the degree of alkalization is too large, the production of the fiber itself becomes difficult. The viscosity average degree of polymerization of the ethylene-vinyl alcohol-based copolymer may be selected as needed, for example, 200 to 2,500, more preferably 300 to 2,000, still more preferably 400 to 1,500. When the degree of polymerization is in this range, the balance between the spinnability and the wet heat bondability is excellent. The cross-sectional shape of the wet heat-bonding fiber (10 322972 201207176 perpendicular to the length of the fiber) and the S-shaped circular or profiled section [flat, elliptical, polygonal, 3 to 14 leaf-shaped, τ-shaped, H-shaped, -V-shaped, dog bone (1-shaped shape), etc.] 'may also have a hollow cross-section or the like. The ^wet heat-bonding fiber may also be a composite fiber composed of at least a plurality of secret fats containing a moist heat-bearing tree. The composite fiber, the damp heat bond, and the portion having at least the surface of the fiber have a moist heat-adhesive resin. From the viewpoint of adhesion, the form of the joint in the longitudinal direction occupies the surface to the heat of the wetting. The resin is preferred. The coverage rate of the damp heat-adhesive resin is more than 50%, and more preferably 80% or more, and more preferably 90% or more. Society. 'The cross section of the composite fiber that occupies the surface of the thermal adhesive fiber can be exemplified by the same core core sheath type, the eccentric core type, the side by side (side by side, the punishment, your sin, Bu, island type, multi-layer Adhesive type, radial adhesive type, see 丨 。. Type, etc.. In these cross-sectional structures, the core-sheath type is a structure in which the full-surface wet heat bonding resin is connected in the longitudinal direction. (That is, the sheath portion is composed of a wet heat-heated potato resin (4) sheath-type structure). In the case of a person, the fiber is one-dimensional, although the wet heat-adhesive resin can be grouped together with the non-wet heat. A combination of a resin and a non-wet heat followed by a sapphire: a dihydric water-insoluble or hydrophobic resin, which may be exemplified by a poly(hydrocarbon hydrazine=base) acrylic resin, a chlorinated vinyl resin, a styrene resin, and a poly The ester-based peppers are sa Q-polyamine vinegar-based resin, sputum, poly- urethane-based resin, polycarbonate-based resin, and resin, and may be a plastic elastomer or the like. These non-wet heat adhesive properties may be used in combination of two or more. 322972 11 201207176 Among these non-wet heat-adhesive resins, the melting point is higher than that of the wet heat-adhesive resin (especially ethylene-vinyl alcohol copolymer) from the viewpoint of heat recovery and dimensional stability, for example. A polypropylene resin, a polyester resin, and a polyamine resin are preferable, and a polyester resin or a polyamine resin is preferable from the viewpoint of excellent balance between heat resistance and fiber formability. As a polyester resin, an aromatic polyester resin (polyethylene terephthalate (PET), polytrimethylene terephthalate) such as polyc 2 to 4 alkyl aromatic acid ester-based resin is used. S is intended to be a polybutylene terephthalate or a polyethylene naphthalate resin, and particularly a polyethylene terephthalate resin such as PET. Polypyridyl acid succinic acid S is intended to be used in addition to the ethylene terephthalate unit, and may also contain other dicarboxylic acids (for example, m-benzoic acid I naphthalene 2,6-carboxylic acid). , phthalic acid, 4,4, diphenyldicarboxylic acid, bis(singly phenyl), 5-monothioisophthalic acid, etc., or diol (for example. Diethylene glycol, propylene glycol, 14-butanediol, 1,6-hexanediol, neodymium dioxime, cyclohexane-dimethanol, polyethylene glycol, polytetramethyl glycol, etc. 2〇% of the following percentages. As the polyamine-based resin, aliphatic amines such as polyamine 6, polyamin, polystyrene, polyamine II, polyamine 12, polyamine 6-12, and the like The substance is preferably composed of an aromatic di- and an aliphatic di-branched amine: a dimeric amine or the like. The above-mentioned polyamine-based resin oxime may contain other units which can be copolymerized. The ratio of the resin to the (four) heat-bonded Wei resin (fiber-forming poly =) can be adapted to the structure (for example, the type of the wet-heat adhesive resin can be selected as long as it exists on the surface, and no special 322972 12 201207176 Do not limit 'for example, wet heat adhesive resin / non-wet heat adhesive resin = 90 / to 1 〇 / 9 〇 ' and preferably from 8 〇 / 2 〇 to 15 / 85, from 60 / 40 to 2 〇 / 80 When the ratio of the wet heat adhesive resin is too large, the strength of the fiber is increased. When the ratio of the wet heat adhesive resin is too small, the wet heat bonding resin becomes difficult to form in the longitudinal direction of the fiber surface. Then, the tendency is lowered. This tendency is the same as the application of the wet heat adhesive resin to the surface of the non-flat heat-adhesive resin. The average fineness of the wet heat bonding fibers, depending on the application, for example, can be from 0. The range of 01 to 100 dtex is selected, and the range from 〇" to 5〇 dtex is preferably 0. The degree of 5 to 30 dtex (especially 1 to 10 dtex) is better. When the average fineness is in this range, the strength of the fiber is excellent in balance with the appearance of wet heat bonding. The average fiber length of the wet heat bonding fibers can be selected, for example, from a range of up to 100 mm, preferably from 2 〇 to 8 〇 mm, and more preferably from 25 to 75 mm (especially from 35 to 55 mm). When the average fiber length is within this range, the mechanical strength of the fiber assembly can be improved due to the sufficient entanglement of the fibers. Further, when the fiber length is too long, it becomes difficult to form a uniform nonwoven fabric aggregate having a uniform basis weight. The crimp ratio of the wet heat bonding fibers is, for example, 1 to 50%, and is 3 to 40°/. Preferably, it is preferably 5 to 3 % (especially 1 to 2 %). Further, the number of crimps is, for example, 1 to 1 inch / 25 mm, preferably 5 to 5 inches / 25 mm, and more preferably 1 to 3 inches / 25 mm. The number of crimps after heating is, for example, 5/25 mm or more (for example, 5 to 2/25 mm), and preferably 5 to 150/25 mm, from 1 to 1〇〇322972. 13 201207176 / 25 mm is better. In the present invention, the adhesion of the aggregate units to each other can be improved by the shrinkage of the wet heat bonding fibers. In addition to these fibers, the nonwoven fabric aggregate may contain other fibers in addition to the properties of the fibers. As other fibers, for example, in addition to the non-wet heat-bonding resin exemplified in the wet heat-bonding fiber item, cellulose fibers (for example, natural fibers (wood wool, wool, silk, hemp, etc.), Semi-synthetic fibers (acetate fibers such as triacetate fibers, etc.), regenerated fibers (嫘萦, high-moisture modulus viscose (Polynosic), cupra (a type of Japanese man-made fiber), and Lyocell (for example, registered trademark "Tencel" "fibers, etc.", etc., inorganic fibers (for example, carbon fibers, glass fibers, metal fibers, etc.). The average fineness and average fiber length of other fibers are the same as those of the wet heat bonding fibers. These other fibers may be used alone or in combination. Two or more of these fibers are used. Among these other fibers, semi-synthetic fibers such as rayon, semi-synthetic fibers such as acetate, polyolefin fibers such as polypropylene or polyethylene, polyester fibers, polyamide fibers, and the like are used. In particular, when the wet heat adhesive fiber is a polyester fiber, the other fiber may be a polyester fiber. The ratio of the wet heat bond fiber is relative to The entire woven fiber assembly is, for example, 10% by mass or more, and preferably 30% by mass or more. Especially from the viewpoint of the subsequent connection between the nonwoven fabric aggregate units, the root of the wet heat bonding fiber in the surface of the aggregate The number ratio may be 30% or more, for example, 50% or more, preferably 70% or more, more preferably 90% or more. The nonwoven fabric aggregate may further contain a conventional additive such as a stabilizer (copper). Thermal stabilizers such as compounds, UV absorbers, Gwangan 14 322972 201207176 formula, antioxidants, etc.), antibacterial agents, deodorants, perfumes, colorants (dyes, pigments, etc.), fillers, antistatic agents, difficult A fuel, a plasticizer, a lubricant, a crystallization rate retarder, etc. These additives may be used singly or in combination of two or more. These additives may be supported on the surface of the fiber or may be contained in the fiber. (Characteristics of Non-woven Fiber Aggregate) The above-mentioned nonwoven fabric aggregate (granular or massive nonwoven fabric aggregate) has at least a non-woven fiber knot formed by wet heat-bonding fibers. Further, in the nonwoven fabric molded article of the present invention, since the nonwoven fabric structure having high volume and air permeability is provided, the internal shape of the nonwoven fabric assembly is melted by the wet heat bonding fibers. It is necessary to adjust the bonding state of the fiber moderately. In detail, the non-woven fiber assembly system uses the intersection of the wet heat bonding fibers with each other or with other fibers (that is, the intersection of the wet heat bonding fibers with each other, the wet heat bonding fibers and In the present invention, in the nonwoven fabric assembly, the fibers constituting the nonwoven fabric structure are joined by the wet heat bonding fibers at the contact points of the respective fibers, in order to The number of contact points maintains the form of the fiber assembly, and the subsequent point is preferably distributed substantially uniformly around the entire surface of the aggregate. When the subsequent points are concentrated on the surface or the inside, etc., the shape stability of the portion where the dots are less will be lowered. For example, a high-volume non-woven fabric aggregate obtained by a thermal bonding method is excessively close to a heat source portion, so that the surface is hardened, but the inside from the heat source is less followed by a point and the shape is unstable. Further, 15 322972 201207176 The formation of the next point, because the excess heat experience will be imparted to the fiber, the non-woven fabric assembly cannot be re-engaged. On the other hand, in the vicinity of the surface of the aggregate, the non-woven fabric aggregate is distributed substantially evenly across the entire interior, and in order to efficiently fix the fibers, the number of points by the wet heat-bonding fibers may be small. Appearance stability can also be combined with specific accumulation and ventilation. Further, since the fibers are fused by the wet heat-bonding fibers, the fibers can be prevented from falling off, so that the structure is less likely to be broken. Further, since the water vapor is softened at a level of about 100 to 120 ° C, the wet heat-bonding fibers are not subjected to excessive heat history, and are not subjected to temporary heat treatment for producing the nonwoven fabric aggregate, and may be renewed. The fiber aggregates are not woven together. Further, the nonwoven fabric aggregate is not only uniformly melted by the wet heat bonding fibers but also becomes a point of convergence, and the points are followed by a short melting point distance (for example, several tens to several hundreds/m). Therefore, the dense network structure can be hung around. When the molded body is formed by the nonwoven fabric assembly having such a structure, the molded body of the present invention has a high degree of followability even if it has an external force, and at the same time, the melting point of the finely dispersed fibers is due to an external force. The dispersion becomes small, and it can be presumed that high form stability can be exhibited. The apparent density of the nonwoven fabric aggregate can be selected according to the use, for example, 0. 05 to 0. 7 g/cm3, and 0. 08 to 0. 5 g/cm3 is better, more preferably 0. 1 to 0. 4 g/cm3 degree. Especially in the case of producing a hard molded body, the apparent density may also be 0. 2 to 0. 7 g/cm3, and 0. 25 to 0. 65 g/cm3 is preferred, more preferably 0. 3 to 0. 6 g/cm3 degree. Moreover, in the case of producing a soft molded body, the apparent density may also be 0. 05 to 0. 5 g 16 322972 201207176 /cm3, with 0. 08 to 0. 4 g/cm3 is better, more preferably 0. 1 to 0. 35 g / cm3 degree. When the density is too small, it is difficult to manufacture by the current manufacturing method. Difficult, but productivity declines. On the other hand, when the density is too large, the lightness or the gas permeability may decrease. The basis weight of the nonwoven fabric aggregate can be selected, for example, from the range of from 50 to 10,000 g/m2, more preferably from 100 to 8000 g/m2, still more preferably from 200 to 6000 g/m2. When the weight per unit area is too small, it is difficult to ensure the hardness. Moreover, when the weight per unit area is too large, the web becomes too thick. Therefore, in the hot and humid processing, the high-temperature steam cannot fully enter the inside of the net, but in the thickness direction. Difficult to make a uniform structure. The air permeability is formed by the Frazir Type method of the nonwoven fabric aggregate. 1cm3/(cm2·s) or more [for example, 0. 1 to 300 cm3 / (cm 2 · sec)], preferably 1 to 250 cm 3 / (cm 2 · sec), more preferably 5 to 200 cm 3 / (cm 2 · sec). When the air permeability is too small, it is difficult for the high-temperature steam or hot air to reach the inside, and it becomes difficult to manufacture the molded body. On the other hand, when the air permeability is too large, the air permeability is increased, but the fiber voids in the aggregate become excessively large, and the form stability is lowered. In the nonwoven fabric assembly, the fibers constituting the nonwoven fabric structure are selected by the above-mentioned wet heat-bonding fibers, and the fiber adhesion ratio can be selected from the range of about 1 to 85%, and the hard molded body is, for example, 10 to 85. %, preferably 20 to 80%, more preferably 30 to 75%. Further, the soft molded body is, for example, 1 to 60%, preferably 2 to 50%, more preferably 3 to 35% (particularly 3 to 30%). In addition, the ratio of the minimum value (minimum/maximum value) of the nonwoven fabric aggregate in the thickness direction, in each of the three equal divisions, relative to the fiber adhesion rate of 17 322972 201207176 (fiber ratio is relative to the maximum The ratio of the smallest field of the field), for example, more than 5% (for example, 50 to 1%), and preferably 55 to 99%, and 60 to 98% (especially 70 to 97%) More preferably, it can be uniformly followed in the thickness direction. The fiber adhesion ratio and the uniformity thereof can be calculated from the ratio of the number of cross-sections of the two or more fibers in the cross section of the non-woven fiber, and can be calculated in the international publication. The method described in JP-A-116676 (Patent Document 1). The volume of the nonwoven fabric aggregate can be selected from the range of 〇1 to 300 cm3 and is 0. 1 to l 〇〇 cm 3 is preferred, and more preferably 〇 5 to 5 〇 item 3. The volume of the non-woven fiber aggregate is cm1 cm3 hours, and the density is difficult to make. When the low-density molded body of 05 g/cm3 or less is larger than 3 〇〇 cm3, when the mold is filled with the aggregate, it becomes impossible to uniformly fill. The shape of the non-woven fabric assembly may be an equilateral shape such as a spherical shape or a braid shape, a rod shape (a square shape or a columnar shape), a plate shape or a sheet shape, a conical shape, a pyramid shape, a block shape, or an indefinite shape. An anisotropic shape such as a shape. Among these shapes, an anisotropic shape such as an indefinite shape, a rod shape, a plate shape, or a sheet shape is preferable from the viewpoint of stability of the molded body and the like. Further, the shapes of the respective aggregates may be the same or different. The size of the nonwoven fabric aggregate can be selected according to the intended shaped body, for example, it can be selected from the range of an average diameter of 1 to 500 mm, and preferably 2 to 100 mm, and 3 to 5 mm (especially 5 to 3 gongs) The degree is better. In particular, in the case of a rod, for example, the long diameter is 3 to 1 mm, and the 322972 18 201207176 is preferably 5 to 80 mm, and more preferably 10 to 50 mm (especially 15 to 40 mm). The average diameter of the section is 0. 1 to 50 mm, and 0. 5 to . 30 mm is preferred, with a degree of 1 to 20 mm (especially 3 to 10 mm) being more preferred. In the case of a plate or a sheet, for example, the average shape has an average diameter of 5 to 300 mm, preferably 1 to 200 mm, and 15 to 100 mm (especially 20 to 80 mm). Is 0. 1 to 30 mm, and 0. 3 to 20 mm is preferred, with 0. A degree of 5 to 15 mm (especially 1 to 10 mm) is more preferable. The size and shape of each aggregate are the same, and they can be the same or different. In the nonwoven fabric assembly, the ratio (mass ratio) of the wet heat bonding fibers to the non-wetting heat bonding fibers is a wet heat bonding fiber/non-wet heat bonding fiber = 10/90 to 100/0 (for example, 10/90 to 99/1), preferably 30/70 to 100/0 (for example, 30/70 to 95/5), and 50/50 to 100/0 (for example, 50/50 to 90/10) good. When the ratio of the wet heat bonding fibers is too small, the morphology of the fiber assembly is liable to collapse. From the viewpoint of improving the adhesion between the nonwoven fabric assembly units, it is also possible to use wet heat bonding fibers/non-wet heat bonding fibers = 70 /30 to 100/0, and 80/20 to 100/0. Preferably, it is preferably from 90/10 to 100/0, and may be formed by wet heat bonding fibers alone. The nonwoven fabric aggregate may further contain crimped fibers. The crimped fiber may also be a composite resin in which a plurality of resins having different heat shrinkage ratios form a phase separation structure 19 322972 201207176. For example, the crimped fibers disclosed in JP-A-2009-97133, JP-A-2009-183363, JP-A-2010-84284, and the like can be used. The ratio of the crimped fibers is preferably 50% by mass or less, more preferably 1 to 40% by mass, even more preferably 5 to 30% by mass, based on the entire nonwoven fabric assembly. [Non-woven fiber molded body] The nonwoven fabric molded article of the present invention is formed by combining a plurality of the above-mentioned nonwoven fabric assembly units, and the nonwoven fabric assembly units are formed by wet heat to form a molded body. The alignment of each of the nonwoven fabric aggregates (especially the alignment of the aggregate of anisotropic shapes) is not particularly limited, and may be a regular alignment or a random alignment. In the nonwoven fabric molded article of the present invention, a void portion may be provided between the respective nonwoven fabric aggregates, and a void portion penetrating the molded body may be particularly provided, but each of the nonwoven fabric aggregates is in close contact with each other. Preferably, in particular, in a rigid molded body, each unit is in close contact with each other, and the void portion of the through-molded body is preferably not included. Fig. 1 is a schematic view showing an example of the nonwoven fabric molded body of the present invention in which the nonwoven fabric assembly is regularly aligned. The nonwoven fabric molded body 1 is formed by combining a plurality of rod-shaped nonwoven fabric aggregates having a substantially rectangular cross section, and the main nonwoven fabric aggregate 2 is arranged in a direction parallel to the plane direction, and is arranged. At intervals, the nonwoven fabric aggregate 3 has a longitudinal direction aligned with the plane direction and arranged. In the rod-shaped aggregate in which the longitudinal direction and the surface direction are arranged in parallel, the rod-shaped aggregate in which the longitudinal direction and the surface direction are perpendicularly arranged is present at an appropriate interval, so that the rod-shaped aggregate is a surface. In the direction and thickness direction, the well-balanced connection is 20 322972 201207176, and the formed body has uniform strength. Fig. 2 is a schematic perspective view showing an example of the nonwoven fabric molded body of the present invention in which the nonwoven fabric aggregates are irregularly aligned. The nonwoven fabric molded body 11 is formed by combining a plurality of rod-shaped nonwoven fabric aggregates 12 having a substantially square cross section, and each of the nonwoven fabric aggregates 12 is disposed in an irregular direction. In the molded body, since the anisotropically shaped nonwoven fabric aggregates are aligned in an irregular direction, the respective nonwoven fabric aggregates are arranged in various directions, and the aggregates are separated from each other by a moderate interval. Further, it is uniformly dispersed, and a moderate void portion is formed inside the molded body. Therefore, such a molded article is excellent in light weight and ventilating property, and can exhibit uniform strength and folding resistance by random alignment of the rod-shaped aggregate. Fig. 3 is a schematic perspective view showing another example of the nonwoven fabric molded body of the present invention in which the nonwoven fabric assembly is aligned in an irregular direction. The nonwoven fabric molded body 21 is formed by combining a plurality of plate-shaped nonwoven fabric aggregates 22 having a planar shape and an indefinite shape, and each of the nonwoven fabric aggregates 22 is arranged in an irregular direction. The nonwoven fabric aggregate is soft, and the nonwoven fabric aggregate also includes an aggregate that is joined to the other aggregate in a folded state. In the molded article, since the plate-shaped nonwoven fabric aggregate is in surface contact, it is not limited to being soft, and is excellent in the integrity of the molded body. Such a molded article is excellent in cushioning property and is not easily separated. It can be used as a quilt, etc. Among the molded articles, the shape of the nonwoven fabric aggregate is an anisotropic shape, and the productivity is high, and the lightness of the nonwoven fabric or the strength of the molded body 21 322972 201207176 is also high. It is preferred that each of the nonwoven fabric aggregates is formed into a shape which is aligned in an irregular direction. (Characteristics of the nonwoven fabric molded article) Further, in order to form the molded article of the present invention into a molded article having high volume, air permeability, durability, and moldability, the molded article has an internal shape. The nonwoven fabric aggregates are fused to each other, and the state needs to be appropriately adjusted. The nonwoven fabric molded article of the present invention is a point of intersection with the nonwoven fabric assembly unit or with other structural units (fiber aggregates or granules not containing wet heat bonding fibers) (that is, non-woven The intersection of the fiber aggregates, the intersection of the nonwoven fabric aggregates with other structural units, and then the fusion is preferred. Since the respective nonwoven fabric aggregate units are fused to each other, the fall of the nonwoven fabric aggregate can be suppressed, and the structure is less likely to be broken. Further, since the water vapor is softened at a level of about 100 to 120 ° C and then the nonwoven fabric aggregate is not subjected to excessive heat, the nonwoven fabric aggregates may be indirectly indirectly in contact with each other, and the recycling property is excellent. The area of the contiguous point between the nonwoven fabric aggregates (the one non-woven fabric assembly unit is adjacent to the adjacent non-woven fabric assembly unit, or the other structural unit is followed by a plurality of locations, and each subsequent dot area) is 0. 1 to 100 cm2, preferably 1 to 10 cm2, more preferably 1 to 5 cm2. Than 0. When the area of 1 cm2 is small, the structure is easily broken when subjected to an external force, and when it is larger than 100 cm2, it is impossible to form a complicated 3-dimensional structure because the formability is lost. The density of the nonwoven fibrous formed article of the present invention, specifically, the apparent density 22 322972 201207176 For example, it can be from 001 to 0. The range of 7 g/cm3 is selected, for example, 0. 02 to 0. 4 g/cm3, and 0. 05 to 0. 4 g/cm3 is better, with 0. 07 . To 0. 3 g/cm3 is more preferred. When the apparent density is too low, although the air permeability is improved, the form stability is lowered. On the contrary, when the form is too high, the form stability can be ensured, but the air permeability is lowered, and the lightness is deteriorated. In the present invention, by the high uniformity of melting, on the one hand, there is a relatively low density, and the shape of the molded body can be maintained on one side. Further, as described above, each of the nonwoven fabric aggregates is modulated by the manufacturing limit. In the present invention, by molding a plurality of nonwoven fabric assembly units, it is possible to prepare a low-density molding which cannot be achieved by a conventional nonwoven fabric assembly. body. That is, the apparent density of the nonwoven fabric molded article of the present invention may be, for example, 0. 01 to 0. Low density of 05 g/cm3. In the nonwoven fabric molded article of the present invention, voids are formed between the fibers due to the nonwoven fabric structure. These voids are different from those of a resin foam such as a sponge, and are continuous because they are not independent voids, so that they have air permeability. The air permeability of the molded body of the present invention has a gas permeability of 0 by the Frazir Type method. 1 cm3/(cm2·s) or more (for example, 0. 1 to 300 cm3 / (cm2 · sec)), and 0. 5 to 250 cm 3 /(cm 2 · sec) (for example, 1 to 250 cm 3 /(cm 2 · sec)), preferably 5 to 200 cm 3 /(cm 2 · sec), usually 1 to 100 cm 3 / ( Cm2 · sec) degree. When the air permeability is too small, it is necessary to add pressure from the outside in order to pass air in the formed body, which makes it difficult to naturally enter and exit the air. On the other hand, when the air permeability is too large, the air permeability is increased, and the fiber voids in the molded body become larger than 23 322972 201207176, and the form stability is lowered. The nonwoven fabric of the present invention has high heat insulating properties and a low thermal conductivity of 0. 1 W/m. Below K, for example, 0. 03 to 0. 1 W/m. K, but with 0. 05 to 0. 08 W/m. The K degree is better. The nonwoven fabric molded article of the present invention may contain other structural grains or structural materials (or granular materials) in addition to the nonwoven fabric aggregate, without impairing the properties of the nonwoven fabric assembly. The other structural unit is not a wet heat-bonding fiber, and examples thereof include a fiber aggregate (for example, a nonwoven fabric aggregate) formed of a non-wet heat-bonding fiber. The ratio of the other structural unit may be 10% by weight or less (especially 5% by weight or less) with respect to the entire molded body. In the nonwoven fabric molded article of the present invention, the conventional additive exemplified in the above-mentioned nonwoven fabric assembly may be simultaneously blended in the nonwoven fabric assembly. Since the formation of the nonwoven fabric molded article of the present invention is formed by combining a plurality of nonwoven fabric aggregates, it is not limited to a secondary shape such as a sheet shape or a plate shape, and various three-dimensional shapes can be formed. [Method for Producing Non-Textile Fiber Molded Body] The method for producing a nonwoven fabric molded article of the present invention includes a step of thermally heating a plurality of nonwoven fabric aggregates. The method of the present invention further includes a forming step of forming a nonwoven fibrous aggregate. (Step of Forming Non-woven Fiber Assembly) In the molding step of the nonwoven fabric assembly, first, the fibers containing the wet heat-bonding fibers are reticulated. As a method of forming the net, a conventional method such as a silk bond method (spunbond), a direct method of dissolving 24 322972 201207176 melt flow method (meltblow), a melt flow fiber or a short fiber (staple) may be used. Card method, air filling method, etc. Dry method, etc. Among these methods, a carding method using melted flowing fibers or short-fiber fibers is particularly the most widely used in the use of short-fiber fibers. The net obtained by using the short fiber may, for example, be a random net, a semi-regular net, a net in the same direction, a crosslinked overlapping net or the like. Next, the resulting web is fed to the next step by a conveyor belt to heat treatment with high-temperature steam, whereby the wet heat-bonding fibers are fused to each other. In the present invention, as a method of heating, uniform melting can be exhibited by using the high temperature steam treatment method 'from the surface of the fiber assembly across the entire interior. Further, as the former step of the melting step, from the viewpoint of suppressing the scattering of the fibers, it is also possible to pass a part of the fibers of the obtained fiber web by spraying low-pressure water (for example, 〇. The method of spraying or spraying (spraying) and transferring the water, such as 1 to 15 MPa, preferably 〇·5 to 1 MPa, etc., can be slightly carried out. Specifically, the obtained web is transported to the next step by a conveyor belt, and then sprayed by superheating or high-temperature pure (high-pressure steam) flow to obtain a fiber aggregate having a non-woven structure. In other words, when the fiber web conveyed by the belt is passed through the high-speed high-temperature water vapor stream discharged from the nozzle of the steam injection device, the wet heat-bonding fibers are fused by the high-temperature steam to be blown. In particular, in the present invention, since the fiber web is air permeable, the high temperature water vapor can be impregnated into the inside, and a fiber aggregate having a slightly uniform structure can be obtained. 〃 The conveyor belt used can be used as long as it does not substantially confuse the fiber 322972 25 201207176 mesh shape used in processing. It is suitable for the use of the ring: two steam = ie: no special limit field A single conveyor belt 'between: live in the net; another conveyor belt machine to transport in two belts. By carrying it in this way, it is possible to suppress the deformation of the conveyed fiber _ shape by using an external force such as (4) water, high-temperature steam, and vibration of the conveyor belt in the treatment of the fiber web. Further, by the interval of the conveyor belt, the density or thickness of the treated nonwoven fabric can be suppressed. In order to supply water vapor to the fiber web, a conventional water-assisted gas jet device can be used. As the steam injection device, it is preferable to use a desired pressure and amount to uniformly and uniformly dispense water money over the entire width of the entire net. In the case of combining two conveyor belts, the equipment in the conveyor belt on the side, through the water-conducting conveyor belt, or through the conveyor network placed on the conveyor belt, supplies water to the net. The suction box (SUCti〇n b〇X) can also be installed on the other side conveyor belt. By means of the suction box, it is possible to attract excess water vapor which is discharged through the fiber web. X, the surface of the fiber web and the sides of the fiber mesh are temporarily steam-treated, and in the conveyor belt of the conveyor belt with the money vapor injection device, the water vapor (four) projecting device portion of the device is used. The transportation (4) can also be set up with other money. (4) The situation of the steam injection device and the financial box of the Junjun 2, the condition of the steam treatment fiber web and the inside of the fiber web can also be passed through the reprocessing device. To replace. Inversion is carried out. The endless belt is used in the conveyor belt, and is not particularly limited as long as it does not interfere with the conveyance of the web or the high-temperature steam treatment. However, in the case of high-temperature water 322972 26 201207176, it is preferable to appropriately select the surface of the fiber web due to the condition of the transfer belt surface 矣 'month shape. Especially when it comes to the flat fiber assembly of '1 ® ', just use the mesh... The thin mesh net II II is 9 日 9 〇 mesh is the upper limit, A is thicker than 90 mesh, ', 々 10 to 50 mesh level) is preferred. This is through the fine mesh of the eye, and it is difficult for I1 to pass low water vapor. The material of the mesh belt is made of a metal, a heat-treated polyacetate resin, a polyphenylene sulfide resin, or a polyacetic acid vine tree, from the viewpoint of heat resistance such as steam treatment. A heat-resistant resin such as a wholly aromatic polyester resin or an aromatic polyamide resin is preferable. The high-temperature steam sprayed by the steam injection device is a gas flow, and unlike the water flow kneading treatment or the perforation treatment, the fibers in the fiber web of the object to be treated do not largely move into the fiber web. By the action of the water vapor flow in the fiber web and the moist heat effect, the water vapor flow can effectively cover the surface of each fiber existing in the fiber web to become a hot and humid state, and the heart can be uniformly heated. . Further, since the inside of the fiber can be sufficiently thermally conductive as compared with the dry heat treatment, the degree of curling in the surface and the thickness direction becomes substantially uniform. The nozzle for ejecting the high-temperature steam may be a continuous parallel plate or a press die in the width direction by using the predetermined spray holes, and the spray holes may be arranged in parallel in the wide direction of the supplied fibers and crucibles. Columns can be as long as 1 column or more. Further, the nozzles of the nozzle rows having one row may be arranged in a plurality of rows. When opening a nozzle type nozzle on a plate, the thickness of the plate can also be 27 322972 201207176
與捲縮顯現可以有效率地實現之 ’但喷孔的直徑通常是0.05至2 以0.2至0,5 mm程度為更祛。The crimping can be achieved efficiently. However, the diameter of the orifice is usually 0.05 to 2, which is more than 0.2 to 0,5 mm.
是0.5至1 mm程度， 合作為目的之纖維固定， 條件就可以而無特別限制， mm，而以0.1至1 mm為佳， 喷孔的間距，通常是0.5至3 加工精度變低，有加工變困難之設備問題點，與容易產生 堵住網眼之所謂的運轉上的問題點。相反的’喷孔的直徑 太大時’則變成要得到充分的水蒸氣喷射力會有困難。另 一方面，間距太小時，由於喷嘴孔變得太密，噴嘴本身的 強度會下降。另一面，間距太大時，由於會產 氣不能充分對準纖維網之情形，變成難以確保網的強度;、 關於使用的高溫水蒸氣，也是只要作為目的的纖維之 固定能實K可以，而無特別限定，藉由使㈣纖維材質 或形態而没定即可’但壓力例如是在0]至2 MPa，以〇 2 至L5 MPa為佳，以0.3至i Mpa程度為更佳。水蒸氣的 壓力過高，太強時，形成網的纖維會產生超過必要之振動 而導致質地的混亂，而使纖維熔融過度部分變成不能保持 纖維形狀，可能會有超過必要的接著，又，壓力太弱時， 不能對被處理物’網上賦與纖維的融著或捲縮顯現所必要 之熱量’或水蒸氣不能貫通網，或在厚度方向有變成纖維 融著斑或捲縮不均勻的情形。也會有自喷嘴之水蒸氣均勻 地喷出的控制變成困難的情形。 高溫水蒸氣的溫度，例如是1 〇〇至1 322972 28 201207176 至120 C為佳’更佳是loo至u〇°c程度。高溫水蒸氣的處 理速度’例如是2〇〇m/分鐘以下，而以〇.1至1〇〇 m/分 鐘為佳’更佳是1至50 m/分鐘程度。 必要的話，也可以將複數張板狀的纖維集合體重疊作 成積層體，也可以形成與其他的資材積層的積層體。 再且’纏結不織纖維集合體的網之步驟，如前述，可 將濕熱接著性纖維藉由高溫水蒸氣接著而得到，但藉由其 他慣用方法，例如，針刺（needlepunch)等的處理方法也可 以接著。 以如此的方法所得之不織纖維集合體，通常為形成薄 片狀或板狀。薄片狀不織纖維集合體藉由破碎、粉碎、 :斷作成如前述大小’而形成本發明中的不織丄: 體。只要成為目的的體積的話，不織纖維集入 "& 法，並無特別限定，也可以使用慣用的機械的0的成形方 雙輛破碎機、高速切斷機。進一步，在本發日輪破碎機、 維集合體，也可以使用將廢材，例如是在本中，不織纖 程中切斷或破碎過程等發生的切斷末端、戈麼的I造過 用過的不織纖維集合體（例如是板狀形態等使棄物，或使 維集合體，或本發明的不織纖維成形體)經粉用的不織纖 的集合體。在本發明中由於可關用如此之或切斷處理 收再利用性也很優異。 廢材，所以回 (不織纖維集合體的熱接著步驟） 在熱接著步驟中，熱接著複數的不織 、方法並無待别限^，也可以使賴 體單元 、水等之加熱方 322972 201207176 法，但與不織纖維集合體的成形步驟相同以使用高溫水蒸 氣熱接著的方法為佳。使用高溫水蒸氣時，作為不織纖維 集合體者，即使使用前述之廢材也可以良好地熱接著，例 如，即使重覆複數次（例如，5次以上）熱接著處理，由於不 織纖維集合體可以良好地熱接著，故可以重覆再利用。 將不織纖維集合體相互間接著，作為成形板狀的方法 者，可以列舉一面將在前述輸送帶上的不織纖維集合體均 勻地分散，一面蒸氣處理的方法。 要成形複雜的立體結構物時，可以使用蒸氣加壓成形 機。蒸氣加壓成形機並無特別限定，但從生產性的觀點而 言，下部模具為凹形狀，也可以是能充填不織纖維集合體 的成形機。蒸氣的供給也可以在模具中設置蒸氣供給孔而 行之。第4圖表示蒸氣加壓成形機之一個例子的模式圖。 蒸氣加壓成形機30是具備上部模具31，與此之上部模具 31可能嵌合，並且在内部有可能充填不織纖維集合體的空 隙部32的下部模具33，在下部模具33的底部有用以供給 高溫水蒸氣的蒸氣孔34。蒸氣加壓成形機並不限定如此之 蒸氣加壓成形機，也可以將上部模具作成開放狀態，自此 之間隙供給蒸氣。關於在模具打開蒸氣供給孔的直徑或間 距，只要塊狀不織纖維集合體相互間可以充分接著的話就 可以而無特別限制，通常是0.1至3 mm，而以0.5至2mm 程度為佳。蒸氣供給孔太小時，喷嘴的加工精度變低，有 加工變困難之設備問題點，與容易產生堵住網眼之所謂的 運轉上的問題點。相反的，太大時，則變成難以得到充分 30 322972 201207176 的水蒸氣喷射力。 在蒸氣加壓成形機中充填之不織纖維集合體的充填 . 量，並無特別限定，以調整充填量，不拘不織纖維集合體 - 的表觀密度，都可以調整成形體的表觀密度在0.01至0.7 g /cm3之間。在本發明，將不織纖維集合體在無規則方向 配向時，只要將所定量的不織纖維集合體在蒸氣加壓成形 機（特別是有空隙部的下部模具的蒸氣加壓成形機）充填並 熱接著著，就可以製造成形體，故成形體之生產性優異。 又，藉由變換模具的形狀，也可以容易形成有複雜的立體 結構的三次元形狀的成形體。 關於使用的蒸氣，也只要不織纖維集合體相互間能充 分接著即可，並無特別限制，壓力，例如是在0.05至2 MPa，以0.07至1.5 MPa為佳。在蒸氣的壓力過高，或太 強時，不織纖維集合體會超過必要振動而變成不均勻的接 著結構，蒸氣供給孔的周邊會有超過必要的接著，有可能 高密度化。又，壓力太弱時，在不織纖維集合體的接著變 成得不能賦予必要的熱量，密度會變成不均勻的情形。再 且，也有難以控制自蒸氣供給孔的蒸氣均勻喷出之情形。 也可以在蒸氣加壓成形機裝著吸引扇，吸引自蒸氣喷 出孔滯留在模具内的蒸氣後，並冷卻。冷卻可以使濕熱接 著的固著時間提早。 作為模具的保溫溫度者，期望是1〇〇至120°C，模具 的溫度不到100 °C時，在模具的表面蒸氣會結露而引起接 著斑點。超過120°C時，在濕熱接著性纖維由於賦予過剩 31 322972 201207176 的熱經歷，而不能再成形。 可將不織纖維集合體與其他素材的結構單元混合之 後，以前述之方法得到成形體。 實施例 以下，根據實施例具體的進一步說明本發明，但本發 明並不侷限於此等實施例。實施例中各物性值是藉由以下 所示方法來測定。同時，實施例中的「份」及「％」若無 限定則表示質量基準。 (1) 單位面積重量（g/m2) 根據JIS L 1913「一般短纖維不織布試驗方法」測定。 (2) 厚度（mm )、表觀密度（g/cm3) 根據JIS L 1913「一般短纖維不織布試驗方法」測定 厚度，由此值與單位面積重量的值算出表觀密度。 (3) 捲縮數 根據JIS L 1015「化學纖維短纖試驗方法」（8.12.1)評 估。 (4) 熱傳導率 根據「JIS R 2648，由耐火隔熱磚瓦的熱線法之熱傳 導率的試驗方法」，藉由非定常熱線法測定。 (5) 通氣度 根據 JIS L 1096 以 Frazir Type 法測定。 (6) 成形性 1 cm3的不織纖維集合體20 g充填到有如第4圖所示 形狀的模具（寬22 cm，深度30 cm，高度10 mm)的蒸氣加 32 322972 201207176 壓成形機中，成形為密度0.03 g/cm3，厚度10 mm的成 形體。以目視觀察成形體可否維持模具的形狀，以下述基 . 準評估。 , 〇：幾乎維持模具的形狀，不織纖維集合體相互間有 接著。 △:雖仍維持模具的形狀，但可看到一部分的不織纖 維集合體脫落。 X :不能維持模具的形狀，可看到很多部分的不織纖 維集合體脫落。 (7) 回收性 在成形試驗所得之成形體再度裁斷成每個1 cm3碎 片，再度使用如第4圖的蒸氣加壓成形機，賦予0.07MPa 的蒸氣30秒鐘，可得密度0.03 g/ cm3，厚度10 mm的 再生品。在將此重覆5次後，以目視觀察成形體可否維持 模具形狀，使用以下的基準來評估。 〇：幾乎維持模具的形狀，不織纖維集合體相互間有 接著。 △:雖仍維持模具的形狀，但可看到一部分的不織纖 維集合體脫落。 X :不能維持模具的形狀，可看到很多部分的不織纖 維集合體脫落。 (8) 彎曲韌性 根據JIS K 7017所記載的方法之中的A法（3點彎曲法) 測定。此時，測定樣品是使用30 mm寬X 200 mm長的樣 33 322972 201207176 品’支點間距離定為5〇 mm，試驗速度定在2則^分鐘 進打測^。同時，採取喊方向(MD)成為平行方式的測定 樣品。本發明中在f曲變成3〇咖時，以目視觀察樣品是 否彎曲破壞，使用以下的基準來評估。 〇··幾乎維持試驗前的樣品形態。 X:試驗前的樣品形態有顯著變形。 (9)吸音率 · 根據「JISA 1429殘響室法吸音率之測定方法」，測定 在 250 Hz、500 Hz、1000 Hz、2000 Hz、5000 Hz 的 5 個 地方之頻率的吸音率，使用以下的基準來評估。同時，在 此評估中，吸音率在50%以上(0.5以上）的地方也沒有i個 時，反響音變大，而無吸音效果，吸音率在5〇%以上的地 方有1至3個地方時，只吸收特別頻率的音，變得不自然 的音場而令人不愉快。 〇：4個地方以上的頻率全部吸音率在5〇%以上。 △:在1至3個地方的頻率吸音率在5〇%以上。 x :雖吸音率在50%以上，但1個地方也沒有。 (11)自立性(形態安定性） 在吸音率試驗製作的120 cm(高度）、直徑22 cm的圓 柱·狀的吸音體為以目視確認可否自立1分鐘重覆3次，使 用以下基準來評估。 〇：3次都沒有倒而自立著。 △:有1至2次倒而自立著。 x : 1次也沒有自立。 34 322972 201207176 實施例1 準備作為濕熱接著性纖維者，芯成分為聚對苯二曱酸 . 乙二酯，鞘成分為乙烯一乙烯醇共聚物（乙烯含量44莫耳 _ %，鹼化度98.4莫耳％)的芯鞘型複合短纖維(Kuraray (股） 製，「SOPHISTA」，纖度3.3 dtex，纖維長51 mm，芯鞘質 量比=50/50，捲縮數21個/25 mm，捲縮率13.5%)。 將前述芯鞘型複合短纖維（濕熱接著性纖維），藉由梳 棉法製作單位面積重量約500 g/m2的梳棉網。 將該梳棉網（card web)移送到裝備50網眼，寬500 mm 的不銹鋼製的環狀金屬絲網的輸送帶。同時，該輸送帶的 金屬絲網上部裝備有相同金屬絲網的輸送帶，分別以相同 速度同方向回轉，使用此兩金屬絲網之間隔可以任意地調 整的輸送帶。 其次，對在下側的輸送帶所具備的水蒸氣噴射裝置導 入梳棉網，由該裝置將0.2 MPa的高溫水蒸氣以向梳棉網 的厚度方向通過方式（垂直）喷出，進行水蒸氣處理，而得 到不織纖維集合體。該水蒸氣喷射裝置在下側的輸送帶 内，以隔著輸送網將高溫水蒸氣向網喷吹方式設置喷嘴， 在上側的輸送帶設置吸水裝置。又，在該喷射裝置的網進 行方向中的下游側，裝置另一台喷嘴與吸水裝置的配置為 逆轉的組合之喷射裝置，對網的表裡兩面實施水蒸氣處理。 水蒸氣喷射喷嘴的孔徑是0.3 mm，使用喷嘴為沿著輸 送帶的寬方向以1mm間距並排1列的水蒸氣喷射裝置。加 工速度是5 m/分鐘，喷嘴侧與吸水侧的上下輸送帶間的 35 322972 201207176 間隔（距離）是設定為5mm。噴嘴是在輸送帶的裡側與輸送 帶幾乎連接地配置。 其次，以高速裁斷機裁斷5 mm厚度的板（寬1 cm X 長度2 cm) ’作成lcm3的不織纖維集合體。該不織纖維集 合體的密度是0.1 g/cm3,通氣度是51cm3/(cm2·秒），纖 維接著率疋表面31〇/0、中央28%，裡面。進一步將 在第4圖所示形狀的模具（寬22咖、深度3〇咖、高度⑺咖） 2 WOC中{呆溫’在其凹部充填2〇g前述的不織纖維集合 c 3送入0.〇7 MPa的蒸氣3〇秒鐘，而得到密度〇 1〇g/ ^厚度1〇賴的成形體。所得到的成形體有良好的通 氣^隔熱性、耐久性。進-步，該成形體再度裁斷成 作為再生。。的材料，再度充填模具，授與⑽ 3。秒鐘，可得到密度。。3 g/em3、厚度ig匪的 =㈤樣的再生重覆5次，不織纖維集合體相互間的 示者狀態是良好，回收再利用性也良好。結果在表i中表 實施例2 摔作除了使用17〇〇的熱風爐以外’其餘與實施例1同樣 得到由不織纖維集合體所成的成形體。所得之成 ^通錄、隔熱性、耐久性良好。進—步，該成形體與 ΓΓ Γ操1Γ再生品。所得再生品雖保持模具的 =例Γ 合體的一部分有脫落現象。 除了使用聚對苯二甲酸乙二醋纖維(纖度3dtex，纖維 322972 36 201207176 長51 mm )藉由梳棉法得到單位面積重量約500 g/m2的 網（web)之外，其餘與實施例1同樣，試圖得到由不織纖維 . 集合體所成的成形體，但由於不含濕熱接著性纖維，故未 能形成不織纖維集合體相互間的接著結構而未能保持形 態。結果在表1中表示。 比較例2 關於市售的發泡苯乙烯（10mm厚），評估的結果在表1 中表示。 比較例3 關於市售的發泡聚胺醋（Inoac公司製，10 mm厚），評 估的結果在表1中表示。 表1 密度 (g/cm3) 通氣性 (cm3/cm2/s) 熱傳導性 (W/mk) 成形性 回收性 彎曲 韌性 實施例1 0.032 191 0.037 〇 〇 〇 實施例2 0.031 183 0.038 〇 △ 〇 比較例1 不能測定 — _ X X — 比較例2 0.015 0 0.030 — — X 比較例3 0.031 0 0.032 — 一 〇 由表1的結果可知，實施例的成形體之成形性、回收 再利用性、彎曲韌性均優異。 實施例3 37 322972 201207176 與實施例1同樣，將所得到的不織纖維集合體之裁斷 物，在實施例1使用的模具中，將凹部分的形狀為圓柱狀 的模具(截面圓形狀的直徑22 cm ’高度40cm)在100°c中 保溫，在該凹部分充填前述的不織纖維集合體475 g。將 0.07 MPa的蒸氣送入30秒鐘，而得到密度0.03 g/cm3、 截面圓形狀的直徑23 cm、高度40cm的成形體。製作此成 形體3個，堆積成高度120 cm的圓柱方式製作1.4 kg的 吸音體。所得成形體之吸音性能優異、質輕、自立。同時， 各頻率中吸音率的圖表如在第5圖中表示。 比較例4 除了喷嘴侧與吸水側的上下輸送帶間的間隔（距離）定 為10mm之外，其餘與實施例相同，得到10 mm厚的板。 其次，將所得之10 mm厚的板使用直徑22 cm的模具穿孔 加工，得到密度〇.〇5 g/cm3的圓盤狀成形體（直徑22 cm、 厚度10 mm)。將該成形體120個堆積製作2.3 kg的吸音 體。所得成形體之吸音性能優異、質輕，但要使其自立有 困難。同時，各頻率中吸音率的圖表在第5圖中表示。 比較例5 將市售的12 k玻璃綿輥（Glass wool roll;密度0.012 g /cm3、厚度100 mm、寬1200 mm)切斷成95 cm。將切斷 物捲成親筒狀（如海苔卷狀），試圖製作成直徑 22 cm、高度 120 cm /·4 kg的吸音體，但因沒有剛性而不能自立。 實知例3及比較例4至5的評估結果在表2中表示。 38 322972 201207176 表2 密度 白 音 性 評 彳古 吸音率(X100%) (g/cm3) 立 性 250Hz 500Hz 1000Hz 2000Hz 5000Hz 實施例3 0.03 〇 〇 0.57 1.00 1.18 1.18 0.49 比較例4 0.05 Δ 〇 0.76 1.34 1.42 1.32 0.66 比較例5 0.03 X — — — — _ 由表2的結果可知’實施例3的成形體是吸音性優 異，同時，自立性也高。相對於此，比較例中，自立性低。 尤其是，在比較例4，除了自立性低之外，厚度大的三次 元成形體的製造也有困難。 產業上的可利用性 本發明的不織纖維成形體，具有質輕且體積高，同 時，由於通氣性、隔熱性、耐久性、成形性、回收再利用 性優良，故可以作為吸音材、隔熱材、地板(fl〇〇ring)材、 空調用濾過材及排水過濾材、熱發散板、屋上墙壁面綠化 基材、水質淨化用微生物擔體、擦拭材、吸水材等利用。 又緩衝性優，故可以利用來作為食品或水果的梱包材、或 各種領域（工業、農業、生活資材等）的緩衝材，例如，沙 發、床墊、枕頭、車輛用的緩衝材、頭盔、鞋的内墊、坐 墊等進步，因質輕有吸音性，同時，形態安定性也優， 故可以在建築物(例如是住宅、工㈣屋子或設備、大履、 醫院、學校、體育館、文化會館、人民會館、高速公路之 322972 39 201207176 隔音墙壁等）或在車輛（例如，汽車等的車輛、飛機等）等使 用的各種吸音材也可以有效利用。 【圖式簡單說明】 第1圖表示使不織纖維集合體規則地配向的本發明不 織纖維成形體之一個例子的模式圖。 第2圖表示使不織纖維集合體在不規則方向配向的本 發明不織纖維成形體之一個例子的概略斜視圖。 第3圖表示使不織纖維集合體在不規則方向配向的本 發明不織纖維成形體之其他例子的概略斜視圖。 第4圖表示在本發明之製造方法中所使用的蒸氣加壓 成形機之一個例子的模式圖。 第5圖表示相對於實施例3及比較例4所得之吸音體 的頻率之吸音率圖表。 【主要元件符號說明】 1,11,21 不織纖維成形體 2,3，12,22不織纖維集合體 30 蒸氣加壓成形機 31 上部模具 32 空隙部 33 下部模具 34 蒸氣供給孔 40 322972It is 0.5 to 1 mm, for the purpose of fiber fixation for cooperation, the condition can be made without special limitation, mm, and preferably 0.1 to 1 mm, the spacing of the orifices is usually 0.5 to 3, the processing precision is low, and there is processing. Equipment problems that become difficult, and so-called operational problems that tend to block the mesh. On the contrary, when the diameter of the orifice is too large, it becomes difficult to obtain a sufficient steam injection force. On the other hand, if the pitch is too small, the strength of the nozzle itself is lowered because the nozzle holes become too dense. On the other hand, when the pitch is too large, it is difficult to ensure the strength of the mesh due to the fact that the gas is not sufficiently aligned with the fiber web; and the high-temperature steam used is also a fixed energy of the target fiber. It is not particularly limited, and it may be determined by making the material or form of the fiber. However, the pressure is, for example, 0 to 2 MPa, preferably 〇2 to L5 MPa, and more preferably 0.3 to i MPa. When the pressure of water vapor is too high, when the fiber is too strong, the fibers forming the net will generate more than necessary vibrations, causing the texture to be confused, and the excessive melting of the fibers will become unable to maintain the fiber shape, which may exceed the necessary, and then, the pressure When it is too weak, it is impossible to apply the heat required for the object to be melted or curled up on the net or the water vapor cannot penetrate the net, or it may become a fiber fusion spot or a non-uniform crimp in the thickness direction. situation. There is also a case where the control of uniformly ejecting water vapor from the nozzle becomes difficult. The temperature of the high-temperature steam is, for example, 1 〇〇 to 1 322972 28 201207176 to 120 C is better ‘more preferably loo to u〇°c. The treatment speed of the high-temperature steam is ', for example, 2 〇〇 m / min or less, and preferably 〇 1 to 1 〇〇 m / min' is more preferably about 1 to 50 m / min. If necessary, a plurality of plate-shaped fiber assemblies may be stacked to form a laminate, or a laminate laminated with other materials may be formed. Further, the step of entanglement of the web of the non-woven fabric assembly, as described above, may be obtained by subjecting the wet heat-bonding fiber to high-temperature steam, but by other conventional methods, for example, needle punching or the like. The method can also be followed. The nonwoven fabric assembly obtained by such a method is usually formed into a sheet shape or a plate shape. The flaky nonwoven fabric assembly is formed into a woven body of the present invention by crushing, pulverizing, or breaking into a size as described above. The non-woven fabric is not particularly limited as long as it is a target volume, and a conventional machine-made double-cylinder crusher or a high-speed cutter can be used. Further, in the present Japanese-made wheel crusher and the assemblage, it is also possible to use the waste material, for example, in the present, the cutting end of the non-woven fiber cutting or breaking process, etc. The non-woven fabric aggregate (for example, a waste material such as a plate-like form, or a non-woven fabric aggregate obtained by powder-forming or a nonwoven fabric molded article of the present invention). In the present invention, it is also excellent in that it can be used in this way or the cutting process is recyclable. Waste material, so back (heating step of non-woven fiber assembly) In the heat-advancing step, the heat is followed by a plurality of non-woven methods, and the method is not limited to ^, and the heating unit of the body unit, water, etc. can also be used. The method of 201207176 is the same as the step of forming the nonwoven fabric aggregate, and it is preferred to use a method in which high-temperature steam is used. When high-temperature steam is used, it is possible to use a waste fabric as a nonwoven fabric assembly, and it is possible to heat it well, for example, even if it is repeated several times (for example, five times or more), the nonwoven fabric assembly is used. It can be well heated, so it can be reused again. In the method of forming a sheet shape, the method of forming a sheet shape is a method of uniformly dispersing the nonwoven fabric assembly on the conveyor belt while performing steam treatment. When forming a complicated three-dimensional structure, a vapor press molding machine can be used. The vapor press molding machine is not particularly limited, but the lower mold has a concave shape from the viewpoint of productivity, and may be a molding machine capable of filling a nonwoven fabric assembly. The supply of steam can also be carried out by providing a vapor supply hole in the mold. Fig. 4 is a schematic view showing an example of a vapor press molding machine. The vapor press molding machine 30 is a lower mold 33 including an upper mold 31 and possibly fitted to the upper mold 31, and may have a void portion 32 in which the nonwoven fabric assembly is filled, and is used at the bottom of the lower mold 33. A vapor hole 34 for supplying high temperature steam. The vapor press molding machine is not limited to such a vapor press molding machine, and the upper mold may be opened and steam may be supplied from the gap. Regarding the diameter or the interval at which the vapor supply holes are opened in the mold, it is not particularly limited as long as the block-like nonwoven fabric aggregates can sufficiently follow each other, and is usually 0.1 to 3 mm, preferably 0.5 to 2 mm. When the vapor supply hole is too small, the processing accuracy of the nozzle is lowered, and there is a problem of equipment which is difficult to process, and a problem of so-called operation which is likely to cause blocking of the mesh. Conversely, when it is too large, it becomes difficult to obtain a sufficient water jet force of 30 322972 201207176. The amount of the nonwoven fabric aggregate to be filled in the vapor press molding machine is not particularly limited, and the apparent density of the molded body can be adjusted by adjusting the filling amount without depending on the apparent density of the woven fabric assembly. Between 0.01 and 0.7 g / cm3. In the present invention, when the nonwoven fabric assembly is aligned in a random direction, the predetermined nonwoven fabric assembly is filled in a vapor press molding machine (particularly, a vapor press molding machine having a lower mold having a void portion). After the heat is formed, the molded body can be produced, so that the molded body is excellent in productivity. Further, by changing the shape of the mold, it is also possible to easily form a three-dimensional shaped body having a complicated three-dimensional structure. The vapor to be used is not particularly limited as long as the nonwoven fabric aggregates can be sufficiently filled with each other, and the pressure is, for example, 0.05 to 2 MPa, preferably 0.07 to 1.5 MPa. When the pressure of the vapor is too high or too strong, the nonwoven fabric aggregate will become a non-uniform structure in excess of the necessary vibration, and the periphery of the vapor supply hole may be more than necessary, and the density may be increased. Further, when the pressure is too weak, the non-woven fabric aggregate subsequently becomes unable to impart necessary heat, and the density becomes uneven. Further, it is also difficult to control the uniform discharge of the vapor from the vapor supply hole. A suction fan may be attached to the vapor pressure molding machine to suck the vapor remaining in the mold from the vapor discharge hole, and then cooled. Cooling can prematurely fix the damp heat. As the holding temperature of the mold, it is desired to be 1 Torr to 120 ° C, and when the temperature of the mold is less than 100 ° C, the vapor on the surface of the mold will condense and cause spots to be attached. Above 120 °C, the wet heat-bonding fibers cannot be reshaped due to the thermal history of the excess 31 322972 201207176. After the nonwoven fabric assembly is mixed with the structural unit of another material, the molded body is obtained by the aforementioned method. EXAMPLES Hereinafter, the present invention will be specifically described based on examples, but the present invention is not limited to the examples. The physical property values in the examples were determined by the methods shown below. Meanwhile, the "parts" and "%" in the examples represent the quality standard unless otherwise specified. (1) The weight per unit area (g/m2) is measured in accordance with JIS L 1913 "Test method for general short-fiber nonwoven fabrics". (2) Thickness (mm) and apparent density (g/cm3) The thickness was measured in accordance with JIS L 1913 "Test method for general short fiber nonwoven fabric", and the apparent density was calculated from the value of the value and the basis weight. (3) The number of crimps is evaluated in accordance with JIS L 1015 "Test method for chemical fiber staple fibers" (8.12.1). (4) Thermal conductivity The measurement method is based on "JIS R 2648, Test method for heat conductivity by hot wire method of refractory insulating bricks" by an unsteady hot line method. (5) Air permeability Determined by the Frazir Type method according to JIS L 1096. (6) A mold-forming 1 cm3 non-woven fabric assembly 20 g is filled in a mold having a shape as shown in Fig. 4 (22 cm in width, 30 cm in depth, and 10 mm in height) in a 32 322972 201207176 press molding machine. A molded body having a density of 0.03 g/cm3 and a thickness of 10 mm was formed. The shape of the mold can be visually observed to maintain the shape of the mold, and the basis weight is evaluated. 〇: The shape of the mold is almost maintained, and the nonwoven fabric aggregates are followed by each other. △: Although the shape of the mold was maintained, a part of the nonwoven fabric aggregate was observed to fall off. X: The shape of the mold cannot be maintained, and many parts of the nonwoven fabric aggregate can be seen to fall off. (7) Recyclability The molded body obtained in the forming test was again cut into pieces of 1 cm3, and the vapor pressure forming machine as shown in Fig. 4 was used again, and 0.07 MPa of vapor was applied for 30 seconds to obtain a density of 0.03 g/cm3. Recycled product with a thickness of 10 mm. After repeating this five times, the shape of the mold was visually observed to maintain the shape of the mold, and it was evaluated using the following criteria. 〇: The shape of the mold is almost maintained, and the nonwoven fabric aggregates are followed by each other. △: Although the shape of the mold was maintained, a part of the nonwoven fabric aggregate was observed to fall off. X: The shape of the mold cannot be maintained, and many parts of the nonwoven fabric aggregate can be seen to fall off. (8) Bending toughness Measured according to the A method (three-point bending method) among the methods described in JIS K 7017. At this time, the sample is measured using a sample of 30 mm wide by 200 mm long. 33 322972 201207176 The distance between the fulcrums is set to 5 〇 mm, and the test speed is set at 2 ^ minutes. At the same time, take the direction of the shout (MD) into a parallel measurement sample. In the present invention, when f is changed to 3 〇, the sample was visually observed for bending failure and evaluated using the following criteria. 〇··Almost maintain the sample shape before the test. X: The shape of the sample before the test was significantly deformed. (9) Sound absorption rate ・According to the "JISA 1429 Reverberation Room Method for Measuring Sound Absorption Rate", the sound absorption rate at five frequencies of 250 Hz, 500 Hz, 1000 Hz, 2000 Hz, and 5000 Hz is measured, and the following Benchmark to evaluate. At the same time, in this evaluation, when there is no i in the place where the sound absorption rate is 50% or more (0.5 or more), the reaction sound becomes large, and there is no sound absorption effect, and the sound absorption rate is 1 to 3 places where the sound absorption rate is more than 5%. At the time, it is unpleasant to absorb only the sound of a particular frequency and become an unnatural sound field. 〇: The frequency of all frequencies above 4 places is above 5%. △: The frequency absorption rate in 1 to 3 places is 5 % or more. x : Although the sound absorption rate is 50% or more, there is no one place. (11) Self-supporting (morphological stability) The sound-absorbing body of a cylinder of 120 cm (height) and a diameter of 22 cm produced by the sound-absorbing rate test was visually confirmed to be able to stand three times for one minute, and was evaluated using the following criteria. . 〇: I haven’t stood up for three times. △: There are 1 to 2 times and it stands on its own. x : There is no self-reliance once in 1 time. 34 322972 201207176 Example 1 Prepared as a wet heat bonding fiber, the core component is polyterephthalic acid. Ethylene glycol, the sheath component is ethylene-vinyl alcohol copolymer (ethylene content 44 m _ %, alkalinity 98.4 Core-sheath composite short fiber (Muraray), "SOPHISTA", denier 3.3 dtex, fiber length 51 mm, core sheath mass ratio = 50/50, crimp number 21 / 25 mm, roll The reduction rate is 13.5%). The core-sheath type composite short fibers (wet heat-bonding fibers) were subjected to a carding method to produce a card web having a basis weight of about 500 g/m2. The card web was transferred to a conveyor belt equipped with a 50 mesh, 500 mm wide stainless steel ring-shaped wire mesh. At the same time, the upper part of the wire mesh of the conveyor belt is equipped with a conveyor belt of the same wire mesh, which are respectively rotated in the same direction at the same speed, and the conveyor belt which can be arbitrarily adjusted by the interval of the two wire meshes can be used. Next, the water vapor ejecting apparatus provided in the lower conveyor belt is introduced into the carding net, and the high-temperature steam of 0.2 MPa is ejected by the apparatus in the thickness direction of the carding web (vertical) to perform steam treatment. And a non-woven fiber aggregate is obtained. In the water vapor ejecting apparatus, a nozzle is provided in the lower conveyor belt to spray high-temperature steam to the net via a conveyor net, and a water suction device is provided on the upper conveyor belt. Further, on the downstream side in the web traveling direction of the injection device, the other nozzle and the water absorbing device are arranged in a reversed combination, and the water vapor treatment is applied to both the front and back sides of the net. The water vapor injection nozzle has a hole diameter of 0.3 mm, and the nozzle is a water vapor injection device in which one row is arranged at a pitch of 1 mm along the width direction of the conveyor belt. The processing speed is 5 m/min, and the interval (distance) between the nozzle side and the upper and lower conveyor belts on the water suction side is set to 5 mm. The nozzle is disposed on the inner side of the conveyor belt and is almost connected to the conveyor belt. Next, a 5 mm-thick plate (width 1 cm X length 2 cm) was cut by a high-speed cutting machine to make a lcm3 nonwoven fabric assembly. The nonwoven fabric assembly had a density of 0.1 g/cm3, a gas permeability of 51 cm3/(cm2·s), and a fiber adhesion ratio of 31 〇/0 in the surface and 28% in the center. Further, in the mold of the shape shown in Fig. 4 (width 22 coffee, depth 3 coffee, height (7) coffee) 2 WOC {stay temperature' is filled in the concave portion 2 〇g the aforementioned nonwoven fabric set c 3 is sent to 0 〇 7 MPa of steam for 3 〇 seconds to obtain a molded body having a density of 〇 1 〇 g / ^ thickness of 1 。. The obtained molded body has good heat and heat resistance and durability. In the further step, the formed body is again cut into regeneration. . The material is refilled with the mold and given (10) 3. In seconds, the density is available. . 3 g/em3, thickness ig = = (5) Regeneration was repeated five times, and the non-woven fabric aggregates were in good condition with each other, and the recycling property was also good. As a result, in Table i, Example 2 was thrown into a molded body made of a nonwoven fabric assembly in the same manner as in Example 1 except that a hot air furnace of 17 inches was used. The results are excellent, thermal insulation and durability. Further, the formed body and the Γ Γ Γ Γ Γ Γ 。 。 。. Although the obtained recycled product maintains the mold = a part of the composite has a peeling phenomenon. Except for the use of polyethylene terephthalate fiber (denier 3dtex, fiber 322972 36 201207176 length 51 mm) by a carding method to obtain a web having a basis weight of about 500 g/m2, the rest and the embodiment 1 Similarly, attempts have been made to obtain a molded body composed of a nonwoven fabric assembly. However, since the wet heat-bonding fibers are not contained, the subsequent structure of the nonwoven fabric aggregates cannot be formed and the form is not maintained. The results are shown in Table 1. Comparative Example 2 With respect to commercially available expanded styrene (10 mm thick), the results of the evaluation are shown in Table 1. Comparative Example 3 Commercially available foamed polyamine vinegar (manufactured by Inoac Co., Ltd., 10 mm thick), the results of the evaluation are shown in Table 1. Table 1 Density (g/cm3) Air permeability (cm3/cm2/s) Thermal conductivity (W/mk) Formability recovery bending toughness Example 1 0.032 191 0.037 〇〇〇Example 2 0.031 183 0.038 〇△ 〇Comparative Example 1 Cannot be measured - _ XX - Comparative Example 2 0.015 0 0.030 - X Comparative Example 3 0.031 0 0.032 - From the results of Table 1, the molded article of the example was excellent in formability, recycling property, and bending toughness. . Example 3 37 322972 201207176 In the same manner as in Example 1, the cut piece of the obtained nonwoven fabric assembly was used in the mold used in Example 1, and the shape of the concave portion was a cylindrical mold (the diameter of the circular cross section) 22 cm 'height 40 cm) was kept at 100 ° C, and the aforementioned non-woven fiber aggregate 475 g was filled in the concave portion. 0.07 MPa of steam was fed for 30 seconds to obtain a molded body having a diameter of 0.03 g/cm3 and a circular cross-sectional shape of 23 cm in diameter and 40 cm in height. Three shaped bodies were produced and stacked into a cylindrical shape with a height of 120 cm to make a 1.4 kg sound absorbing body. The obtained molded body is excellent in sound absorbing performance, light in weight, and self-supporting. Meanwhile, a graph of the sound absorption rate in each frequency is shown in Fig. 5. Comparative Example 4 A 10 mm thick plate was obtained in the same manner as in the Example except that the interval (distance) between the upper and lower conveyor belts on the nozzle side and the water absorption side was set to 10 mm. Next, the obtained 10 mm thick plate was perforated using a mold having a diameter of 22 cm to obtain a disk-shaped formed body (diameter: 22 cm, thickness: 10 mm) having a density of 〇.5 g/cm3. 120 molded bodies were stacked to produce a 2.3 kg sound absorbing body. The obtained molded body is excellent in sound absorbing performance and light in weight, but it is difficult to make it stand up. At the same time, a graph of the sound absorption rate at each frequency is shown in Fig. 5. Comparative Example 5 A commercially available 12 k glass wool roll (Glass wool roll; density 0.012 g / cm 3 , thickness 100 mm, width 1200 mm) was cut into 95 cm. The cut piece is rolled into a tubular shape (such as a seaweed roll), and an attempt is made to produce a sound absorbing body having a diameter of 22 cm and a height of 120 cm /·4 kg, but it is not self-supporting because it has no rigidity. The evaluation results of the known Example 3 and Comparative Examples 4 to 5 are shown in Table 2. 38 322972 201207176 Table 2 Density White Sound Evaluation Ancient Sound Absorption Rate (X100%) (g/cm3) Standhold 250Hz 500Hz 1000Hz 2000Hz 5000Hz Example 3 0.03 〇〇0.57 1.00 1.18 1.18 0.49 Comparative Example 4 0.05 Δ 〇0.76 1.34 1.42 1.32 0.66 Comparative Example 5 0.03 X — — — — _ As is clear from the results of Table 2, the molded article of Example 3 is excellent in sound absorbing property and high in self-standing property. On the other hand, in the comparative example, the self-supporting property was low. In particular, in Comparative Example 4, in addition to low self-supporting property, it was difficult to manufacture a three-dimensional molded body having a large thickness. INDUSTRIAL APPLICABILITY The nonwoven fabric molded article of the present invention is light in weight and high in volume, and is excellent in air permeability, heat insulating properties, durability, moldability, and recycling property, and thus can be used as a sound absorbing material. Use of heat-insulating materials, flooring (fl〇〇ring), filter materials for air-conditioning, drainage filters, heat-dissipating plates, greening substrates for roof walls, microbial supports for water purification, wiping materials, and water absorbing materials. It has excellent cushioning properties, so it can be used as a wrapper for food or fruit, or as a cushioning material for various fields (industrial, agricultural, living materials, etc.), for example, sofas, mattresses, pillows, cushioning materials for vehicles, helmets, The inner cushions and cushions of the shoes are improved, because of the light weight and sound absorption, and the shape stability is also excellent, so it can be in buildings (such as houses, workers (four) houses or equipment, big shoes, hospitals, schools, gymnasiums, cultures). Various sound-absorbing materials used in halls, people's clubs, highways, 322972 39 201207176, soundproof walls, etc., or in vehicles (for example, vehicles, airplanes, etc.) can also be used effectively. [Brief Description of the Drawings] Fig. 1 is a schematic view showing an example of the nonwoven fabric molded body of the present invention in which the nonwoven fabric aggregates are regularly aligned. Fig. 2 is a schematic perspective view showing an example of the nonwoven fabric molded body of the present invention in which the nonwoven fabric assembly is aligned in an irregular direction. Fig. 3 is a schematic perspective view showing another example of the nonwoven fabric of the present invention in which the nonwoven fabric assembly is aligned in an irregular direction. Fig. 4 is a schematic view showing an example of a vapor press molding machine used in the production method of the present invention. Fig. 5 is a graph showing the sound absorption rate of the frequency of the sound absorbing body obtained in Example 3 and Comparative Example 4. [Main component symbol description] 1,11,21 Non-woven fabric molded body 2,3,12,22 Non-woven fabric assembly 30 Vapor press molding machine 31 Upper mold 32 Void portion 33 Lower mold 34 Vapor supply hole 40 322972