WO2012008169A1 - 発泡成形用不織布積層体 - Google Patents
発泡成形用不織布積層体 Download PDFInfo
- Publication number
- WO2012008169A1 WO2012008169A1 PCT/JP2011/051912 JP2011051912W WO2012008169A1 WO 2012008169 A1 WO2012008169 A1 WO 2012008169A1 JP 2011051912 W JP2011051912 W JP 2011051912W WO 2012008169 A1 WO2012008169 A1 WO 2012008169A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- nonwoven fabric
- layer
- laminate
- foam molding
- dense
- Prior art date
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Classifications
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
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- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/718—Weight, e.g. weight per square meter
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/724—Permeability to gases, adsorption
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2323/00—Polyalkenes
- B32B2323/10—Polypropylene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2601/00—Upholstery
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/608—Including strand or fiber material which is of specific structural definition
- Y10T442/609—Cross-sectional configuration of strand or fiber material is specified
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/659—Including an additional nonwoven fabric
- Y10T442/66—Additional nonwoven fabric is a spun-bonded fabric
- Y10T442/662—Needled
Definitions
- the present invention relates to a non-woven fabric laminate for foam molding that has excellent peeling resistance between layers and has a reinforcing effect and urethane seepage prevention performance, and particularly relates to a non-woven fabric laminate for foam molding disposed at the bottom of a foam molded product such as polyurethane. .
- foamed molded products such as soft polyurethane foam are used.
- a reinforcing base fabric is disposed at the bottom of such a foam molded product for the purpose of increasing the rigidity of the foamed urethane molded product and for preventing urethane from oozing out to the back surface.
- a combination of cold water and slab urethane, or a coarse blanket is used as the reinforcing base fabric, but the rigidity of the urethane molded product is not sufficiently improved, and the prevention of seepage from the back of the urethane is insufficient. There is a risk of it.
- Patent Document 2 2-258332: Patent Document 2
- Patent Document 3 Various methods such as a method using a melt blown nonwoven fabric having a fiber diameter of 10 ⁇ m or less as a layer (Japanese Patent Laid-Open No. 2004-353153: Patent Document 3) have been proposed.
- Patent Document 1 since the reinforcing material base for foam molding described in Patent Document 1 has a low basis weight of a dense layer, there is a possibility that the seepage of urethane cannot be effectively prevented.
- the foam base material described in Patent Document 2 can prevent the seepage of urethane, the basis weight of the base fabric is too large, so that urethane is impregnated excessively, resulting in a decrease in cushioning properties and urethane density.
- Patent Document 3 describes that a melt-blown nonwoven fabric having a basis weight of 40 g / m 2 or less, more preferably 15 to 20 g / m 2 and a fiber diameter of 10 ⁇ m or less is used as the dense layer.
- a melt blown nonwoven fabric layer and a spunbond nonwoven fabric layer having a small fiber diameter are joined by a needle punch, the fiber diameter of the fiber forming the meltblown nonwoven fabric layer and the fiber forming the spunbond nonwoven fabric layer is too different. There is little entanglement between the layers, and there is a possibility that the layers may be peeled off. Further, the fibers of the meltblown nonwoven fabric layer may be cut by the needle, and powder may be generated on the surface of the foam molding nonwoven fabric.
- the present invention has excellent delamination resistance between layers, and even when laminated (entangled) using a needle punch, there is no dust blowing on the surface of the fiber waste of the meltblown nonwoven fabric layer, and the reinforcing effect and urethane exudation performance It aims at obtaining the nonwoven fabric laminated body for foam molding which has these.
- At least one side (also referred to as one side) of the dense layer (hereinafter referred to as “one side”).
- a non-woven fabric laminate for foam molding formed by laminating a reinforcing layer,
- the dense layer is on both sides (also referred to as both sides) of the meltblown nonwoven fabric layer (A) [hereinafter referred to as “both sides”. ].
- the spunbond nonwoven fabric layer (B) is laminated, and the meltblown nonwoven fabric layer (A) and the spunbond nonwoven fabric layer (B) are partially thermocompression-bonded.
- a nonwoven fabric laminate is provided.
- the present invention also provides a nonwoven fabric laminate for foam molding obtained by further laminating urethane foam on the reinforcing layer side of the nonwoven fabric laminate for foam molding.
- the present invention also provides a vehicle seat or chair including a foam molded nonwoven fabric laminate in which urethane foam is laminated on the reinforcing layer side of the foam molded nonwoven fabric laminate.
- the dense layer is formed by partially thermocompression bonding the meltblown nonwoven fabric layer and the spunbond nonwoven fabric layer. Even when installed, the penetration of the resin liquid for foam molding can be stopped halfway. For example, in the case of an automobile seat, it is possible to effectively prevent abnormal noise caused by rubbing between metal parts and foamed urethane. It becomes.
- melt-blown nonwoven fabric layer and the spunbond nonwoven fabric layer which are the dense layers, are made of a laminate that is partially thermocompression bonded. There is no risk of delamination even when it is impregnated with resin solution for use or afterwards, forming a dense foamed layer, which is effective for improving the rigidity, and in addition, powder on the surface of the fiber waste of the meltblown nonwoven fabric layer. There is no blowing.
- thermoplastic resin used as the raw material of the nonwoven fabric for forming the dense layer and the reinforcing layer of the present invention is not particularly limited as long as it is a thermoplastic resin capable of forming a nonwoven fabric, and various known thermoplastic resins, specifically High-pressure low-density polyethylene, linear low-density polyethylene (so-called copolymer), which is a homopolymer or copolymer of ⁇ -olefins such as ethylene, propylene, 1-butene, 1-hexene, 4-methyl-1-pentene and 1-octene LLDPE), high density polyethylene (so-called HDPE), polypropylene (propylene homopolymer), polypropylene random copolymer, poly-1-butene, poly-4-methyl-1-pentene, ethylene / propylene random copolymer, ethylene / 1 -Polyolefin such as butene random copolymer, propylene /
- high-pressure method low-density polyethylene linear low-density polyethylene (so-called LLDPE) and ethylene-based polymers such as high-density polyethylene, propylene-based polymers such as polypropylene and polypropylene random copolymers, or polyethylene terephthalate, Polyamide and the like are more preferable.
- LLDPE linear low-density polyethylene
- ethylene-based polymers such as high-density polyethylene, propylene-based polymers such as polypropylene and polypropylene random copolymers, or polyethylene terephthalate, Polyamide and the like are more preferable.
- the thermoplastic resin according to the present invention includes an antioxidant, a weather stabilizer, a light stabilizer, an anti-blocking agent, a lubricant, a nucleating agent, a pigment, a softening agent, a hydrophilic agent, an auxiliary agent, as long as the object of the present invention is not impaired.
- Various known additives such as agents, water repellents, fillers and antibacterial agents may be added.
- thermoplastic resins polyolefins are preferable from the viewpoints of spinning stability during molding, processability and breathability of the nonwoven fabric, flexibility, lightness, and heat resistance, and propylene polymers are particularly preferable.
- ⁇ Propylene polymer> As the propylene polymer according to the present invention, a propylene homopolymer having a melting point (Tm) of 125 ° C.
- the melt flow rate (MFR: ASTM D-1238, 230 ° C., load 2160 g) is not particularly limited, but when used for a melt-blown nonwoven fabric constituting a dense layer, it is usually 10 ⁇ 3000 g / 10 min, preferably 50 to 2000 g / 10 min, more preferably 100 to 1000 g / 10 min.
- MFR melt flow rate
- the spunbond nonwoven fabric and reinforcing layer constituting the dense layer usually 1 to It is in the range of 500 g / 10 minutes, preferably 5 to 200 g / 10 minutes, more preferably 10 to 100 g / 10 minutes.
- the melt blown nonwoven fabric layer (A) constituting the dense layer according to the present invention is a nonwoven fabric layer made of the above-mentioned thermoplastic resin, and usually has a fiber diameter of 0.1 to 5 ⁇ m, preferably 0.5 to 3 ⁇ m, and a basis weight. Usually, it is in the range of 0.1 to 5 g / m 2 , preferably 1 to 3 g / m 2 .
- urethane liquid or foamed urethane when used as a sheet reinforcing base fabric, a urethane liquid or foamed urethane (hereinafter sometimes referred to as “urethane” in some cases). Even if the dense layer and the base material layer are joined with a needle punch, the fibers of the meltblown nonwoven fabric layer (A) are less likely to be cut by the needle and the resulting nonwoven fabric for foam molding can be obtained. The weight of the laminate can be reduced.
- the basis weight of the meltblown nonwoven fabric layer exceeds the above range, the prevention of the seepage of urethane has already reached the upper limit of the improvement effect within the above range, so there is no further effect.
- the basis weight exceeds the above range, there is a possibility that a large amount of fibers forming the meltblown nonwoven fabric layer is cut at the time of processing with the needle punch when laminating with the base material layer and the possibility of generating powder is increased.
- the meltblown nonwoven fabric layer has a relatively limited improvement effect on the strength of the resulting foamed nonwoven fabric laminate and the entanglement strength with the needle punch, the viewpoint of reducing the weight of the resulting foamed nonwoven fabric laminate Therefore, it is preferably within the above range.
- the spunbond nonwoven fabric layer (B) constituting the dense layer according to the present invention is a nonwoven fabric layer composed of the above thermoplastic resin, and usually has a fiber diameter of 10 to 40 ⁇ m, preferably 10 to 20 ⁇ m, and a basis weight of 10 to 50 g. / M 2 , preferably in the range of 10 to 20 g / m 2 .
- the dense layer constituting the nonwoven fabric laminate for foam molding according to the present invention is formed by laminating the spunbond nonwoven fabric layer (B) on both sides of the meltblown nonwoven fabric layer (A), and the meltblown nonwoven fabric layer (A).
- the spunbond nonwoven fabric layer (B) is partially thermocompression bonded.
- various methods can be used as described later, but embossing can be preferably used.
- “partially” means a range of 5 to 30%, preferably 5 to 20% in terms of area ratio.
- the dense layer according to the present invention preferably has a bulk density in the range of 0.05 to 0.5 g / cm 3 , preferably 0.05 to 0.3 g / cm 3 . It is preferable for the bulk density to be in the above-mentioned range since the denseness of the fibers can be maintained even after entanglement and there is a good effect on the seepage of urethane.
- the basis weight of the dense layer according to the present invention (total basis weight after laminating the meltblown nonwoven fabric layer (A) and the spunbond nonwoven fabric layer (B)) is usually 10 to 60 g / m 2 , preferably 10 to 35 g / m 2 , more preferably in the range of 10 to 25 g / m 2 .
- the dense layer according to the present invention is produced by using various known melt blown nonwoven fabric production methods and spunbond nonwoven fabric production methods in combination.
- the thermoplastic resin is spun from a spinning nozzle in advance, and the spun long fiber filament is cooled with a cooling fluid or the like, and tension is applied to the filament with drawn air to obtain a predetermined fineness.
- the collected filaments are collected on a moving collection belt to obtain a spunbond nonwoven fabric layer (B), and then the thermoplastic resin is melt extruded onto the spunbond nonwoven fabric layer (B) and spun from a melt blow spinneret.
- the fiber is spun as an ultrafine fiber stream with a high-temperature and high-speed gas, and the melt-blown nonwoven fabric layer (A) is formed with a collection device to form a fine-blown nonwoven fabric layer (A). After laminating the layer (B), it can be produced by partially thermocompression bonding.
- the method for partial thermocompression bonding of the meltblown nonwoven fabric layer (A) and the spunbond nonwoven fabric layer (B) is not particularly limited, and various known methods can be employed.
- the dense layer is thermocompression bonded by embossing or the like, it is easy to adjust the bulk density of the obtained dense layer within the above range, and the rigidity of the dense layer is improved, and no sag is generated. Mounting is easy and the working speed is increased. Moreover, it is preferable at the point which can prevent passage of urethane liquid.
- the embossed area ratio is usually in the range of 5 to 30%, preferably 5 to 20%.
- the stamped shape include a circle, an ellipse, an ellipse, a square, a rhombus, a rectangle, a square, a quilt, a lattice, a turtle shell, and a continuous shape based on these shapes.
- the dense layer according to the present invention is obtained by laminating a spunbond nonwoven fabric layer (B) having a larger fiber diameter on both sides of (A) than the fiber diameter forming the meltblown nonwoven fabric layer (A). ) More effectively as a reinforcing material.
- a nonwoven fabric laminate for foam molding is formed by laminating a reinforcing layer on at least one side of the dense layer, preferably on both sides.
- the side on which the reinforcing layer is laminated is the urethane side, that is, the layer configuration of urethane foam / reinforcing layer / dense layer Become.
- the reinforcing layer laminated on the dense layer may be a single layer or two or more layers.
- the nonwoven fabric laminate for foam molding of the present invention may be prepared by various known methods, specifically, for example, heat fusion methods such as heat embossing or ultrasonic fusion, mechanical entanglement methods such as needle punch or water jet,
- the dense layer and the reinforcing layer are laminated by a method using an adhesive such as a hot-melt adhesive or a urethane-based adhesive, extrusion lamination, or the like.
- the dense layer and the reinforcing layer are laminated by mechanical bonding or heat treatment with a needle punch.
- the method of making it wear can be taken.
- the needle punch method is preferable in that it provides appropriate air permeability to the obtained foamed nonwoven fabric laminate, allows gas generated when urethane foams to pass, and controls impregnation of the urethane liquid.
- the nonwoven fabric is used as long as the effect of the present invention is not hindered in order to reduce yarn breakage during needle punching or to reduce noise between the foam and the metal part.
- an oil agent such as a softening agent or a slip agent may be kneaded or applied.
- the foamed nonwoven fabric laminate of the present invention has a dense layer on both sides of the meltblown nonwoven fabric layer (A) and a spunbond nonwoven fabric layer (B). ) Are laminated by thermocompression bonding, for example, even when the dense layer and the reinforcing layer are joined by the needle punch method, the fibers forming the spunbond nonwoven fabric layer (B) and the fibers forming the reinforcing layer are both broken.
- the nonwoven fabric laminate for foam molding of the present invention preferably has an air permeability in the range of 25 to 160 cm 3 / cm 2 / sec, preferably 25 to 110 cm 3 / cm 2 / sec.
- the air permeability is in the above range, the prevention of seepage of urethane is better.
- a foam layer can be formed densely as a result, it is effective in improving the rigidity of the foam.
- the nonwoven fabric laminate for foam molding of the present invention preferably has a basis weight of 20 to 160 g / m 2 , more preferably 25 to 120 g / m 2 , and still more preferably 30 to 100 g / m 2 .
- the reinforcing layer constituting the nonwoven fabric laminate for foam molding of the present invention is not particularly limited, and various known nonwoven fabrics, for example, long fiber nonwoven fabrics such as spunbond nonwoven fabric and melt blown nonwoven fabric, wet nonwoven fabric, dry nonwoven fabric, dry pulp nonwoven fabric, Various known nonwoven fabrics such as short fiber nonwoven fabrics such as flash-spun nonwoven fabrics and spread nonwoven fabrics can be exemplified.
- the spunbonded nonwoven fabric layer (C) is particularly preferred from the viewpoint of the strength of the foamed nonwoven fabric laminate obtained.
- the spunbond nonwoven fabric layer (C) according to the present invention is a nonwoven fabric layer made of the above thermoplastic resin, and usually has a fiber diameter of 12 to 50 ⁇ m, preferably 15 to 40 ⁇ m, and usually has a basis weight of 10 to 50 g / m 2. Preferably, it is in the range of 15 to 35 g / m 2 .
- the spunbond nonwoven fabric layer (C) according to the present invention preferably has a larger fiber diameter than the fibers constituting the spunbond nonwoven fabric layer (B) constituting the dense layer.
- the spunbond nonwoven fabric layer (C) has excellent entanglement properties during joining by the needle punch method, and there is little yarn breakage.
- the resulting nonwoven fabric laminate for foam molding has rapid impregnation of urethane. It is preferable because the entanglement strength and tensile strength with the dense layer can be secured while securing.
- the fiber forming the spunbond nonwoven fabric layer (C) according to the present invention may be a single fiber, a side-by-side type or a core-sheath type composite fiber, or a crimped fiber.
- the cross-sectional shape of the fiber may be an irregular cross-section such as a V shape, a cross shape, or a T shape in addition to the round shape. You may add to a core part and a sheath part as a concentric fiber.
- the spunbond nonwoven fabric layer (C) according to the present invention is a nonwoven fabric composed of a single fiber, it is a mixed fiber formed by mixing fibers composed of two or more different thermoplastic resins, or two different shapes. It may be a mixed fiber formed by mixing more than one kind of fibers.
- the foam-molded nonwoven fabric laminate of the present invention may be used by laminating with other layers as long as the effects of the present invention are not impaired.
- the other layer laminated with the nonwoven fabric of the present invention include a knitted fabric, a woven fabric, a nonwoven fabric, a film, and a paper product.
- thermal embossing thermal fusion methods such as ultrasonic fusion
- mechanical entanglement methods such as needle punch and water jet
- hot melt adhesive Various known methods such as a method using an adhesive such as a urethane-based adhesive, extrusion lamination, and the like can be adopted.
- the non-woven fabric laminate for foam molding according to the present invention may be used after being subjected to secondary processing such as gear processing, printing, coating, laminating, heat treatment, and shaping, as long as the object of the present invention is not impaired.
- Air permeability (cm 3 / cm 2 / sec) A test piece of 200 mm (MD) ⁇ 50 mm (CD) was collected from the nonwoven fabric laminate for foam molding, and was subjected to a Frazier air permeability measuring machine according to JISL1096.
- Example 1 ⁇ Manufacture of dense layer> Using a propylene homopolymer having an MFR of 60 g / 10 min, melt spinning at 230 ° C., and depositing the obtained fibers on a collecting surface, a spunbond nonwoven fabric layer having a basis weight of 5.9 g / m 2 ( B-1) (fiber diameter 15 ⁇ m) was produced. Next, a propylene homopolymer having an MFR of 400 g / 10 min was melted with an extruder at 280 ° C., and the obtained melt was discharged from the spinneret and heated air at 280 ° C. was blown at the outlet of the discharge hole.
- a fiber having a fiber diameter of 3 ⁇ m is deposited on the spunbond nonwoven fabric (B-1) by a melt blown method to form a meltblown nonwoven fabric layer (A-1) having a basis weight of 1.2 g / m 2 , and further on the meltblown nonwoven fabric layer (A-1)
- a spunbond nonwoven fabric (B-2) similar to the spunbond nonwoven fabric (B-1) was laminated, and the three layers were integrated with a hot embossing roll with an engraving area ratio of 18% to obtain a dense layer made of an SMS nonwoven fabric.
- the total basis weight of the dense layer was 13 g / m 2 .
- MFR performs melt spun at 230 ° C.
- Examples 2 to 5 A non-woven fabric laminate for foam molding was obtained in the same manner as in Example 1 except that the basis weight of the meltblown nonwoven fabric layer and the spunbond nonwoven fabric layer used for the dense layer was as shown in Table 1. The physical properties of the obtained foamed nonwoven fabric laminate were measured by the method described above. The results are shown in Table 1.
- Example 6 After obtaining a dense layer similar to that in Example 2, two identical dense layers were laminated, and in addition, a spunbond nonwoven fabric layer was laminated on both sides of this dense layer in the same manner as in Example 1. A laminate was obtained. The physical properties of the obtained foamed nonwoven fabric laminate were measured by the method described above. The results are shown in Table 1.
- Example 7 After obtaining a dense layer similar to that of Example 3, the same three dense layers were laminated, and a spunbond nonwoven fabric layer was laminated on both sides of this dense layer in the same manner as in Example 1 to produce a nonwoven fabric for foam molding. A laminate was obtained. The physical properties of the obtained foamed nonwoven fabric laminate were measured by the method described above. The results are shown in Table 1.
- Example 8 After obtaining a dense layer similar to that in Example 3, the same two dense layers were laminated, and the basis weight of the spunbond nonwoven fabric layer laminated on both sides of the dense layer was 50 g / m 2 and the fiber diameter was 35 ⁇ m. Except for the above, a nonwoven fabric laminate for foam molding was obtained in the same manner as in Example 1. The physical properties of the obtained foamed nonwoven fabric laminate were measured by the method described above. The results are shown in Table 2.
- Example 9 After obtaining a dense layer similar to that in Example 3, the same three dense layers were laminated, and the basis weight of the spunbond nonwoven fabric layer laminated on both sides of the dense layer was 50 g / m 2 and the fiber diameter was 35 ⁇ m. Except for the above, a nonwoven fabric laminate for foam molding was obtained in the same manner as in Example 1. The physical properties of the obtained foamed nonwoven fabric laminate were measured by the method described above. The results are shown in Table 2.
- Example 10 Except for the basis weight of the meltblown nonwoven fabric layer and the spunbond nonwoven fabric layer used in the dense layer shown in Table 1, the basis weight of the spunbond nonwoven fabric layer laminated on both sides is 25 g / m 2 and the fiber diameter is 20 ⁇ m. As in Example 1, a nonwoven fabric laminate for foam molding was obtained. The physical properties of the obtained foamed nonwoven fabric laminate were measured by the method described above. The results are shown in Table 2.
- Example 11 After obtaining a dense layer similar to that in Example 3, the nonwoven fabric laminate for foam molding is the same as in Example 1 except that the basis weight of the spunbond nonwoven fabric layer laminated on both sides is 25 g / m 2 and the fiber diameter is 20 ⁇ m. Got the body. The physical properties of the obtained foamed nonwoven fabric laminate were measured by the method described above. The results are shown in Table 2.
- Example 1 A nonwoven fabric laminate for foam molding was obtained in the same manner as in Example 1 using only a meltblown nonwoven fabric layer having a basis weight of 7 g / m 2 for the dense layer. During needle punching, a large amount of powder was generated and was remarkably seen on the surface of the nonwoven fabric laminate. Moreover, from the microscopic observation, the entanglement between the meltblown fiber of the dense layer and the spunbond fiber of the base material layer was hardly observed. The results are shown in Table 2.
- Comparative Example 2 A nonwoven fabric laminate for foam molding was obtained in the same manner as in Comparative Example 1 except that the basis weight of the spunbond nonwoven fabric layer laminated on both sides was 50 g / m 2 and the fiber diameter was 35 ⁇ m. Similar to Comparative Example 1, a large amount of powder was generated during needle punching, and was remarkably seen on the surface of the nonwoven fabric laminate. Moreover, from the microscopic observation, the entanglement between the meltblown fiber of the dense layer and the spunbond fiber of the base material layer was hardly observed. The results are shown in Table 2.
- the reinforcing material for foamed molded product of the present invention can be applied to any foamed molded product.
- it can be applied to a foamed molded product made of urethane or the like to give good rigidity and noise prevention.
- the present invention can be applied to molding foam molded products for various uses such as seats for vehicle seats such as automobile seats, furniture, chairs, and beds.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Laminated Bodies (AREA)
- Mattresses And Other Support Structures For Chairs And Beds (AREA)
- Chair Legs, Seat Parts, And Backrests (AREA)
Abstract
Description
しかしながら、特許文献1に記載された発泡成形用補強材基布は、緻密な層の目付が低いため、ウレタンの染み出しを有効に阻止することが出来ない虞がある。また、特許文献2に記載された発泡成形用補強材基布は、ウレタンの染み出しは阻止できるものの、基布の目付が大きすぎるために、ウレタンが過度に含浸し、クッション性低下やウレタン密度低下による強度ダウン、素材自体の重量アップからの経済性低下などの虞がある。
一方、特許文献3には、緻密層として、目付が40g/m2以下、より好ましくは15~20g/m2で、繊維径が10μm以下のメルトブローン不織布を用いることが記載されている。しかしながら、繊維径が細いメルトブローン不織布層とスパンボンド不織布層とをニードルパンチで接合した場合は、メルトブローン不織布層を形成する繊維とスパンボンド不織布層を形成する繊維の繊維径が違いすぎる為か、繊維同士の絡み合いが少なく、層間が剥離する虞があり、又、ニードルにより、メルトブローン不織布層の繊維が切れて、発泡成形用不織布の表面に、粉が発生する虞がある。
緻密層が、メルトブローン不織布層(A)の両側(両面ともいう。)〔以下、「両側」とする。〕に、スパンボンド不織布層(B)が積層され、かつ、当該メルトブローン不織布層(A)とスパンボンド不織布層(B)とが、部分的に熱圧着されてなることを特徴とする発泡成形用不織布積層体を提供するものである。
本発明の緻密層及び補強層を形成する不織布の原料となる熱可塑性樹脂は、不織布を形成し得る熱可塑性樹脂であれば、特に限定はされず、種々公知の熱可塑性樹脂、具体的には、エチレン、プロピレン、1-ブテン、1-ヘキセン、4-メチル-1-ペンテンおよび1-オクテン等のα-オレフィンの単独若しくは共重合体である高圧法低密度ポリエチレン、線状低密度ポリエチレン(所謂LLDPE)、高密度ポリエチレン(所謂HDPE)、ポリプロピレン(プロピレン単独重合体)、ポリプロピレンランダム共重合体、ポリ1-ブテン、ポリ4-メチル-1-ペンテン、エチレン・プロピレンランダム共重合体、エチレン・1-ブテンランダム共重合体、プロピレン・1-ブテンランダム共重合体等のポリオレフィン、ポリエステル(ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリエチレンナフタレート等)、ポリアミド(ナイロン-6、ナイロン-66、ポリメタキシレンアジパミド等)、ポリ塩化ビニル、ポリイミド、エチレン・酢酸ビニル共重合体、エチレン・酢酸ビニル・ビニルアルコール共重合体、エチレン・(メタ)アクリル酸共重合体、エチレン-アクリル酸エステル-一酸化炭素共重合体、ポリアクリロニトリル、ポリカーボネート、ポリスチレン、アイオノマーあるいはこれらの混合物等を例示することができる。これらのうちでは、高圧法低密度ポリエチレン、線状低密度ポリエチレン(所謂LLDPE)及び高密度ポリエチレン等のエチレン系重合体、ポリプロピレン及びポリプロピレンランダム共重合体等のプロピレン系重合体、あるいは、ポリエチレンテレフタレート、ポリアミド等がより好ましい。
<プロピレン系重合体>
本発明に係るプロピレン系重合体としては、通常、融点(Tm)が125℃以上、好ましくは130~165℃の範囲にあるプロピレンの単独重合体若しくはプロピレンと極少量のエチレン、1-ブテン、1-ペンテン、1-ヘキセン、1-オクテン、4-メチル-1-ペンテン等の炭素数2以上(但し炭素数3を除く)、好ましくは2~8(但し炭素数3を除く)の1種または2種以上のα-オレフィンとの共重合体が好ましい。
<メルトブローン不織布層(A)>
本発明に係る緻密層を構成するメルトブローン不織布層(A)は、上記熱可塑性樹脂からなる不織布層であって、通常、繊維径が0.1~5μm、好ましくは0.5~3μm、目付が通常、0.1~5g/m2、好ましくは1~3g/m2の範囲にある。
<スパンボンド不織布層(B)>
本発明に係る緻密層を構成するスパンボンド不織布層(B)は、上記熱可塑性樹脂からなる不織布層であって、通常、繊維径が10~40μm、好ましくは10~20μm、目付が10~50g/m2、好ましくは10~20g/m2の範囲にある。
<緻密層>
本発明の発泡成形用不織布積層体を構成する緻密層は、上記メルトブローン不織布層(A)の両側に、上記スパンボンド不織布層(B)が積層されてなり、かつ、当該メルトブローン不織布層(A)とスパンボンド不織布層(B)とが、部分的に熱圧着されてなる。熱圧着する方法としては、後述のように各種方法を用いうるが、エンボス加工を好ましく用いることができる。なお、本発明において「部分的に」とは、面積率で5~30%、好ましくは5~20%の範囲をいう。
<発泡成形用不織布積層体>
本発明の発泡成形用不織布積層体は、上記緻密層の少なくとも片側に、好ましくは、両側に補強層が積層されてなる。
(1)目付(g/m2)
不織布から、機械方向(MD) 100mm×横方向(CD)100mmで10点採取し、平均値を算出した。
(2)厚さ(mm)
上記目付測定用試料の中央、四隅5点を測定する。50点の平均値を算出した。荷重は2g/cm2(荷重面積 4cm2)の厚み計を使用した。
(3)嵩密度(g/cm3)
不織布の嵩密度は、上記(1)及び(2)で得られた目付及び厚さを用い、次式により求めた。
嵩密度=目付(g/m2)/( 上記厚さ(mm)/10×100×100)
JIS L1906に準拠して測定した。発泡成形用不織布積層体から200mm(MD)×50mm(CD)の試験片を採取し、引張試験機(島津製作所製:オートグラフ AGS-J)を用いてチャック間距離100mm、ヘッドスピード100mm/minでMD:5点、CD:5点を測定し、平均値を算出し、強度とした。
(5)通気度(cm3/cm2/sec)
発泡成形用不織布積層体から200mm(MD)×50mm(CD)の試験片を採取し、JISL1096に準じたフラジール通気度測定機によって行った。
発泡釜へ発泡成形用不織布積層体(400mm(MD)×400mm(CD))を取り付け、ウレタンの染み出しを、以下の基準により目視にて評価した。
認められない : ◎
ほとんど認められない : ○
やや認められる : △
かなり認められる : ×
尚、発泡成形は、樹脂材料としてポリウレタン、及び自動車座席シート形状の発泡釜を使用して行った。
ニードルパンチして得られた発泡成形用不織布積層体の表面に、目視にて確認できる0.5~3mm程度の粉があるかどうかを以下の基準により評価した。
認められない : ◎
ほとんど認められない : ○
やや認められる : △
かなり認められる : ×
ニードルパンチして得られた発泡成形用不織布積層体の断面を、走査電子顕微鏡((株)日立製作所製 S-3500N形)にて35倍の倍率にて撮影した。撮影後の写真から緻密層の繊維と基材層の繊維の交絡が認められるかどうか、以下の基準により評価した。
認められない : ×
ほとんど認められない : △
やや認められる : ○
かなり認められる : ◎
<緻密層の製造>
MFRが60g/10分のプロピレン単重合体を用い230℃にて溶融紡糸を行い、得られた繊維を補集面上に堆積させ、目付量が5.9g/m2のスパンボンド不織布層(B-1)(繊維径15μm)を製造した。
次に、MFRが400g/10分のプロピレン単重合体を280℃にて押出機で溶融し、得られた溶融物を、紡糸口金から吐出するとともに、吐出孔出口において280℃の加熱空気を吹付けるメルトブローン法によって繊維径3μmの繊維を前記スパンボンド不織布(B-1)上に堆積させ、目付量1.2g/m2のメルトブローン不織布層(A-1)を形成し、さらにその上に前記スパンボンド不織布(B-1)と同様のスパンボンド不織布(B-2)を積層し、刻印面積率18%の熱エンボスロールにて3層を一体化してSMS不織布からなる緻密層を得た。緻密層の合計の目付は13g/m2であった。
<補強層の製造>
MFRが60g/10分のプロピレン単重合体を用い230℃にて溶融紡糸を行い、得られた繊維を補集面上に堆積させ、目付量が35g/m2であるスパンボンド不織布(C-1)(繊維径21μm)を製造した。
<発泡成形用不織布積層体の製造>
前記方法で得られた緻密層の両側に、スパンボンド不織布層(C-2)を積層し、ニードルパンチにより接合して、発泡成形用不織布積層体を得た。得られた発泡成形用不織布積層体の物性を上記記載の方法で測定した。結果を表1に示す。
緻密層に用いるメルトブローン不織布層と、スパンボンド不織布層の目付を表1に示す目付にする以外は実施例1と同様に、発泡成形用不織布積層体を得た。得られた発泡成形用不織布積層体の物性を上記記載の方法で測定した。結果を表1に示す。
実施例2と同様の緻密層を得てから、この緻密層を2層同じものを積層し、さらに実施例1と同様にこの緻密層の両側にスパンボンド不織布層を積層し、発泡成形用不織布積層体を得た。得られた発泡成形用不織布積層体の物性を上記記載の方法で測定した。結果を表1に示す。
実施例3と同様の緻密層を得てから、この緻密層を3層同じものを積層し、さらに実施例1と同様にこの緻密層の両側にスパンボンド不織布層を積層し、発泡成形用不織布積層体を得た。得られた発泡成形用不織布積層体の物性を上記記載の方法で測定した。結果を表1に示す。
実施例3と同様の緻密層を得てから、この緻密層を2層同じものを積層し、緻密層の両側に積層するスパンボンド不織布層の目付量を50g/m2、繊維径35μmとする以外は、実施例1と同様に、発泡成形用不織布積層体を得た。得られた発泡成形用不織布積層体の物性を上記記載の方法で測定した。結果を表2に示す。
実施例3と同様の緻密層を得てから、この緻密層を3層同じものを積層し、緻密層の両側に積層するスパンボンド不織布層の目付量を50g/m2、繊維径35μmとする以外は、実施例1と同様に、発泡成形用不織布積層体を得た。得られた発泡成形用不織布積層体の物性を上記記載の方法で測定した。結果を表2に示す。
緻密層に用いるメルトブローン不織布層と、スパンボンド不織布層の目付を表1に示す目付にし、両側に積層するスパンボンド不織布層の目付量を25g/m2、繊維径20μmとする以外は、実施例1と同様に、発泡成形用不織布積層体を得た。得られた発泡成形用不織布積層体の物性を上記記載の方法で測定した。結果を表2に示す。
実施例3と同様の緻密層を得てから、両側に積層するスパンボンド不織布層の目付量を25g/m2、繊維径20μmとする以外は、実施例1と同様に、発泡成形用不織布積層体を得た。得られた発泡成形用不織布積層体の物性を上記記載の方法で測定した。結果を表2に示す。
緻密層に目付が7g/m2のメルトブローン不織布層のみを用いて、実施例1と同様に発泡成形用不織布積層体を得た。ニードルパンチ加工時に、粉が多く発生し不織布積層体表面に顕著に見られた。また、顕微鏡観察から、緻密層のメルトブローン繊維と基材層のスパンボンド繊維の間の交絡はほとんど観察されなかった。結果を表2に示す。
両側に積層するスパンボンド不織布層の目付を50g/m2、繊維径35μmとする以外は、比較例1と同様に発泡成形用不織布積層体を得た。比較例1と同様に、ニードルパンチ加工時に、粉が多く発生し不織布積層体表面に顕著に見られた。また、顕微鏡観察から、緻密層のメルトブローン繊維と基材層のスパンボンド繊維の間の交絡はほとんど観察されなかった。結果を表2に示す。
Claims (15)
- 緻密層の少なくとも片側に補強層が積層されてなる発泡成形用不織布積層体であって、
緻密層が、メルトブローン不織布層(A)の両側に、スパンボンド不織布層(B)が積層され、かつ、当該メルトブローン不織布層(A)とスパンボンド不織布層(B)とが、部分的に熱圧着されてなることを特徴とする発泡成形用不織布積層体。 - 緻密層を構成するメルトブローン不織布層(A)の繊維径が0.1~5μmの範囲にある請求項1記載の発泡成形用不織布積層体。
- 緻密層を構成するメルトブローン不織布層(A)の目付が0.1~5g/m2の範囲にある請求項1記載の発泡成形用不織布積層体。
- 緻密層を構成するスパンボンド不織布層(B)の繊維径が10~20μmの範囲にある請求項1記載の発泡成形用不織布層積層体。
- 緻密層を構成するスパンボンド不織布層(B)の目付が10~20g/m2の範囲にある請求項1記載の発泡成形用不織布層積層体。
- 緻密層の嵩密度が0.05~0.5g/cm3の範囲にある請求項1記載の発泡成形用不織布層積層体。
- 緻密層の目付が10~60g/m2範囲にある請求項1記載の発泡成形用不織布層積層体。
- 補強層が、繊維径が12~50μm、及び目付が10~50g/m2の範囲にあるスパンボンド不織布層(C)であることを特徴とする請求項1記載の発泡成形用不織布積層体。
- 発泡成形用不織布積層体の通気度が25~160(cm3/cm2/sec)であることを特徴とする請求項1記載の発泡成形用不織布積層体。
- 発泡成形用不織布積層体の目付が20~160g/m2であることを特徴とする請求項1記載の発泡成形用不織布積層体。
- メルトブローン不織布層(A)と、スパンボンド不織布層(B)が、ともにプロピレン系重合体から形成されることを特徴とする請求項1記載の発泡成形用不織布積層体。
- 前記不織布積層体の補強層側に、さらに発泡ウレタンを積層してなる請求項1に記載の発泡成形用不織布積層体。
- 請求項12に記載の発泡成形用不織布積層体を含んでなる車両用シート。
- 請求項12に記載の発泡成形用不織布積層体を含んでなる椅子。
- メルトブローン不織布層(A)の両側に、スパンボンド不織布層(B)を積層後、部分熱圧着してなる緻密層と当該緻密層の少なくとも片面に補強層を積層した後、交絡処理することを特徴とする発泡成形用不織布積層体の製造方法。
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WO2014030730A1 (ja) * | 2012-08-23 | 2014-02-27 | 三井化学株式会社 | メルトブローン不織布及びその用途 |
CN103781955A (zh) * | 2012-05-22 | 2014-05-07 | 三井化学株式会社 | 发泡成型用非织造布层叠体、使用该非织造布层叠体的氨基甲酸酯发泡成型体复合物、以及发泡成型用非织造布层叠体的制造方法 |
WO2015034069A1 (ja) | 2013-09-06 | 2015-03-12 | 三井化学株式会社 | 発泡成形用不織布積層体、発泡成形用不織布積層体の製造方法、不織布積層体を用いたウレタン発泡成形体複合物、車両用シート、及び椅子 |
JP2018029670A (ja) * | 2016-08-22 | 2018-03-01 | 株式会社イノアックコーポレーション | シートバックおよびその製造方法 |
JP2019516875A (ja) * | 2016-05-18 | 2019-06-20 | ファイバーテクス・パーソナル・ケア・アクティーゼルスカブ | メルトブローン不織層及びスパンボンド不織層を備えた不織ラミネート布 |
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Also Published As
Publication number | Publication date |
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KR101197877B1 (ko) | 2012-11-05 |
EP2447402A1 (en) | 2012-05-02 |
US20160075103A1 (en) | 2016-03-17 |
IN2012DN00772A (ja) | 2015-06-26 |
CN102471968B (zh) | 2012-12-19 |
EP2447402A4 (en) | 2012-07-04 |
CN102471968A (zh) | 2012-05-23 |
US20120119558A1 (en) | 2012-05-17 |
MY152024A (en) | 2014-08-15 |
JPWO2012008169A1 (ja) | 2013-09-05 |
KR20120021332A (ko) | 2012-03-08 |
EP2447402B1 (en) | 2013-06-19 |
JP4855557B1 (ja) | 2012-01-18 |
US10029444B2 (en) | 2018-07-24 |
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