JPH04361032A - Nonwoven fabric laminate - Google Patents

Abstract

PURPOSE:To enhance the solvent resistance and alkali resistance of a nonwoven fabric laminate by providing a composite nonwoven fabric layer based on two kinds of thermoplastic resin fibers having different melting points and subjected to heat-melting treatment on its outside surface as the uppermost layer and providing a single nonwoven fabric layer based on a polyolefin fiber as the lowermost layer. CONSTITUTION:A composite nonwoven fabric layer 2 based on two kinds of thermoplastic resin fibers having different melting points and subjected to heat- melting treatment 3 on its outside surface is provided as the uppermost layer of a nonwoven fabric laminate and a single nonwoven fabric layer 1 based on a polyolefin fiber is provided as the lowermost layer of said laminate. By this method, the desired nonwoven fabric layer is obtained.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The present invention relates to a nonwoven fabric laminate, and in particular, it has excellent solvent resistance and alkali resistance, so it is suitable as a base fabric for waterproof materials, and it does not emit abnormal noise even when it comes in contact with metal members. , relates to a nonwoven fabric laminate suitable also as a reinforcing material for foam molded products such as automobile seats.

0002

2. Description of the Related Art Urethane waterproofing materials are often used for waterproofing the roofs and floors of buildings. By the way, this urethane-based waterproof material contains a large amount of solvents such as toluene and xylene. When a nonwoven fabric made of polyethylene, polypropylene, nylon, etc. is applied as a base fabric to this urethane-based waterproof material, it swells and deforms due to solvent, so polyethylene terephthalate nonwoven fabric, which has excellent solvent resistance, is mainly used.

[0003]Furthermore, foam molded products such as automobile seats are attached to the vehicle body using a metal mounting jig, but the main material of the seat is urethane foam and the metal mounting jig. There was a problem that an abnormal noise was generated when the two came into contact with each other. Therefore, conventionally, a nonwoven fabric, a coarse blanket, or the like is pasted to the portion of the seat that comes into contact with the metal member.

0004

[Problems to be Solved by the Invention] However, the conventional polyethylene terephthalate nonwoven fabric has poor alkali resistance, so it is vulnerable to alkaline-containing water that leaches from the concrete surfaces of buildings and floors, and has a short lifespan. Ta. Furthermore, the latter method of attaching the nonwoven fabric to the automobile seat must be carried out through post-processing, which poses a problem of increasing costs and reducing production efficiency.

Therefore, the object of the present invention is to provide a fabric that is suitable as a base fabric for waterproof materials due to its excellent solvent resistance and alkali resistance, and that can prevent urethane penetration while maintaining breathability, and that does not come into contact with metals. It is an object of the present invention to provide a nonwoven fabric laminate suitable also as a reinforcing material for foamed molded products, which does not generate abnormal noise even when the product is heated.

[0006]

[Means for Solving the Problems] In order to solve the above-mentioned problems, the present invention provides a nonwoven fabric laminate having two or more types of nonwoven fabric layers, the uppermost layer of which has two types of thermoplastic resin fibers having different melting points. The object of the present invention is to provide a nonwoven fabric laminate having a composite nonwoven fabric layer as a main material and whose outer surface is heated and melted, and further including a single nonwoven fabric layer mainly composed of polyolefin fibers as the bottom layer.

[0007] It is preferable that at least one intermediate nonwoven fabric layer is provided between the uppermost layer and the lowermost layer.

[0008] It is preferable that the two types of thermoplastic resin fibers having different melting points are polyethylene terephthalate fibers and polyethylene fibers, and that the bottom layer is mainly made of polypropylene fibers.

The present invention also provides a waterproof sheet having a base layer made of the nonwoven fabric laminate described above.

[0010] Furthermore, the present invention also provides a reinforcing material for foamed molded products having a base material layer made of the nonwoven fabric laminate.

[0011] The nonwoven fabric laminate of the present invention, as well as the waterproof sheet and reinforcing material for foamed molded products using the same as a base layer, will be explained in detail below.

The uppermost composite nonwoven fabric layer of the nonwoven fabric laminate of the present invention is mainly composed of two types of thermoplastic resin fibers having different melting points. That is, this composite nonwoven fabric layer is made of high melting point thermoplastic resin fibers (hereinafter abbreviated as "high melting point fibers").
and low-melting point thermoplastic resin fibers (hereinafter abbreviated as "low-melting point fibers"). Combinations of high melting point fibers and low melting point fibers include combinations of polyethylene terephthalate fibers and polyethylene fibers, combinations of polypropylene fibers and polyethylene fibers, combinations of polyethylene terephthalate fibers and co-polyethylene terephthalate fibers, and polypropylene fibers.
Examples include a combination of ethylene/vinyl acetate copolymer fibers.

[0013] In this composite nonwoven fabric layer, the high melting point fibers and the low melting point fibers may be arranged in parallel, or they may be in the form of a sheath in which the high melting point fibers are the core and the low melting point fibers surround the core. You can. When high-melting point fibers and low-melting point fibers are arranged in the form of a core and sheath, the sheath section made of the low-melting point fibers is eccentric or non-eccentric with respect to the core section made of the high-melting point fibers. engaged with and adhered to the sheath, and
The low melting point fibers are intertwined with each other. In this composite nonwoven fabric layer, the high melting point fibers have a function as a shape retaining material, and the low melting point fibers have a function as an adhesive component.

The high melting point fibers constituting this composite nonwoven fabric layer are made of crystalline or amorphous resin, preferably amorphous resin. For example, IV
Polyethylene terephthalate fiber with a value of 0.45 to 0.80, fiber diameter: 1 to 3d, or density: 0.80 to
Examples include poly-4-methylpentene-1 fibers having a weight of 0.85 g/cm3 and a fiber diameter of 1 to 3 d.

[0015] Also, it is better for the low melting point fiber to have a melting point as low as possible than the high melting point fiber to be combined, and the difference in melting point is 20
~200°C, preferably 50°C or higher. When combined with polyethylene terephthalate fiber, for example, density: 0.860 to 0.970 g/cm3, fiber diameter: 0
．． 5-20d, preferably density: 0.90-0.92g
/cm3, fiber diameter: 1-5d polyethylene fiber, or density: 0.90-0.98g/cm3, fiber diameter: 0.5-20d, preferably density: 0.93-0.9
Examples include ethylene-vinyl acetate copolymer fibers having a weight of 5 g/cm3 and a fiber diameter of 1 to 5 d.

[0016] The content ratio of high melting point fibers/low melting point fibers in this composite nonwoven fabric layer is usually 0.5 to 2.0 in weight ratio.
It is about 0.8 to about 1.2, preferably about 0.8 to 1.2.

[0017] This composite nonwoven fabric can be produced according to a conventional method and is not particularly limited.

[0018] The method for forming the composite fiber into a nonwoven fabric includes:
There are no particular limitations, and any method such as a spunbond method, a dry method, or a wet method may be used. For example, when manufacturing by the spunbond method, after melting high melting point fibers and low melting point fibers in an extruder,
The core and sheath (eccentric or concentric) may be extruded, collected on a screen belt, and formed into a nonwoven fabric.

The thickness of this composite nonwoven fabric layer is usually 0.2
It is about 5.0 mm, preferably about 0.3 to 2.0 mm. In addition, the basis weight of the composite nonwoven fabric layer is usually 20 to
About 500g/m2, preferably 40-200g/m
It is about 2.

Furthermore, in the nonwoven fabric laminate of the present invention,
The outer surface of this composite nonwoven fabric layer is heated and melted,
For example, it has a heat-melted layer in which the low melting point fibers contained in the composite nonwoven fabric layer are melted, the fibers constituting the nonwoven fabric are bonded, and the surface is formed into a film shape. The degree of heat-melting treatment on the outer surface is from film-like to
For example, if air permeability is not required, it may be in the form of a completely porous film, and if breathability is required, it may be in the form of a porous film. The thickness of this heat-fused layer is usually 0.1 to 1
．． It is formed to have a thickness of about 0 mm.

[0021] The heating and melting treatment for forming the heating and melting layer may be performed on the composite nonwoven fabric alone, or may be performed after it is formed into a nonwoven fabric laminate as described later. When heat-melting treatment is performed on the composite nonwoven fabric alone, the heat-melting treatment can be carried out, for example, by passing the composite nonwoven fabric between two heated rolls on one or both sides and pressing them together.

[0022] The temperature of the heating melting treatment is usually 130 to 2
The temperature is about 00°C, preferably about 140 to 170°C.

The lowermost layer of the nonwoven fabric laminate of the present invention is composed of a single nonwoven fabric layer mainly composed of polyolefin fibers. Examples of this polyolefin fiber include polypropylene.

[0024] The thickness of this single nonwoven fabric layer is usually 0.5
~5.0mm, preferably 1.0~2.5
It is about mm.

[0025] Also, the basis weight of this single nonwoven fabric layer is usually about 50 to 500 g/m2, preferably 1
It is about 00 to 300 g/m2.

[0026] The polyolefin fibers which are the main material of this single non-woven fabric layer may have either a round or irregular cross-sectional shape and are not particularly limited, and the fiber diameter is usually about 1 to 20 d. , preferably about 2 to 10 d.

[0027] The method for producing the polyolefin fiber into a nonwoven fabric is not particularly limited, and examples include spunbond method,
Any method such as a dry method or a wet method may be used. For example, in the case of manufacturing by spunbonding, polyolefin resin is melted in an extruder, extruded from a die into fibers, and then stretched with air and collected on a screen belt to form a nonwoven fabric.

Further, it is preferable that the nonwoven fabric laminate of the present invention has an intermediate nonwoven fabric layer between the uppermost layer and the lowermost layer, since the solvent resistance is improved. Examples of the nonwoven fabric used for this intermediate nonwoven fabric layer include those made of polyethylene terephthalate fibers. When the intermediate nonwoven fabric layer is composed of polyethylene terephthalate fibers, the polyethylene terephthalate fibers may have any cross-sectional shape, such as round or irregular shape. In addition, the fiber diameter is usually 1
It is about ~5d.

[0029] The thickness of this intermediate nonwoven fabric layer is usually 0.5
~5.0mm, preferably 0.5~2.0m
It is about m.

[0030] The basis weight of this intermediate nonwoven fabric layer is usually about 50 to 500 g/m2, preferably about 6
It is about 0 to 200 g/m2.

The production of the nonwoven fabric constituting this intermediate nonwoven fabric layer may be carried out according to a conventional method and is not particularly limited. Examples include a spunbond method, a dry method, a wet method, and the like. For example, nonwoven fabrics made of polyethylene terephthalate fibers can be produced by spunbond methods, dry methods, wet methods, and the like.

The nonwoven fabric laminate of the present invention can be produced by laminating the above-mentioned composite nonwoven fabric, single nonwoven fabric, and preferably intermediate nonwoven fabric, and forming a composite by needle punching. The method of laminating each nonwoven fabric is not particularly limited as long as the layer made of the composite nonwoven fabric is disposed as the top layer and the layer made of the single nonwoven fabric is disposed as the bottom layer.

Next, if the outer surface of the composite nonwoven fabric layer of the laminated nonwoven fabrics has not been heat-melted in advance, a pair of heating rolls or the like in which only the roll in contact with the composite nonwoven fabric layer is heated is used. The outer surface of the uppermost composite nonwoven fabric layer may be heated and melted by pressing and heating the uppermost layer by an appropriate means to form a heat-melting layer.

Hereinafter, embodiments of the nonwoven fabric laminate of the present invention will be described in detail based on the schematic cross-sectional views shown in FIGS. 1 and 2.

As shown in (A), the nonwoven fabric laminate shown in FIG. to form a laminate, and then, as shown in (B),
The composite nonwoven fabric layer 2 is heated and melted to form a heat-melted layer 3 on its outer surface layer.

Furthermore, the nonwoven fabric laminate shown in FIG.
As shown in FIG. 1, a single nonwoven fabric layer 1 made of polyolefin fibers is used as the bottom layer, and a composite nonwoven fabric layer 2 is laminated on the single nonwoven fabric layer 1 via an intermediate nonwoven fabric layer 4 to form a laminate. As shown in (B), the composite nonwoven fabric layer 2 is heated and melted to form a heat-melted layer 3 on its outer surface layer.

Furthermore, the nonwoven fabric laminate of the present invention can be applied to various uses, such as a composite nonwoven fabric layer using polyethylene terephthalate fiber as the high melting point fiber and polyethylene fiber as the low melting point fiber in the uppermost layer. In this case, this composite nonwoven fabric layer has excellent solvent resistance, and since it has a single nonwoven fabric layer made of polypropylene nonwoven fabric as the bottom layer, it can be used as a base material for waterproof sheets by taking advantage of its excellent alkali resistance. It can be used as a layer. Further, by appropriately adjusting the degree of heating and melting of the uppermost layer and the pressure bonding force in the lamination process, a waterproof sheet having a desired air permeability can be obtained.

A waterproof sheet using the nonwoven fabric laminate of the present invention as a base layer can be used for either a solvent-based waterproofing material or a non-solvent-based waterproofing material.

Furthermore, the nonwoven fabric laminate of the present invention uses a composite nonwoven fabric layer made of the above-mentioned two types of thermoplastic resins having different melting points, that is, high melting point fibers and low melting point fibers, as the uppermost layer, and furthermore, the lowermost layer If a single nonwoven layer made of polyolefin nonwoven fabric is used as a reinforcing material for foamed molded products, taking advantage of its ability to prevent urethane foam from seeping onto the surface, this reinforcing material can be used to mold seat seats. When used, no abnormal noise is generated due to rubbing between the metal and the urethane foam, which is preferable.

This reinforcing material for foamed molded products is suitable for automobile seats, furniture, and office seats.

[0041]

[Examples] Examples and comparative examples of the present invention are listed below.
Although the present invention will be specifically described, these examples are not intended to limit the scope of the present invention in any way.

(Example 1) Polyethylene terephthalate (PET) fiber (fiber diameter: 1d, fiber cross-sectional shape: round)
with a core of polyethylene (PE) fiber (fiber diameter: 2d,
Fabric weight: 80g/cm2 with fiber cross-sectional shape: round) as sheath
A composite nonwoven fabric (W1), a nonwoven fabric (W2) with a basis weight of 60 g/cm2 made of polyethylene terephthalate fibers (fiber diameter: 2d, fiber cross-sectional shape: round), and polypropylene fibers (fiber diameter: 4d, fiber cross-sectional shape: circular)
Non-woven fabric (W3) with a basis weight of 100g/cm2 consisting of
and further heat rolls at 130-150℃ to heat the
The uppermost layer is made of composite nonwoven fabric (W1), and the middle layer is made of nonwoven fabric (W1).
W2), and a nonwoven fabric (W3) as the bottom layer.
), and a nonwoven fabric laminate in which the surface layer of the uppermost composite nonwoven fabric (W1) had a film shape was obtained. A urethane waterproofing material (toluene 4
When 0% content) was applied, no swelling or deformation due to toluene occurred.

(Example 2) A nonwoven fabric (W2
) was used as the intermediate layer, a nonwoven fabric laminate was produced in the same manner as in Example 1, and a urethane waterproofing material (containing 40% toluene) was applied.
No deformation occurred.

(Example 3, Comparative Example 1) The nonwoven fabric laminate obtained in Example 1 (Example 3) and the polypropylene nonwoven fabric having the same denier and same basis weight as Example 1 (Comparative Example 1)
were applied to the inside of a mold when molding urethane foam for automobile seats, and urethane foam molding was performed. As a result, in the case of a single polypropylene nonwoven fabric, the urethane liquid oozed out to the surface, but in the case of using the nonwoven fabric laminate of Example 1, the urethane liquid stopped before the film-like layer on the surface. There was no urethane solution seeping out on the surface. In addition, the obtained seat sheet made of urethane foam did not generate any abnormal noise due to contact with metal fixtures.

[0045]

Effects of the Invention The nonwoven fabric laminate of the present invention has excellent solvent resistance and alkali resistance, so it is suitable as a base fabric for waterproof materials.It also prevents the penetration of urethane while maintaining breathability, and has excellent resistance to metals. It is also suitable as a reinforcing material for foamed molded products because it does not generate any abnormal noise even when it comes into contact with.

[Brief explanation of drawings]

FIG. 1 (A) and (B) of FIG. 1 are diagrams illustrating a first embodiment of the nonwoven fabric laminate of the present invention.

FIG. 2 (A) and (B) of FIG. 2 are diagrams illustrating a second embodiment of the nonwoven fabric laminate of the present invention.

[Explanation of symbols]

1 Single nonwoven layer 2 Composite nonwoven fabric layer 3 Heating and melting layer 4 Intermediate nonwoven fabric layer

Claims (5)

[Claims] Claim 1: A nonwoven fabric laminate having two or more types of nonwoven fabric layers, the uppermost layer being a composite nonwoven fabric whose main material is two types of thermoplastic resin fibers with different melting points, and whose outer surface is heated and melted. A nonwoven fabric laminate having a single nonwoven fabric layer mainly composed of polyolefin fibers as the bottom layer. 2. The nonwoven fabric laminate according to claim 1, further comprising at least one intermediate nonwoven fabric layer between the uppermost layer and the lowermost layer. 3. The nonwoven fabric according to claim 1, wherein the two types of thermoplastic resin fibers having different melting points are polyethylene terephthalate fibers and polyethylene fibers, and the lowermost layer is mainly composed of polypropylene fibers. laminate. 4. A waterproof sheet having a base layer made of the nonwoven fabric laminate according to claim 3. 5. A reinforcing material for a foamed molded product, comprising a base layer made of the nonwoven fabric laminate according to any one of claims 1 to 3.