JPH0582533U - Non-woven interior material - Google Patents

Abstract

(57) [Summary] [Purpose] To facilitate recycling of cut waste after molding such as automobile mats and used mats after automobile scrapping, remove the harmful effects of waste pollution and improve the backing layer,
Improves moldability by reducing weight. [Structure] A synthetic resin film is formed on one surface of a non-woven base layer 1 formed by mixing regular type synthetic fibers with flame-retardant synthetic fibers and low-melting-point synthetic fibers, and bonding the fibers by fusion of the low-melting-point synthetic fibers. It is a non-woven fabric interior material in which the backing layer 3 is layered and the synthetic fiber and the synthetic resin are fibers or resins whose basic components are the same synthetic high molecular weight polymer material.

Description

[Detailed description of the device]

[0001]

[Industrial applications]

 The present invention relates to a non-woven fabric interior material that is easy to recycle when used in an automobile interior material or an interior field requiring flame retardancy.

[0002]

[Prior Art]

 Conventionally, non-woven fabrics used for automobile interior materials such as trunk mats and interior interior materials are made of regular type polyester fibers and polyamide fibers as raw materials, and 100% of these fibers are used to form a fiber layer and needling. In addition to being integrated, it is bonded with a resin binder and then backed with rubber or styrene-butadiene-rubber (SBR), or as a molding film, various laminates such as polyethylene film, EVA mass back laminate, PVC mass back laminate, etc. Those that have been subjected to are mainly used.

[0003]

[Problems to be solved by the device]

 However, since the non-woven fabric interior materials such as those mentioned above are made of different materials, it is complicated because it is necessary to separate the scraps during molding and used materials after car scrapping into each material. Recycling was almost impossible. In the case of backing with SBR or film, the former cannot avoid decreasing the rigidity of the resin, especially in the case of flame-retardant backing, and when both types of backing are used in combination, weight is increased and weight reduction is desired. It didn't fit the trend. In addition, the elongation at the time of molding was small and the moldability was difficult.

In view of the above situation, the present invention deals with this situation, in particular, by using the same material as a base and mixing binder fibers to prepare an interior material, cutting waste after molding such as an automobile mat. The purpose is to facilitate the recycling of used mats after scrapping automobiles and to eliminate the harmful effects of waste pollution, improve the backing layer, reduce the weight, and improve the moldability.

[0005]

[Means for Solving the Problems]

 That is, the interior material of the present invention which meets the above-mentioned purpose is made by mixing regular type synthetic fibers with flame-retardant synthetic fibers and low melting point synthetic fibers, and by bonding the low melting point synthetic fibers together, the non-woven base layer is formed. A backing layer made of a synthetic resin film is provided on one surface of the composite fiber, and a fiber or resin containing the same synthetic polymer composite material as a basic component is used as the synthetic fiber and the synthetic resin. Here, the above-mentioned synthetic high-component polymer material is preferably one material selected from polyester, polyamide, and polypropylene, and these are not used together but used as synthetic fibers or synthetic resins alone as the interior material of the present invention. Used for the material.

[0006]

[Action]

 Since the interior material of the present invention as described above is made of the same material, it becomes easy to recycle when used, or when cutting scraps are produced during molding, and is discarded as waste. It can be used without In addition, by mixing fibers with a low melting point and bonding the fibers together by melting, it is possible to increase the elongation, improve moldability and reduce the defect rate, and achieve weight reduction by omitting the resin backing layer. ..

[0007]

【Example】

Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. The figure shows a cross-section of a part of the interior material according to the present invention. In the figure, (1) is a base layer in which regular-type synthetic fibers are mixed with flame-retardant fibers and low-melting-point fibers having a lower melting point than the above-mentioned fibers. Each of the above fibers is formed into a fiber layer having a required basis weight of, for example, 300 to 800 g / m ² , and this is subjected to needling so that the fibers are entangled together and a fork needle or the like is formed. The pile (2) is formed on the surface by using it, and the low melting point fiber is melted by heat treatment, and is fused and bonded as a nonwoven fabric.

Here, the flame-retardant fiber is obtained by mixing a flame-retardant agent such as a commercially available phosphorus-based flame-retardant agent, while the low-melting point fiber usually has a melting point higher than that of a regular type fiber. It is lower than 40 ° C. The mixing ratio of regular type synthetic fibers with flame-retardant fibers and low-melting-point fibers is appropriately determined in consideration of the flame retardant effect, binder effect, appearance, etc., and regular type synthetic fibers 10 to 90%, flame retardant It is practical if it is within the range of 5 to 60% of the characteristic fiber and 5 to 30% of the low melting point fiber, but the preferable ratio is 50%: 30%: 20% in that order. In this case, it is also possible to use a composite fiber having a regular type synthetic fiber component as a core and a low melting point fiber component mixed with the above flame retardant as a sheath component, serving as both a flame retardant fiber and a low melting point fiber. Is.

(3) is a backing film layer formed on one surface of the base layer (1) formed as described above, the lower surface in the figure, and the backing film layer (3) is 100 to 300 g / m ² It has a certain weight and is joined to the base layer (1) in a layered manner.

In the above-mentioned interior material, however, the synthetic fiber, the flame-retardant fiber, and the low-melting point fiber that form the base layer (1) and the material that forms the backing film layer (3) are the same synthetic polymer material. For example, polyester (PET) is all PET-based, and polyamide is all polyamide-based. Examples of such synthetic high molecular weight polymer materials include the above polyesters and polyamides, and polypropylene and the like, all of which are used uniformly.

Next, a specific example of making the non-woven fabric interior material according to the present invention will be described. 50% of regular polyester fiber (PET) (melting point 250 ° C) of 10 denier and fiber length of 76 mm, 6 denier containing phosphorous flame retardant, 30% of flame retardant polyester fiber of 64 mm fiber length and 4 denier, A low melting point polyester fiber having a fiber length of 51 mm (melting point 120 ° C.) 20% is mixed to form a fiber layer having a basis weight of 400 g / m ² , and a needle density of 60 fibers / cm is applied from below to a depth of 15 mm. The first needling is performed, then the second needling is performed from the upper side at a needle density of 100 needles / cm at a depth of 15 mm, and then the fork needle is again used from the lower side to feed 3 mm and a napped hair with a depth of 10 mm. It was piled. The back surface of the base layer thus obtained was backed with a modified polyester (PET) film of 300 g / m ² to obtain a nonwoven fabric interior material of the present invention.

On the other hand, for comparison, a non-woven fabric interior material was obtained by using a resin backing of 100 g / m ² and a polyethylene sheet backing of 300 g / m ² in the same base layer. Both have the same base layer, but the comparative one has a weight of 400 g / m ² when the resin and the polyethylene sheet are used together, whereas the present invention uses only the film backing layer (300 g / m ² ). 100 g / m ² lighter, and when both were tried to be recycled, the product of the present invention was easy to recycle because it was the same material, but the comparative product was different because the materials were different. In addition, the interior material of the present invention has large elongation and good moldability, and also passed the light resistance test at 83 ° C × 200 Hr. It also has good pill resistance and is extinguished within 5 cm in the flame retardancy test. showed that.

[0013]

[Effect of the device]

 As described above, according to the present invention, the base layer is formed by mixing the regular type synthetic fiber with the flame-retardant fiber and the low melting point fiber, and the backing film is provided on one side of the base layer, and the fiber and the backing film have the same synthetic polymer weight. Since it uses a coalescing material, it is easy to recycle the cut layer after molding and the used car mat after car scrapping, which eliminates waste pollution and mixes with low melting point fibers during molding. The moldability is improved by increasing the elongation of the resin, and since it is a single material, there is no curling of the interior material such as mat after molding, improving the fit property and finishing feeling, and reducing the weight by omitting the resin backing. As a result, it is possible to reduce the weight as an automobile interior material, etc., and it is expected that the non-woven fabric interior material will have a practical effect as a whole.

[Brief description of drawings]

FIG. 1 is a partial cross-sectional view showing the structure of a nonwoven fabric interior material according to the present invention.

[Explanation of symbols]

 (1) Base layer (3) Backing layer

Claims (2)

[Scope of utility model registration request] 1. A synthetic resin film is provided on one surface of a non-woven base layer formed by mixing regular type synthetic fibers with flame-retardant synthetic fibers and low melting point synthetic fibers and bonding the fibers by fusion of the low melting point synthetic fibers. A non-woven fabric interior material, wherein the backing layer is formed by layering, and the synthetic fiber and the synthetic resin are fibers or resins containing the same synthetic polymer material as a basic component. 2. The synthetic high component polymer material is polyester,
The non-woven fabric interior material according to claim 1, which is one kind selected from polyamide and polypropylene.