JPH01209131A - Fibrous laminate and preparation thereof - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a fibrous laminate with excellent thermoformability and shape retention, and a method for producing the same, and in particular can be deep drawn as an interior material for vehicles such as automobiles. The present invention relates to an m-fibrous calendar body having excellent thermoformability and good shape retention, and a method for producing the same.

[Prior Art] Conventionally, fiber mats and fiber mats with excellent moldability have been used as interior materials for automobiles by coating or impregnating a needle-punched nonwoven fabric with an aqueous emulsion of a thermoplastic resin having a softening point of 100 to 130'C and drying the mixture. Nonwoven fabric mats made of mixed fibers of high-melting point fibers such as polyethylene terephthalate and thermoplastic resin fiber binders with a melting point of 100 to 130°C are heated and press-molded to match the shape of an automobile floor. Carpet is used.

However, these carpets lack luxury on their own, and are unsatisfactory in any of the various performance requirements for carpets such as rigidity, elasticity, and moldability. Covering materials such as tufted carpets and needle punch carpets are adhered to the surface using adhesives or hot melt agents, and carpets lined with resin sheets or foam sheets are also used. However, even these carpets have problems in terms of breathability and flexibility.

On the other hand, the present inventors have developed a method for lining a carpet without first reducing the air permeability of the carpet. A method in which a web produced by needling a felt layer mixed with fibers having a melting point 40°C or more higher than the melting point of the binder is heat-pressed and molded via a fiber binder nonwoven fabric (Japanese Unexamined Patent Publication No. 135614/1983) ) was proposed.

[Problems to be Solved by the Invention] However, the carpet lining method proposed in JP-A No. 61-135614 differs from the conventional method in which the hot melt adhesive film is continuous, and the adhesive layer is Since it is discontinuous with voids, it is excellent in that it does not impair breathability and flexibility.

However, with this method: (1) When a fiber binder is mixed into the fiber mat used for lining, a problem arises in uniformity. Therefore, it is necessary to sufficiently mix the fiber binder and other fibers, and in order to obtain stable moldability, the moldability must be improved and the fibers must be fixed as evenly as possible.

■ To ensure more secure adhesion between the carpet and fiber mat, a water-permeable nonwoven fabric with thermoplastic tjAm binder may be sandwiched between the two and heat-pressed, or hot melt adhesive may be used to bond it to other materials. (Non-woven fabric binder,
thermoplastic resin film, thermoplastic resin powder, etc.) are required.

■ In the case of molded materials used for floors etc., filling voids or
In order to absorb uneven surfaces and provide cushioning properties,
The underfelt must be bonded to the molded body at the same time during hot molding.

There are other problems.

Note that if needling is the only bonding method used, the surface of the upholstery will be rough and the adhesive strength will be insufficient, and if a hot melt adhesive and needling are used in combination, the surface of the carpet will be rough.

[Means for Solving the Problems] The present invention further improves the carpet lining method proposed above, and provides a simple and inexpensive lining that is highly decorative and has excellent moldability and shape retention. The present invention provides a method for manufacturing a fibrous laminate that can be used to manufacture carpets of different colors.

That is, the present invention provides upper and lower nonwoven fabric layers (
A), (B), and the thermoplastic fiber binder nonwoven fabric sandwiched between the upper and lower nonwoven fabric layers (A), (B) mainly composed of synthetic fibers or natural fibers having a melting point 40°C or more higher than the melting point of the nonwoven fabric. a fiber mat layer (C), and the fibers of the fiber binder nonwoven fabric of the upper and lower nonwoven fabric layers (A) and (B) are intertwined and bonded with the synthetic fibers or natural fibers of the fiber mat layer (C). In a fibrous laminate formed by laminating a body mat (D) and a facing material (E), a fiber mat layer (C) containing the synthetic fiber or natural fiber as a main component.
A fibrous laminate, characterized in that the emulsion resin solid content of a resin having a glass transition point of 50° C. or higher is 10 to 100 parts by weight per 100 parts by weight of the fibers, and
Thermoplastic fiber binder The thermoplastic fiber binder is applied to the front and back surfaces of the fiber mat layer (C) mainly composed of synthetic fibers or natural fibers having a melting point higher than the melting point of the nonwoven fabric layers (A) and (B) by 40°C or more. A laminate mat (D) obtained by laminating the nonwoven fabric layers (A) and (B) and applying needle punching was immersed in an emulsion of a resin having a glass transition point of 50°C or higher to impregnate the emulsion. After that, the facing material (E) is further layered and heated and compressed to dry the emulsion and melt the fiber binders of the fiber binder nonwoven fabric layers (A) and (B) to form the facing material (E). This is a method for producing a fibrous laminate, characterized by heat-sealing the fiber mat layer (C).

[Detailed Description of the Invention (1) Fibrous Laminate The fibrous laminate of the present invention, as shown in FIG.
The upper and lower fiber binder nonwoven fabric layers (A), It has a structure in which a covering material (E) such as needle punch carpet is layered on one side of a laminate mat (D) in which the fibers of (B) and the fibers of the fiber mat layer (C) are intertwined and bonded. be.

Fiber binder\AB The fiber binder nonwoven fabric layers (A) and (B) constituting the fibrous laminate of the present invention are layers made of a nonwoven fabric formed from thermoplastic resin fibers, and include polyethylene, polypropylene, linear polyester, etc. It is made of resin fibers such as polyamide, or composite fibers thereof, and has a melting point of 60 to 200°C, preferably 90 to 170°C.
℃, and can be thin or thick depending on the purpose, but is usually 3 denier or more, and the fiber length is 8.
The above is preferable and can be obtained by intertwining the resin fibers by a spun-pounding method or a needle-punching method. Further, a fiber web obtained by carding or the like, or a fiber web fixed with a binder may also be used.

These fiber binder nonwoven fabrics (A) and (B) are made by melting pellets of resin such as polypropylene, low-melting point polyester, and low-melting point polyamide using an extruder, and extruding the pellets into a tocoroten shape through a die with many thin holes. It may also be manufactured by blowing the fibers on the wind, pulling them out so that they do not converge, depositing them on a screen below the die, and taking them off with a winder.

Such fiber binder nonwoven fabrics have many gaps through which water can pass, and are manufactured by Diapond Industrial Co., Ltd., for example.
The product name of "Meltron W" is P, which is made of polyamide.
AY-200, RAS-200, polyester type is ES-500, ethylene/acetic acid copolymer type is Y
It is commercially available under the grade name -7, and a polypropylene-based product is available from Mitsui Petrochemical Industries as "Syntex J".
PK-103, PK-108, PK-404, PK-4
08, polyethylene-based fabrics are available under the trade name Admel, and similar nonwoven fabrics from Kureha Sen'i are available under the trade names rDYNAc J, LNS-0000,
LNS-2000, ES-00, B-1000, B-2
It is commercially available with grade names such as 000 and B-3000.

The fiber binder of the fiber binder nonwoven fabric layer (A) preferably has a melting point that is 40° C. or more lower than the melting point of the fibers that are the main component of the fibers in the fiber mat layer (C). The temperature at which the nonwoven fabric layer (A) is melted is usually 20 to
This is because a temperature 30° C. higher is used.

The basis weight of the fiber binders (A) and (B) is usually 6 to 60.
0g/m2. Preferably, the area is 10 to 50,087 m2 and is breathable.

Furthermore, the m-fiber binder nonwoven fabric layers (A) and (B) do not need to be made of a single type of fiber. For example, mixed fibers of polypropylene and polyethylene may be used. Furthermore, there is no problem even if high melting point fiber is mixed as long as it is within 30%. When recycled fibers are used, fibers with a high melting point may be mixed in.

Further, (A) may be a polypropylene fiber binder nonwoven fabric, and (B) may be a polyethylene fiber binder nonwoven fabric.

Synthetic fibers or natural fibers are generally used as the fibers forming the fiber mat layer (C) constituting the fibrous laminate of the present invention, but mixed fibers of both can also be used.

The synthetic fibers include polyethylene terephthalate, polyamide, polyacrylonitrile, etc., which have a melting point higher than the melting point of the fiber binder nonwoven fabric layer (A) by 40°C or higher, preferably 70°C or higher (specifically 200 to 280°C).
℃) is used.

Further, as the natural fiber, cotton, linen, wool, miscellaneous felt, waste polyester fiber, etc. are used.

This fiber mat layer (C) may contain a fiber binder having a melting point of 80 to 200° C. in a proportion of 5 to 50 parts by weight.

The fiber mat layer (C) can be integrated by intertwining the fibers of the fiber binder nonwoven fabric layers (A) and (B) with the fiber binder nonwoven fabric layers (A) and (B) laminated on both the front and back sides by needling. C) Fiber mat layer (
C) It is not necessary to provide sufficient shape retention to itself.

Further, the fibers do not necessarily have to be of high quality, but the purpose can be sufficiently achieved even if a web of waste fibers is used. That is, it contains 50% by weight or more of various fibers having a melting point higher than the melting point of the fiber binder (A) by 40°C or more, preferably 70°C or more, such as wool, nylon, polyacrylonitrile, polyacetate, polyethylene terephthalate, etc. This can be used to create needle punch carpets made into card webs, as well as phenol felts made by hardening fiber laminates with a binder.

In addition, the basis weight of the fiber mat layer (C) is generally 100~
1000 g/m2, preferably 300-750 g/m
It is within the range of 2.

Mat D By applying needling to a laminate consisting of a three-layer structure in which fiber binder nonwoven fabric layers (A) and (B) are superimposed on both sides of the fiber mat layer (C), the fiber mat layer (C) is formed. The fibers in the fiber binder nonwoven fabric layers (A) and (B)
A laminate mat in which the entire area of the (C) layer is impregnated with the emulsion by impregnating the emulsion from the (B) layer side or by immersing the laminate mat in an emulsion bath. (D) is obtained.

In addition, the fiber mat of the fiber mat layer (C) before lamination is impregnated with an emulsion, or the fiber mat is immersed in an emulsion bath, the emulsion is semi-dry to completely dried, and then both sides are covered with a fiber binder nonwoven fabric layer (C). A
) and (B) to obtain a laminate mat CD) in which the (C) layer was impregnated with an emulsion.

The stacking amount of the fiber binder nonwoven fabric layers (A) and (B) is 10 to 100 weight X of the fiber mat layer (c), respectively.

When performing needling, it is necessary to penetrate the fiber binder nonwoven fabric layer and the fiber mat layer, preferably perpendicularly, so that the fiber mat layer CG)
Throughout, the binder fibers of the fiber binder nonwoven layer (A) are inserted into the fiber mat layer (C). Needling is performed until 5 to 8 oz of the fiber binder of the fiber binder nonwoven fabric layer (A) becomes entangled with the fibers of the fiber mat layer (C). However, when a fiber mat layer (C) containing 5 to 50 weight 2 of fiber binder is used before needling, the needles do not necessarily have to be attached to the fiber mat layer (C).
It is not necessary to insert C) completely.

Needling may be performed from either side of the laminate, but when needling is performed from the fiber binder nonwoven fabric layer (A), the binder fibers of the fiber binder nonwoven fabric layer (A) are transferred to the fiber mat layer by needling. (C
), but the remaining 85-20% is the fiber binder nonwoven fabric layer (D) on the surface of the laminate mat (D).
The layer structure of the fiber binder layer (A) and the fiber mat layer (C) is clear, and the fiber mat layer (C) remains as A).
) in which binder fibers of the fiber binder layer (A) are present. In this case, as a matter of course, a portion of the fibers of the fiber mat layer (C) are inserted into the fiber binder nonwoven fabric (B) on the opposite side and intertwined with the nonwoven fabric fibers.

That is, in the laminate mat (D), the fiber binder in the fiber binder nonwoven fabric layer (A) is inserted perpendicularly into the fiber mat layer (C) by needling, and the fibers of the fiber mat layer (C) are also inserted on the opposite side. Fiber binder nonwoven layer (
B) As it penetrates into the interior, the three layers of fibers intertwine and become one. Of course, needling may be performed from the fiber binder nonwoven fabric layer (B) side.

The above #i miscellaneous mat layer (C) and the fiber binder nonwoven fabric layer (
The needling performed after lamination with A) and (B) is
This is done by passing the needles vertically through the opposite side at a rate of 80 to 300 needles per square inch.

The facing material (E) to be superimposed on the needled laminate mat (D) is 40°C or higher, preferably 70°C higher than the melting point of the fiber binder nonwoven* (A).
Needle-punched carpets made from fibers with melting points higher than or above, such as wool, nylon, polyacrylonitrile, polyacetate, and polyethylene terephthalate, and primary base fabrics knitted from polypropylene flat yarns (this includes carpets and (The backing treatment commonly used for woven fabrics, etc. may be applied.)
Raw material for tufted carpet with raised piles made of polyamide or polyethylene terephthalate on top, or raw material for tufted carpet with the above-mentioned needle punch carpet or spunpond nonwoven fabric as the primary base fabric and piles raised on top of the needle punched carpet or spunpond nonwoven fabric. be.

Note that this covering material (E) does not necessarily have to be the carpet itself, and decorative sheets such as woven fabric, synthetic leather, paper, synthetic paper, and plastics may be used depending on the purpose of use.

Mini top! ``3un'' The emulsion to be impregnated into the fiber mat layer (C) constituting the fibrous laminate of the present invention is a resin having a glass transition point of 50°C or higher, preferably 80 to 180°C, as a resin solid content. Alternatively, particles having a particle size of generally 0.01 to 5 #Lm, preferably 0.05 to 1.5, dispersed in an organic solvent,
The resin solid content present in the fiber mat in the fibrous laminate of the present invention is a resin impregnated with the emulsion and dried.

Specific examples of resins with a glass transition point of 50°C or higher include styrene/acrylic acid lower ester copolymer (ester has 2 to 8 carbon atoms) copolymer, styrene/acrylic acid lower ester/acrylic acid Copolymer, methacrylate
Lower ester of acrylic acid (ester has 2 to 8 carbon atoms)
) copolymers, vinylidene chloride copolymers (with a vinylidene chloride content of 85% by weight or more), and styrene-diene copolymers.

Optimally, (a) poly n-propyl methacrylate (7g 81°C),
Polystyrene (Tg 100℃), polyacrylonitrile (Tg 100℃), polymethyl methacrylate (7g
(105°C), aqueous emulsions of homopolymers such as polymethacrylic acid (Tg 130°C), polyitaconic acid (Tg 130°C), and polyacrylamide (Tg 153°C); (b) vinyl, which is the raw material for these polymers; Monomer 50~
100 weight 2, preferably 85 to 95 weight 2 and other vinyl monomers such as 2-ethylhexyl acrylate (7
g85℃), n-butyl acrylate (Tg-54℃),
Ethyl acrylate (Tg-22℃), isopropyl acrylate (Tg-5℃), 2-ethylhexyl methacrylate (Tg-5℃), n-propyl acrylate (7g8℃)
), n-butyl methacrylate (7g 20℃), vinyl acetate (7g 30℃), t-butyl acrylate (Tg 45
℃), 2-hydroxyethyl methacrylate (7g 55℃)
), ethyl methacrylate (Tg 85℃), isobutyl methacrylate (7g 87℃), vinyl chloride (7g 79℃)
etc., or cholerahinyl monomer and vinylidene chloride (
Tg -18℃) (50 weight 2 or less, preferably 35~
Aqueous emulsion of copolymer with 5 wt.
), the Tg shown in parentheses is the glass transition point of these vinyl monomers or vinylidene chloride homopolymers; Examples include a mixture of a resin aqueous emulsion having a Tg of less than 185 DEG to +50 DEG C. with an aqueous resin emulsion of 50 to 3 weight 2, preferably 45 to 5 weight 2.

In this emulsion, fillers such as calcium carbonate, iron oxide, ferrite, barium sulfate, etc. can be blended in order to give the resulting nonwoven fabric a sense of weight.
In order to impart moldability, it is also possible to blend a powder of a low melting point resin such as low density polyethylene, polystyrene, or ethylene/vinyl acetate copolymer.

Such an emulsion is generally used as a laminate mat (D)
By immersing the emulsion in the emulsion, squeezing it with a roll to impregnate it, and drying it if necessary, it is possible to uniformly disperse the emulsion resin solid content in the laminate mat (D).

The content of the impregnated emulsion resin solids is in the range of 10 to 100 parts by weight, preferably 20 to 80 parts by weight, per 100 parts by weight of synthetic fibers or natural fibers in the fiber mat layer (C). If the emulsion resin solid content is less than the above range, no improvement in rigidity can be obtained, and no improvement in shape retention after molding can be expected. Also, if there is too much, it becomes too hard and feels like resin felt.

(2) Production of m-fibrous laminate To produce the fibrous laminate of the present invention, ■ the wAI
II! The laminate mat (D), in which the fiber binder nonwoven fabric layers (A) and (B) are laminated on the front and back surfaces of the mat layer (C) and intertwined with each other by needle punching, is immersed in an emulsion and squeezed with a roll or the like. After the emulsion is further impregnated with the fiber binder nonwoven fabric layer (A), the emulsion is dried by overlapping the facing material (E) and heating and compressing it.

The fiber binder (B) is melted to heat-seal the facing material (E) and the fiber mat layer (C).

■ After layering the laminate mat (D) and the facing material (E),
After thermal welding, the emulsion is impregnated from the fiber binder nonwoven fabric (B) side to at least the entire area of the mat of the (C) layer, followed by drying and heat shaping. These methods are suitable for tufted carpets, raised carpets, and woven fabrics.

■ The facing material (E) is placed on the fiber binder nonwoven fabric layer (A) and is finally heat-sealed. ) and then heat-sealed with the fiber binder nonwoven fabric (A) during thermoforming. However, method (2) has drawbacks such as roughening of the surface of the covering material (E) and the addition of one manufacturing step. This method is easy to apply to plain needle carpets.

The heating is performed at a temperature higher than the temperature at which the fiber binder nonwoven fabric layer (A) melts, and moreover, the heating material (E) and the fiber mat layer (
It is particularly important to heat to a temperature at which the high melting point fibers in C) do not melt (the fiber binder in the mat layer (C) may melt).

For compression, a pressure roll of about 1 kg/cm2 is sufficient when only heat fusing is performed, and when molding to match the shape of the floor at the same time as heat fusing, or when adjusting the density of the mat, a pressure roll of about 1 kg/cm2 is sufficient.
A pressure of about 50 kg/cm2 is required.

Heating and compression in the case of only thermal fusion can also be performed continuously using a roll or the like.

The fibrous laminate of the present invention can be thermoformed to match the shape of the floor on which it is installed. At this time, another material may be heat-sealed to the side of the fibrous laminate opposite to the facing material (E). This heat forming can be carried out at the same time as the above-mentioned heat-sealing of the facing material (E), or the heat-sealed sheet-like material can be formed into the required shape depending on the purpose. .

[Example] To explain the fibrous laminate of the present invention in more detail,
This will be specifically explained below with reference to Examples. However, these Examples are not intended to limit the fibrous laminate of the present invention.

Example 1 The fiber binder nonwoven fabric layer (A) was made of 16 denier, 501A length polypropylene (melting point 164°C) fibers, 250 g/cm2, webbed with a card to a thickness of 3 shoulders 1.
I used the one from In addition, the fiber binder nonwoven fabric layer (B)
The same material with a weight of 50 g/2 mm and a thickness of 1 m was used.

These fiber binder nonwoven fabric layers (A) and (B) are combined with the phenol felt layer (C) of Howa Seni ■
Lay them on the front and back sides of ot J (trade name, 10m thickness, 1 soft type, basis weight 550g/m2), and needle them at a rate of 150 pieces per square inch to obtain a wall thickness of 13mm. Multiplication is density 0.085
A laminate mat (D) of g/cm' was obtained.

The obtained laminate mat (D) was made of styrene (85 weight 2
) φ Methyl acrylate (12 weight x) acrylic acid (3
Weight 2) After immersing in a bath of an aqueous emulsion of the terpolymer (resin average particle size 0.14 m, solid content 50 weight 2, resin softening point approximately 120°C), the laminate is removed from the bath. The mat (D) is squeezed with a roll to produce a laminate with an emulsion resin solid content of 30 parts by weight per 100 parts by weight of fibers in the mat (D) (resin solid content 250 g/m'
).

Next, a plain type needle punch carpet made of a 300g/■3 fiber mat made by randomly stacking colored polyethylene terephthalate (melting point 264℃) fiber cards of 16 denier and fiber length of 85 to 120 degrees is mounted. It was used as material (E) and superimposed on the upper surface of the fiber binder nonwoven fabric layer (A) of the laminate mat (D). Then, this laminate was heated to 190°C to dry the emulsion and melt the polypropylene fiber binder, and then it was heated to 190°C using a cooling press mold.
Pressure molding was carried out for 60 seconds at a pressure of kg/cm2 to obtain an integrated carpet with a thickness of 6 mm that was faithful to the mold. Also, during molding, a felt tube 8tJ (
A layer of 800g thick) was placed and molded in the same manner.

The obtained carpet was evaluated for the following various characteristics. The results are shown in Table 1.

L Tadarei Ninami 11 A sample piece of 1501 m x 50 mm was cut out from this carpet, supported with a span of 100 mm, and the surface material (E) and fiber mat layer (C) of the sample were measured using an Instron type testing machine.
The peel strength was measured.

Summer Uni Soil Stop 1 Laminated mat (D) was heated and compressed to a thickness of 50 cm at 180° C. for 60 seconds, and it was determined whether or not the thickness could be controlled. If the thickness could be controlled, it was rated O, and if it was not possible, it was rated x.

The shape retention of the product was measured by molding at 180°C and 10 kg/cm2. Those in which the shape according to the mold was obtained were marked as ■, and those in which the shape according to the mold was not obtained were marked as ×.

The bending resistance value was measured when a deformation load was applied perpendicularly to the test piece at a rate of 50 centimeters/min using an Instron type testing machine at 100 layers in the longitudinal direction using fixed locations.

The outer dimensions of the parking test piece (height: 300 mm x width: 300 mm x width: 300 cm x width: 250 mm x width)
Place the specimen on a table with a width of 250 mm, and place a 15-layer hole in the center of the specimen.
A pressure of 2.0 kg/c was applied at a pressure of 2.0 kg/cm2 at this time, and those within the wall thickness of this sample piece were considered to have good rigidity, and those exceeding the wall thickness were considered to have poor rigidity.

During mold molding, a felt tube of 8tJ was placed in the mold, and the thermoplastic fiber binder nonwoven fabric layer (B) on the back was placed in the mold.
When the felt adhered to the surface is peeled off and the adhered "felt knob" layer is broken and peeled off, the felt fibers remain on the thermoplastic fiber binder nonwoven fabric layer (B) side and are adhered.
And those that are not left are marked as X.

The degree of adhesion when a cloth duct tape is attached to the thermoplastic fiber binder nonwoven fabric layer (B) on the back side of a molded product without placing a felt tube, and the removal of fibers when the duct tape is peeled off. The looseness was observed, and a case where the fibers did not peel off was rated 0, and a case where the fibers peeled off was rated x.

Comparative Example 1 In Example 1, a thermoplastic fiber binder nonwoven fabric layer (
A fibrous laminate was obtained in the same manner as in Example 1 except that A) and (B) were not used.

Comparative Example 2 In Example 1, the laminate mat CD) was replaced with styrene.
A fibrous laminate was obtained in the same manner as in Example 1, except that the bath was not impregnated with the aqueous emulsion of methyl methacrylate Φ acrylic acid terpolymer.

Example 2 In Example 1, a thermoplastic fiber binder nonwoven fabric layer (
A) and (B) are polyethylene nonwoven fabrics with a melting point of 119°C (manufactured by Mitsui Petrochemical Industries, trade name: "Admel",
Fiber binder material PP: Polypropylene 63°C) pE: Polyethylene 123°C Type of fiber mat pF: Phenol felt F
N: Fine 21 dollar wooden gluten Type of facing material PET: Polyethylene terephthalate A fibrous laminate was obtained in the same manner as in Example 1.

Example 3 In Example 1, as the fiber mat (C), "Fine Needle 850LJ" (trade name, felt containing 20% fiber binder, fabric weight 650 g/
A fibrous laminate was obtained in the same manner except that ya2) was used.

Example 4 A fibrous laminate was obtained in the same manner as in Example 1 except that Kansai Felt's polyester miscellaneous felt (needle felt, 8cm thickness, basis weight 850g/m2) was used as the fiber mat (C). Ta.

Comparative Example 3 A fibrous laminate was obtained in the same manner as in Example 1, except that a polyester fiber nonwoven fabric was used instead of the polypropylene fiber binder nonwoven fabric.

Table 1 shows the physical properties of these fibrous laminates.

[Effects of the Invention] In the fibrous laminate of the present invention, the fiber mat layer (C) contains an emulsion resin solid content, and both sides of the fiber mat layer (C) are coated with the fiber binder nonwoven fabric layer (A),
(B), and by needling, the fiber binders of the fiber binder nonwoven fabric layers (A) and (B) enter into the fiber mat layer (C) and become intertwined with the mating fibers. (C) itself is easily heat set and provides strength, hardness, moldability and shape retention as a base layer.

In addition, a fiber mat layer (C) and a fiber binder nonwoven fabric layer (
Since A) and (B) are overlapped and intertwined by needling, there is no need to uniformly mix both fibers as in the past, which has the advantage of simplifying the process. It is extremely useful industrially.

[Brief explanation of the drawing]

FIG. 1 is a sectional view of a fibrous laminate according to an example of the present invention. A: Fiber binder non-woven fabric B: Fiber binder non-woven fabric C: Two-layer laminate mat of fiber mat impregnated with filament emulsion E: Surface material applicant Mitsubishi Yuka Verdate Co., Ltd. agent Patent attorney Atsushi 1) Katsura Part 1 Figure 1

Claims (3)

[Claims] (1) Upper and lower nonwoven fabric layers (A) and (B) formed from a thermoplastic fiber binder nonwoven fabric with a melting point of 60 to 200°C;
A fiber mat layer (C) mainly composed of synthetic fibers or natural fibers having a melting point 40° C. or more higher than the melting point of the thermoplastic fiber binder nonwoven fabric sandwiched between the upper and lower nonwoven fabric layers (A) and (B). and the upper and lower nonwoven fabric layers (
A facing material (E) is laminated on a laminate mat (D) in which the fibers of the fiber binder nonwoven fabric of A) and (B) are intertwined and bonded with the synthetic fibers or natural fibers of the fiber mat layer (C). In the fibrous laminate, the resin having a glass transition point of 50° C. or higher, which is impregnated as an emulsion in the fiber mat layer (C) mainly composed of synthetic fibers or natural fibers, has a resin solid content of 10 parts by weight per 100 parts by weight of the fibers. A fibrous laminate characterized in that the content is 100 parts by weight. (2) The fibrous laminate according to claim 1, wherein the amount of the fiber binders (A) and (B) is 10 to 100% by weight of the fiber mat layer (C). (3) Thermoplastic fiber binder nonwoven fabric layers (A), (B)
On the front and back surfaces of the fiber mat layer (C) mainly composed of synthetic fibers or natural fibers having a melting point 40 ° C or more higher than the melting point of
A laminate mat (D) obtained by laminating the thermoplastic fiber binder nonwoven fabric layers (A) and (B) and needling them is immersed in an emulsion of a resin having a glass transition point of 50° C. or higher. After impregnating it, the facing material (E) is further layered and heated and compressed to dry the emulsion and melt the fiber binders of the fiber binder nonwoven fabric layers (A) and (B) to form the facing material. A method for producing a fibrous laminate, which comprises heat-sealing (E) and a fiber mat layer (C).