JPH10147191A - Bulk brushed nonwoven fabric for automotive interior and method for producing the same - Google Patents

Abstract

(57) [Abstract] A nonwoven fabric comprising a high-melting polyester staple fiber and a heat-fusible polyester-based binder fiber, and a laminate of a design layer and a base material layer having different constituent fiber compositions, and a surface of the design layer. A bulky brushed non-woven fabric for automobile interiors, which is made by forming a pile on the surface by needle punching and applying a surface design. PROBLEM TO BE SOLVED: To provide a nonwoven fabric having a supporting function and a cushioning function of a base material and an aesthetic function of a skin integrally, and also having a soft touch feeling, excellent sound absorbing and insulating properties, and improved abrasion resistance. To provide automotive interior materials. SOLUTION: The average thickness is 1 to 50 mm and the average apparent density is 0.01 to 1.0 g / cm ³ ,
A bulky brushed nonwoven laminate comprising a high-melting point synthetic fiber staple and a low-melting point binder fiber, comprising a design layer having a colored fiber pile on the surface and a nonwoven base material having a supporting function and a buffering function.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a bulky brushed nonwoven fabric used for a partition surface of a living space such as a ceiling, a wall, a floor (a carpet) and the like, particularly for an interior of an automobile.

[0002]

2. Description of the Related Art Conventionally, ceilings, walls, floors (carpets), etc.
As a partition surface of a living space or interior material of a car,
Nonwoven fabrics having a vertical cross-sectional shape as shown in FIGS. FIG. 1 shows Japanese Patent Application Laid-Open No. Hei 4-30336.
As disclosed in Japanese Patent Publication No. 37, the nonwoven fabric skin 2 is attached to a relatively hard base material 2 in order to obtain a sense of shape stability. In this case, a steel plate, concrete, wood board, resin board, cardboard, resin felt, or the like is used as the base material 2. By adhering or laminating the nonwoven fabric skin 1 on these base materials, it is possible to secure the aesthetic appearance as an interior material.

FIG. 2 shows a tactile sensation and sound absorption / absorptivity by using a foam sheet or felt, such as polyurethane or polyethylene, having a soft and cushioning property between the base material and the skin 3 as the base material (support) 4. This is an example in which the performance is improved. For example, Japanese Patent Application Laid-Open No. 61-237630,
Nos. 162171, 3-176241, 4-176
742 and the like.

FIG. 3 shows an example in which a nonwoven fabric skin 5 is attached to a nonwoven fabric 6 which can be molded as a base material to improve the tactile sensation and the sound absorbing and insulating properties.
No. 217.

However, in the case of FIG. 1, even if the nonwoven fabric skin 1 is stuck to the hard base material 2, there is a problem that the touch is still hard and the sense of quality is impaired. Further, when the interior material is required to have sound absorbing and insulating properties, if the substrate 2 is hard, there is a problem that if the base material 2 is hard, there is no or very small air permeability, and sufficient sound absorbing and insulating properties cannot be obtained.

In the case of FIG. 2, the tactile sensation and the sound absorbing and insulating properties are improved, but the structure becomes complicated and the material cost and the manufacturing cost are increased, which is not preferable.

In the case of FIG. 3, the tactile sensation and the sound absorbing and insulating properties are improved, but a step of attaching separately manufactured ones while using the same nonwoven fabric for the skin 5 and the base material 6 is necessary. There is a problem of cost increase due to an increase in man-hours.

[0008]

SUMMARY OF THE INVENTION The present invention has been made in view of such a conventional problem. At least one surface is provided with a surface design by, for example, a needle punch to provide a support function for a base material layer. In addition to providing an interior material composed of a nonwoven fabric having a single structure having both a cushioning function and an aesthetic function of the skin, and having both a soft touch and excellent sound absorbing and insulating properties, the above-described problem is solved. The purpose is to solve.

[0009]

According to the bulky brushed nonwoven fabric for an interior material of the present invention, constituent fibers including at least one surface are colored to form a nonwoven fabric design layer, and are integrally laminated with the design layer. It comprises a nonwoven fabric base layer having a shape-retaining property enhancing function and a buffering function, and further forms a pile in which some of the constituent fibers of the nonwoven fabric which are colored over the entire surface protrude to reveal a design pattern. It becomes. Further, the bulky brushed nonwoven fabric for the interior material of the present invention is composed of short fibers of thermoplastic synthetic fibers as a whole, and most preferably, a matrix fiber of a high-melting polyester fiber and a heat-fusible binder fiber are blended at a specific blending ratio. It is composed of a stable sound absorbing and insulating nonwoven fabric in which the intersections of the constituent fibers are bonded by binder fibers and the bonding points are distributed substantially uniformly throughout the nonwoven fabric.

The process for producing a bulky brushed nonwoven fabric for interior use according to the present invention comprises the steps of blending and carding a matrix fiber composed of high-melting-point synthetic fiber staples and a heat-fusible binder fiber staple at a specific blending ratio, respectively. The web for the base material layer is made separately, the two are laminated, molded and integrated by needle punching and / or heat bonding, and then a pile is formed on the surface using a fork needle or the like, and the tip of the pile portion is formed. The portion is trimmed by shearing, preferably, a trimmed chord-like pattern or a dielore-like pattern is formed with a predetermined height difference, and heat setting is performed as necessary.

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The constituent fibers of the nonwoven fabric design layer are composed of 76 to 98% by weight of a high-melting polyester staple fiber having 2 to 30 denier as matrix fiber and low-melting copolyester as heat-fusible binder fiber. Is blended with 2 to 24% by weight of 1 to 20 denier polyester heat-fusible staple fiber having a conjugate structure occupying at least a part of the fiber surface.

The heat-fusible binder fiber is bonded at least at a part of intersections with the non-woven fabric constituent fibers by heat fusion, and stabilizes the non-woven design layer formed into a predetermined shape.
The binder fiber is blended in an amount of 2 to 24% by weight, preferably 5 to 20% by weight, based on the weight of the nonwoven fabric design layer. Hair loss frequently occurs, and it is not preferable because sufficient shape retention by heat molding is difficult to obtain. On the other hand, if it exceeds 24% by weight, the cost increases, and the number of bonding points between fibers increases. The pattern such as the cord tone and the Dirower tone formed on the surface of the surface changes after heat molding, and after the molding heating, there is a possibility that the hair may fall down,
There may be cosmetic problems. Further, when the binder fiber of the design layer is limited to the range of 5 to 20% by weight, all of the above concerns are solved, the pile is prevented from coming off completely, and there is no possibility of hair falling after heating for molding. Morphological stability is obtained.

The fineness of the heat-fusible polyester conjugate fiber used for the design layer is in the range of 1 to 20 denier, and more preferably 2 to 15 denier. If the denier is less than 1 denier, the cost of producing the yarn increases, and there is a problem in the card passing property in the nonwoven fabric forming process.
It is difficult to obtain a good quality nonwoven fabric, and if it exceeds 20 denier, the number of fibers decreases and the inter-fiber adhesion point also decreases, which makes it difficult to obtain sufficient shape retention by heat molding, which is not preferable. Further, when the fineness is limited to the range of 2 to 15 deniers, a design layer having further improved quality and shape stability can be obtained, in addition to contributing to cost reduction of expensive conjugate fibers. Further, when the fineness of the high-melting polyester matrix fiber constituting the design layer is less than 2 denier, there is a problem in the card passing property in the nonwoven fabric forming step as described above, and it becomes difficult to obtain a good quality nonwoven fabric raw material. If it exceeds 30 denier, the texture of the pile becomes coarse, and the hardness is increased.

[0014] In order to color the raw material a predetermined color, it is preferable that both or any one of the above-mentioned polyesters is a so-called original fiber in which a pigment is added to a spinning raw material at the spinning stage to be colored. It is also possible to add a light stabilizer and the like.

Further, the nonwoven fabric base layer integrally laminated with the design layer and having a shape-retaining property-enhancing function and a buffer function comprises a high-melting polyester fiber as a matrix fiber and a heat-fusible polyester fiber as a binder fiber. Although the blended fibers are used, the constituent fibers of the nonwoven fabric substrate layer are composed of high melting point polyester staple fibers having an average fineness of 1.5 to 40 denier as matrix fibers, and 30 to 95% by weight based on the weight of the nonwoven fabric substrate. The heat-fusible staple fiber having an average fineness of 1 to 20 deniers having a polyester conjugate structure in which the low-melting copolyester occupies at least a part of the fiber surface as the heat-fusible binder fiber is 5 to 5 wt. 70% by weight.

When the high-melting-point polyester staple fiber constituting the nonwoven fabric base layer has an average fineness of less than 1.5 denier, the rigidity of the fiber itself is small, so that the shape-retaining property as a core material and the buffer function are enhanced. In addition, the production cost is increased due to the lowering of the spinning speed, or the permeability of the carding machine is reduced when forming the non-woven fabric, so that a high-quality non-woven fabric base material cannot be obtained at low cost. On the other hand, if it exceeds 40 denier, the total number of fibers per unit volume in the fiber assembly decreases, and the number of bonding points with the binder fibers decreases, making it difficult to obtain sufficient rigidity. Also, as the fiber diameter increases, the value of surface area / cross-sectional area decreases, making it difficult to efficiently absorb sound energy.

The heat-fusible polyester-based binder fiber constituting the nonwoven fabric base layer is incorporated in an amount of 5 to 70% by weight, preferably 10 to 60% by weight, based on the weight of the nonwoven fabric layer. If the amount is less than 5% by weight, the number of adhesion points between the fibers will be small, so that it is difficult to obtain sufficient shape retention during heat molding, so that it is not preferable. Since the number of bonding points increases, the compression repulsion force becomes excessive, and it may be difficult to exert an appropriate cushioning function. Further, by limiting the amount to be in the range of 10 to 60% by weight, the most appropriate number of adhesion points can be obtained, and the base layer having excellent morphological stability and cushioning function can be produced at a reasonable cost. Provided.

The high-melting polyester fiber used in the present invention is a fiber containing a fiber-forming thermoplastic aromatic polyester as a main component, and particularly, a polyethylene terephthalate fiber, a polybutylene terephthalate fiber, a polyethylene naphthalate fiber, Poly (p-oxybenzoate) fiber, poly [p- (2-hydroxyethyl)
[Oxybenzoate] -based fiber and the like. Among them, polyethylene terephthalate fiber, which is particularly easily available, is preferably used as a matrix fiber having a relatively high melting point, tensile strength and modulus, because it effectively enhances shape retention and effectively functions as a buffer. Furthermore, a conjugate fiber in which a homopolyester and a copolyester or a modified polyester are eccentric along a fiber axis, for example, an eccentric core-sheath type or a side-by-side type, expresses a crimp by heat treatment and develops a nonwoven fabric. There is a feature that the degree of confounding is increased and the formability is increased. Further, the cross-sectional shape of the high-melting polyester fiber, other than circular, flat type, Y type,
There is no particular limitation such as a hollow type.

The low-melting point copolyester used for the binder fiber is usually a copolymer or a blended polymer, typically having a melting point obtained by copolymerizing or blending a comonomer such as isophthalic acid with polyethylene terephthalate. A reduced polyester heat-fusible polymer is preferably used. In general, for example,
Terephthalic acid, isophthalic acid, dibasic acid components such as adipic acid, and, for example, diol components such as ethylene glycol, propylene glycol, diethylene glycol, triethylene glycol, polyethylene glycol, polypropylene glycol, or lactone was copolymerized by ring opening Copolyester and the like can be used. The homopolyester having a supporting function is not particularly limited, but polyethylene terephthalate or a polyester having a component equivalent thereto is inexpensive and most preferable.

Further, the binder fiber may be a single component fiber composed of the above-mentioned heat-fusible polymer, but the heat-fusible polymer may be a conjugate fiber occupying at least a part of the fiber surface, particularly a homopolymer. The use of a core-sheath conjugate fiber having a heat-fusible copolymer as a sheath component as the core component is most preferable because the heat-fusing function can be achieved while maintaining the support function of the core component. Further, if the side-by-side type conjugate fiber is used, hardening of the nonwoven fabric can be prevented by formation of an excessively reduced fusion point.

The binder fibers can be softened or melted by a heat treatment, for example, a heat treatment at a temperature lower than the softening point of the matrix fiber made of a high-melting polyester, thereby exhibiting the fusibility. The heat treatment is performed at a temperature lower than the softening point temperature of the matrix fiber and at a temperature higher than the temperature at which the binder fiber exhibits the fusibility, but it can be performed as a single step or in conjunction with the heat molding step. By such heat treatment, the constituent fibers intersecting with the binder fibers adhere at the intersections to impart morphological stability to the nonwoven fabric, and the binder fibers cooperate with the support function of the matrix fibers to give the nonwoven fabric an appropriate rigidity. Furthermore, the use of the binder fiber makes it possible to absorb irregularities attached to the surface of the nonwoven fabric and to intentionally stably impart irregularities to the surface of the nonwoven fabric.

The melting point of the low melting point copolyester is 100 to 2
The temperature is preferably in the range of 30 ° C, more preferably 1 ° C.
The range is from 05 to 210 ° C. If the melting point is less than 100 ° C., there is a problem that tacking occurs due to fusion between single yarns during spinning, and there is a problem that fibrillation becomes difficult due to fusion between multifilaments. When the melting point exceeds 230 ° C., not only the low-melting component but also the high-melting component may be softened or melted during heating, lose the shape as a fiber in a lump, and may cause a problem in appearance, The heating temperature rises and molding becomes difficult. The melting point is 1
By using a low-melting copolyester in the range of 05 to 210 ° C, the above problem can be completely solved.

It is preferable that the average thickness after molding the bulky brushed nonwoven fabric for interior of the present invention is 1 to 50 mm. 1
If it is less than mm, the tendency to decrease bending rigidity due to insufficient thickness is unavoidably weakened in strength, and even if rigidity can be secured, the desired appropriate ventilation rate can not be obtained, and sound absorption or sound insulation in interior materials It becomes difficult to provide such performances. Further, pressure and the like acting during molding may impair the texture and appearance of the surface. On the other hand, if it exceeds 50 mm, the bending elastic modulus per unit cross-sectional area of the core material itself becomes small in the case of low density, and the self-weight of the core material becomes large in the case of high density. ,
Sag etc. are seen and shape retention performance is reduced.

The bulky raised nonwoven fabric for interior of the present invention has a thickness of 5 to 70 before molding in a laminated state.
mm, and preferably has an areal density (basis weight) of 300 to 2000 g / m ² . When the thickness is less than 5 mm, it is difficult to secure a desired surface density, while
If it exceeds 70 mm, the workability such as handling at the time of molding is reduced because the thickness of the raw material is too large. Further, when the areal density is less than 300 g / m ² , the function as a buffer layer cannot be sufficiently exhibited due to insufficient compression repulsion, and when it exceeds 2000 g / m ² , the fiber aggregate becomes hard. After molding, the surface does not have the desired texture after molding.

The process for producing a bulky brushed nonwoven fabric for interior use according to the present invention comprises, as a design layer, a short fiber web made of thermoplastic synthetic fiber colored by dyeing, dyeing, printing or the like, preferably dyed by dyeing. The body is laminated with the same type of colored or non-colored thermoplastic synthetic fiber as described above and a short fiber web for a buffer layer, which is made of a colored or non-colored thermoplastic synthetic fiber, and molded and integrated by needle punching and / or heat bonding. Then, using a fork needle or the like, a pile is formed on the surface, and the tip of the pile portion is cut and aligned by shearing,
Preferably, patterning is performed in a trimmed chord tone or a deloy tone with an appropriate predetermined height difference.

Further, a preferred specific example of the above-mentioned production method is that 76 to 98% by weight of a high-melting polyester staple fiber having 2 to 30 deniers as matrix fiber and low-melting copolyester as heat-fusible binder fiber are fibers. A short fiber web for a nonwoven fabric design layer is blended with 2 to 24% by weight of a 1 to 20 denier polyester heat-fusible staple fiber having a conjugate structure occupying at least a part of the surface and carding by a conventional method. Made separately, 30 to 95% by weight of a high melting point polyester staple fiber having an average fineness of 1.5 to 40 denier as a matrix fiber, and a polyester in which a low melting point copolyester occupies at least a part of the fiber surface as a heat-fusible binder fiber. Heat fusible fibers with an average fineness of 1 to 20 denier having a conjugated structure Blending the Puru fiber 5-70 wt%, to prepare a short fiber web for nonwoven substrate layer was carded by a conventional method. The short fiber web for the design layer is
For example, it is preferable that the fibers are colored by being composed of original fibers. Next, these short fiber webs are set on a plurality of continuous cross layers, and a colored design layer short fiber web is supplied from at least one cross layer including the outermost layer web supply to form a web laminate, After that, the whole is integrated by needle punching,
Using a fork needle, etc., form a pile on the surface, shear the tip of the pile part, cut and align,
Heat set as needed. This method enables mass production by a continuous process.

The bulky brushed nonwoven fabric thus laminated and integrated can be formed in one step by heating at a temperature between the melting points of the high-melting polyester and the low-melting copolyester. Such a bulky brushed nonwoven fabric for interior materials is
It has improved cushioning properties and a soft touch with a sense of quality, and has even better sound absorption and insulation performance.

[0028]

Embodiments of the present invention will be described below together with their effects. The method of measuring each characteristic value in Examples, Comparative Examples and Conventional Examples was based on the following methods.

Measurement Method 1 (Measurement of Sound Absorption) The interior materials for automobiles obtained by the methods of Examples, Comparative Examples, and Conventional Examples were subjected to the sound absorption coefficient based on JISA1405 “Method of measuring the normal incidence sound absorption coefficient of building materials by the pipe method”. Was measured, and the sound absorbing property was evaluated. Sample size φ1
00 mm, measurement range 125-1600 Hz.

(Abrasion test) The interior material for automobiles obtained by the methods of Examples, Comparative Examples and Conventional Examples was subjected to JIS K720.
4 Abrasion performance was measured based on "Testing method of plastic abrasion by abrasion wheel" to evaluate abrasion. Load 250
gf, number of tests 100 rotations.

(Example 1) As for the composition of the non-woven fabric, the design layer was 10 deniers of gray and 51 mm long circular polyethylene terephthalate staple fibers having a circular cross section: 90% by weight, and similarly 4 deniers of gray 5
Heat-fusible polyester staple fiber having a core-sheath structure with a length of 1 mm (melting type at 110 ° C.): 10% by weight, weight per unit area: 400 g / m ² . Further, the fiber composition of the base material layer is 1
Normal polyethylene terephthalate staple fiber having a circular cross section of 3 denier 51 mm length: 95% by weight, heat-fusible polyester staple fiber having a core-sheath structure of 2 denier 51 mm length (170 ° C. melting type): 5% by weight, basis weight 600 g / It was m ^2. Next, these fibers were blended, carded, cross-layered, and needle-punched, and the design layer and the base material layer were continuously laminated to obtain a nonwoven fabric. Further, a fork needle is penetrated through the obtained design layer of the fabric to form a pile portion, and then a shirring process is performed to obtain a pattern of a deloy pattern, and the thickness is 40 m.
m bulky brushed nonwoven fabric was obtained. The obtained brushed laminated nonwoven fabric was heated to 180 ° C. and put into a press equipped with a mold to obtain a molded body. The shape retention after molding was good, the taper abrasion test result was also good, and the desired texture was maintained with a deloy feel and color tone.

(Example 2) As for the composition of the non-woven fabric, the design layer is a gray polyethylene-coated ordinary polyethylene terephthalate staple fiber having a circular cross section of 2 denier and 51 mm length:
95% by weight, 2 denier 51m also similarly gray
Heat-fusible polyester staple fiber having a core-sheath structure of m length (110 ° C. melting type): 5% by weight, basis weight 20
0 g / m ² . Furthermore, the fiber composition of the base material layer is a normal polyethylene terephthalate staple fiber having a circular cross section of 6 denier 51 mm length: 85% by weight, 1.5 denier 51
Heat-fusible polyester staple fiber having a core-sheath structure of mm length (melting type at 110 ° C.): 15% by weight, weight per unit area: 100 g / m ² . Next, through blending each of these fibers, carding, cross layer, needle punching process, the design layer and the base layer are continuously laminated,
A nonwoven fabric was obtained. Further, a pile portion was formed by penetrating a fork needle through the obtained design layer of the raw fabric, and a shirring treatment was performed to obtain a pattern of a deloy tone to obtain a bulky brushed nonwoven fabric having a thickness of 7 mm. The obtained brushed laminated nonwoven fabric fabric is 1
The mixture was heated to 50 ° C. and put into a press equipped with a molding die to obtain a molded body. The shape retention after molding was good, the taper abrasion test result was also good, and the desired texture was maintained with a deloy feel and color tone.

(Example 3) As for the composition of the non-woven fabric, the design layer was 20 denier of gray and 51 mm in length with a circular cross section of normal polyethylene terephthalate staple fiber: 80% by weight, and similarly, 15 denier of gray Heat-fusible polyester staple fiber having a core-sheath structure of 51 mm length (110 ° C. melting type): 20% by weight,
The basis weight was 500 g / m ² . Further, the fiber composition of the base material layer is a normal polyethylene terephthalate staple fiber having a circular cross section of 2 denier 51 mm length: 80% by weight, a heat-fusible polyester staple fiber having a core-sheath structure of 6 denier 51 mm length (200 ° C. melting type). ): 20% by weight,
The basis weight was 1500 g / m ² . Next, these fibers were blended, carded, cross-layered, and needle-punched, and the design layer and the base material layer were continuously laminated to obtain a nonwoven fabric. Further, a fork needle is penetrated through the obtained design layer of the fabric to form a pile portion, which is then subjected to a shearing process to obtain a pattern of a dielore pattern and a thickness of 70%.
mm bulky brushed nonwoven fabric was obtained. The obtained brushed laminated nonwoven fabric was heated to 210 ° C. and put into a press equipped with a forming die to obtain a formed body. Good shape retention after molding,
The results of the taper abrasion test were good, the texture of the deloy tone was maintained, and the desired color tone was obtained.

(Example 4) As for the composition of the non-woven fabric, the design layer was 13 denier, which was soaked in gray, and ordinary polyethylene terephthalate staple fiber having a circular cross section with a length of 51 mm: 76% by weight, and similarly, 10 denier, which was soaked in gray. Heat fusible polyester staple fiber having a core-sheath structure of 51 mm length (110 ° C. melting type): 24% by weight,
The basis weight was 400 g / m ² . Further, the fiber composition of the base material layer is a normal polyethylene terephthalate staple fiber having a circular cross section of 40 denier 51 mm length: 30% by weight, a heat-fusible polyester staple fiber having a core-sheath structure of 20 denier 51 mm length (170 ° C. melting type). ): 70% by weight and a basis weight of 600 g / m ² . Next, these fibers were blended, carded, cross-layered, and needle-punched, and the design layer and the base material layer were continuously laminated to obtain a nonwoven fabric. Further, after forming a pile portion by passing a fork needle through the obtained design layer of the raw fabric,
Shearing process to make a diorean pattern and thickness 5
A 0 mm bulky brushed nonwoven fabric was obtained. The obtained brushed laminated nonwoven fabric was heated to 180 ° C. and put into a press equipped with a mold to obtain a molded body. The shape retention after molding was good, the taper abrasion test result was also good, and the desired texture was maintained with a deloy feel and color tone.

(Example 5) The composition of the nonwoven fabric was as follows:
The layer is a 10-denier 51mm long circle with a gray color
Normal section polyethylene terephthalate staple fiber
Wei: 85% by weight, 4 denier 5 similarly grayed
Heat-fusible polyester fiber with 1 mm long core-sheath structure
Table fiber (110 ° C melting type): 15% by weight, eye
With 320 / m ^TwoAnd Further, the fiber composition of the base material layer is 13
Ordinary polyethylene tele with a circular cross section of 51 denier length
Phthalate staple fiber: 90% by weight, 2 denier 5
Heat-fusible polyester fiber with 1 mm long core-sheath structure
Table fiber (170 ° C melting type): 10% by weight, eye
1050g / m with^TwoAnd Then each of these fibers
Blend, carding, cross layer, needle
Through the punching process, the design layer and the substrate layer are continuously laminated
Then, a nonwoven fabric was obtained. In addition, the obtained raw fabric design layer
After penetrating the fork needle to form the pile,
Rolling treatment to make the pattern of the deloy tone and thickness 40m
m bulky brushed nonwoven fabric was obtained. The brushed laminated nonwoven fabric obtained
Heat the counter to 180 ° C and press it into a press equipped with a mold.
It was charged to obtain a molded body. Good shape retention after molding.
Good abrasion test results and a deloy texture
And the desired color tone was obtained.

(Example 6) As for the composition of the non-woven fabric, the design layer is 10 denier, 51 mm long circular polyethylene terephthalate staple fiber having a circular cross-section and 85% by weight, and similarly denier is 4 denier. 5
A heat-fusible polyester staple fiber having a core-sheath structure of 1 mm length (110 ° C. melting type): 15% by weight, and a basis weight of 320 g / m ² . Further, the fiber composition of the base material layer is 1
Normal polyethylene terephthalate staple fiber having a circular cross section of 3 denier 51 mm length: 90% by weight, heat-fusible polyester staple fiber having a core-sheath structure of 2 denier 51 mm length (170 ° C. melting type): 10% by weight,
The basis weight was 1050 g / m ² . Next, only the design layer is blended with fibers, carding, cross-layering, and needle punching. The above-mentioned design layer prepared separately was further laminated thereon, and the whole nonwoven fabric having a thickness of 40 mm was obtained by integrating the whole by needle punching. The obtained brushed laminated nonwoven fabric was heated to 180 ° C. and put into a press equipped with a mold to obtain a molded body. The shape retention after molding was good, the taper abrasion test result was also good, and the desired texture was maintained with a deloy feel and color tone.

(Comparative Example 1) As for the composition of the non-woven fabric, the design layer was 40 denier, a gray cross section, a normal polyethylene terephthalate staple fiber having a circular cross section with a length of 51 mm: 75% by weight, and similarly, 30 denier, which was also gray. Heat-fusible polyester staple fiber having a core-sheath structure of 51 mm length (110 ° C. melting type): 25% by weight,
The basis weight was 300 g / m ² . Further, the fiber composition of the base material layer is a normal polyethylene terephthalate staple fiber having a circular cross section of 13 denier 51 mm length: 90% by weight, a heat-fusible polyester staple fiber having a core-sheath structure of 2 denier 51 mm length (170 ° C. melting type). ): 10% by weight, weight per unit area was 1000 g / m ² . Next, these fibers were blended, carded, cross-layered, and needle-punched, and the design layer and the base material layer were continuously laminated to obtain a nonwoven fabric. Further, a pile portion was formed by penetrating a fork needle through the obtained design layer of the raw fabric, and subjected to shirring treatment to obtain a pattern of a deloy tone, thereby obtaining a 50-mm thick bulky brushed nonwoven fabric. The obtained brushed laminated nonwoven fabric was heated to 180 ° C. and put into a press equipped with a mold to obtain a molded body. Although the shape retention after molding was good, the desired appearance and touch were not obtained due to the large fiber diameter of the design layer.

(Comparative Example 2) As for the composition of the non-woven fabric, the design layer was 10 denier, which was soaked in gray, normal polyethylene terephthalate staple fiber having a circular cross section of 51 mm length: 90% by weight, and similarly, 4 denier, which was soaked in gray 5
Heat-fusible polyester staple fiber having a core-sheath structure with a length of 1 mm (melting type at 110 ° C.): 10% by weight, weight per unit area: 300 g / m ² . Further, the fiber composition of the base material layer is 1
Normal polyethylene terephthalate staple fiber having a circular cross section having a length of 3 denier of 51 mm: 97% by weight, heat-fusible polyester staple fiber having a core-sheath structure of 51 mm length of 2 denier (melting type at 230 ° C.): 3% by weight, and a basis weight of 500 g / It was m ^2. Next, these fibers were blended, carded, cross-layered, and needle-punched, and the design layer and the base material layer were continuously laminated to obtain a nonwoven fabric. Further, a pile portion was formed by penetrating a fork needle through the obtained design layer of the raw material, and subjected to shirring treatment to obtain a pattern of a deloy tone, thereby obtaining a bulky brushed nonwoven fabric. 250 ° C.
However, the entire nonwoven fabric was melted, and a desired molded product could not be obtained.

(Comparative Example 3) As for the composition of the nonwoven fabric, the design layer was 90 denier staple fiber having a circular cross section of 10 denier and 51 mm length which was soaked in gray: 90% by weight, and similarly 4 denier soaked in gray 5
Heat-fusible polyester staple fiber having a core-sheath structure with a length of 1 mm (melting type at 110 ° C.): 10% by weight, weight per unit area: 300 g / m ² . Further, the fiber composition of the base material layer is 6
Normal polyethylene terephthalate staple fiber having a circular cross section of 0 denier 51 mm length: 80% by weight, heat-fusible polyester staple fiber having a core-sheath structure of 25 denier 51 mm length (110 ° C. melting type): 20% by weight, basis weight 700 g / It was m ^2. Next, these fibers were blended, carded, cross-layered, and needle-punched, and the design layer and the base material layer were continuously laminated to obtain a nonwoven fabric. Further, after forming a pile portion by passing a fork needle through the obtained design layer of the raw fabric,
Shearing process to make a diorean pattern and thickness 5
A 0 mm bulky brushed nonwoven fabric was obtained. The obtained brushed laminated nonwoven fabric was heated to 180 ° C. and put into a press equipped with a mold to obtain a molded body. The shape retention after molding was good, the taper abrasion test result was good, and the texture of the Deloy tone was maintained, but the desired sound absorbing performance could not be obtained due to the large fiber diameter of the base material layer.

(Comparative Example 4) As for the composition of the non-woven fabric, the design layer was 10 denier, which was soaked in gray, normal polyethylene terephthalate staple fiber having a circular cross section of 51 mm length: 90% by weight, and similarly, 4 denier, which was soaked in gray 5
Heat fusible polyester staple fiber having a core-sheath structure of 1 mm length (melting type at 110 ° C.): 10% by weight, weight per unit area 150 g / m ² . Further, the fiber composition of the base material layer is 1
Normal polyethylene terephthalate staple fiber having a circular cross section of 3 denier 51 mm length: 90% by weight, heat-fusible polyester staple fiber having a core-sheath structure of 2 denier 51 mm length (170 ° C. melting type): 10% by weight,
The basis weight was 50 g / m ² . Next, these fibers were blended, carded, cross-layered, and needle-punched, and the design layer and the base material layer were continuously laminated to obtain a nonwoven fabric. Further, after a fork needle is penetrated through the obtained design layer of the raw fabric to form a pile portion, a shirring process is performed to obtain a pattern of a diroa tone and a thickness of 5 mm.
, A bulky brushed nonwoven fabric was obtained. The obtained brushed laminated nonwoven fabric was heated to 180 ° C. and put into a press equipped with a mold to obtain a molded body. The shape retention after molding was not good due to insufficient surface density of the base material layer, and good surface layer appearance was not obtained due to insufficient surface density. Good,
The results of the taper abrasion test were good, and the texture of the Delore tone was maintained. However, the desired sound absorbing performance could not be obtained because the fiber diameter of the base material layer was large.

(Conventional Example 1) An original nonwoven fabric was obtained using carded polyester fibers through carding, cross layering and needle punching steps. Furthermore, after forming a pile part by penetrating a fork needle through the obtained raw material, a shirring process is performed to make a pattern of Diloa,
The backside was coated with latex to obtain a conventionally used diroa carpet. Felt (25mm thick,
Needle nonwoven fabric (thickness: 3 mm) with a surface density of 1.2 kg / m ² ) as a buffer layer and printed with a lower carpet
Was heated to 180 ° C. and put into a press equipped with a molding die to obtain a molded body.

(Conventional Example 2) A raw nonwoven fabric was obtained by using carded polyester fibers through carding, cross layering and needle punching steps. Furthermore, after forming a pile part by penetrating a fork needle through the obtained raw material, a shirring process is performed to make a pattern of Diloa,
The backside was coated with latex to obtain a conventionally used diroa carpet. Further, a polyester non-woven fabric is used as the buffer layer, and the fiber composition is 13 denier 51
Normal polyethylene terephthalate staple fiber having a circular cross section having a length of mm: 90% by weight, heat-fusible polyester-based staple fiber having a core-sheath structure having a length of 51 mm and 2 denier (170 ° C. melting type): 10% by weight, and a basis weight of 500 g /
It was m ^2. Next, these fibers were subjected to blending, carding, and cross-layer processes to obtain a nonwoven fabric. A needle nonwoven fabric (thickness: 3 mm) on which a die lower carpet was printed was used as a skin, heated to 180 ° C., and put into a press equipped with a mold to obtain a molded body.

Table 1 shows the structures of the bulky brushed nonwoven fabrics of the above Examples, Comparative Examples and Conventional Examples in comparison.

[0044]

[Table 1]

In addition, the nonwoven fabric obtained in each of the examples, the comparative examples, and the conventional example 2 and the interior material of the conventional example 1 were examined for appearance, tactile sensation, sound absorption, simplicity of construction, and abrasion resistance. Table 2 shows the comparison results.

[0046]

[Table 2]

[0047]

As described above in detail, the present invention has been made in view of the above-mentioned conventional problems, and has been described as a fiber constituting a nonwoven fabric raw material, which is composed of a high melting point polyester staple fiber and a heat fusible fiber. Including non-adhesive polyester-based binder fibers, and a non-woven fabric having a structure in which a design layer and a base material layer having different constituent fiber compositions are laminated, and formed by applying a surface design to at least one surface by, for example, needle punching. Therefore, it has a supporting function and a cushioning function of the base material layer and an aesthetic function of the skin integrally, and furthermore, as exemplified in the above examples, has a soft touch and excellent sound absorbing and insulating properties. And an interior material made of a nonwoven fabric having a single structure. Also, utilizing the melting point difference between a low melting point such as copolyester and a high melting point such as homopolyester,
After heating at a temperature between the melting points, it is a bulky nonwoven fabric that can be molded by being put into a press and cooled.
Since heating and molding can be performed in one step, there is a remarkable effect that the cost can be reduced due to the simplification of the manufacturing process and the weight of the product can be further reduced.

[Brief description of the drawings]

FIG. 1 is a vertical sectional view showing a structure of an example of a conventionally known interior material for an automobile.

FIG. 2 is a vertical sectional view showing the structure of another example of a conventionally known automotive interior material.

FIG. 3 is a vertical sectional view showing the structure of still another example of a conventionally known automotive interior material.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Needle nonwoven layer 2 Base material layer 3 Needle nonwoven layer 4 Buffer layer of polyurethane, felt, etc. 5 Needle nonwoven layer 6 Polyester nonwoven buffer layer

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Yoshikazu Nemoto, Nissan Motor Co., Ltd., 2 Takaracho, Kanagawa-ku, Yokohama, Kanagawa Prefecture (72) Hiroshi Sugawara 2 Takaracho, Kanagawa-ku, Yokohama, Kanagawa, Nissan Motor Co., Ltd.

Claims (17)

[Claims] 1. A nonwoven fabric design layer in which a constituent fiber including at least one surface is colored and a part of the constituent fiber is formed over the entire surface to form a pile, and the design layer is integrally formed with the nonwoven fabric design layer. A nonwoven fabric base layer having a laminated shape and a nonwoven fabric layer having a shape-retaining property-enhancing and buffering function, and comprising short fibers of thermoplastic synthetic fibers as a whole, wherein the short fibers further comprise a matrix fiber and a heat-fusible binder fiber. Wherein the design layer comprises 98 to 76% by weight of a high melting point matrix fiber of 2 to 30 denier and 2 to 24% by weight of a heat fusible binder fiber of 1 to 20 denier occupying at least a fiber surface of a low melting point synthetic polymer. %, And the base layer laminated integrally with the design layer has a high melting point matrix fiber of 1.5 to 40 denier 95 to 30% by weight and at least a fiber surface having a low melting point. By blending 5 to 70% by weight of the heat-fusible binder fiber of 1 to 20 denier occupied by the point-synthetic polymer, it is heated at a temperature between the melting point of the matrix fiber and the melting point of the binder fiber. A bulky brushed nonwoven fabric for automotive interiors, characterized in that the fused points formed at the intersections of the constituent fibers are substantially uniformly distributed by the process and have excellent sound absorbing and insulating properties. 2. The bulky brushed non-woven fabric for automotive interior according to claim 1, wherein the heat-fusible binder fiber blended in the design layer has a fineness of 2 to 15 denier. 3. The design layer is composed of a high melting point matrix fiber 95 or more.
3. A bulky brushed nonwoven fabric for automobile interiors according to claim 1, wherein 80% by weight and 5 to 20% by weight of heat-fusible binder fibers are blended. 4. The method according to claim 1, wherein the base material layer has a high melting point matrix fiber of 90 to 90.
40% by weight and 10 to 60% by weight of heat-fusible binder fiber
The bulky brushed nonwoven fabric for automobile interiors according to any one of claims 1 to 3, which is blended with: 5. The bulky brushed nonwoven fabric for an automobile interior according to claim 1, wherein the thermoplastic synthetic fiber is a polyester fiber. 6. The bulky brushed nonwoven fabric for automobile interiors according to claim 1, wherein the high-melting-point matrix fibers are substantially homopolyester fibers. 7. The low-melting point synthetic polymer occupying at least the fiber surface of the heat-fusible binder fiber is a low-melting point copolyester or a blended polyester.
The bulky brushed nonwoven fabric for an automobile interior according to any one of claims 6 to 10. 8. The automotive interior interior conjugate fiber according to claim 7, wherein the heat-fusible binder fiber is a core-sheath conjugate fiber having a low melting point copolyester or blended polyester as a sheath component and a homopolyester as a core component. Loose brushed nonwoven fabric. 9. The low-melting point copolyester of 100 to 2
The bulky brushed nonwoven fabric for automobile interior according to claim 8 having a melting point in the range of 30 ° C. 10. The method according to claim 10, wherein the low melting point copolyester is 105 to 105.
The laminated bulky nonwoven for automotive interior use of claim 9 having a melting point in the range of 210 ° C. 11. A fiber aggregate having an average thickness of 1 to 50 mm after molding and having an average apparent density of 0.01 to 1.0 g / cm ³ when the nonwoven fabric is laminated. The bulky brushed nonwoven fabric for automobile interior according to any one of claims 1 to 10. 12. When the nonwoven fabric is laminated, a thickness of 5 to 70 mm and a thickness of 300 to 2000 g / cm ^{2 are provided.}
The bulky brushed nonwoven fabric for automobile interiors according to any one of claims 1 to 11, which has a basis weight of: 13. A pile of short fibers for a design layer composed of colored thermoplastic synthetic fibers, formed on the surface by needle punching, and further, the tip portions thereof are cut out by shearing. The bulky brushed nonwoven fabric for automobile interiors according to any one of the above. 14. The bulky brushed nonwoven fabric for automobile interiors according to claim 13, wherein the pile tip is trimmed with a predetermined height difference by a shearing process, and is patterned in a cord tone or a derogatory tone. 15. A non-woven fabric for a design layer comprising a colored thermoplastic synthetic fiber having a partly protruding pile, and a non-woven fabric base layer formed separately from the non-woven fabric layer having a shape-retaining and buffering function. A method for producing a bulky brushed nonwoven fabric for automobile interiors, comprising laminating and bonding and integrating both by needle punching and / or heat bonding. 16. A colored design short fiber web for a design layer is supplied from at least one cross layer including a supply of an outermost layer web using a plurality of cross layers continuously, and the design layer is laminated. A car interior characterized by forming a pile of staple fiber webs on the surface by needle punching, trimming the tip of the pile by shearing, and supplying an integrated design layer and base material layer. For producing bulky brushed nonwoven fabric. 17. A high-melting polyester colored staple fiber having 2 to 30 deniers as a matrix fiber.
76% by weight and 2 to 24% by weight of a 1 to 20 denier polyester heat-fusible colored staple fiber having a conjugate structure in which a low melting point copolyester occupies at least a part of the fiber surface as a heat-fusible binder fiber. Is blended and then carded to form a colored short fiber web for a design layer, separately having an average fineness of 1.5 as a matrix fiber.
95 to 30% by weight of high-density polyester staple fiber of -40 denier and low-melting-point copolyester as a heat-fusible binder fiber having a polyester conjugate structure occupying at least a part of the fiber surface, having an average fineness of 1 to 20 denier. After blending 5 to 70% by weight of the heat-fusible staple fiber of the above, carding was performed to form a short fiber web for the base layer, and then the short fiber web for the design layer and the short fiber web for the base layer were continuous. Tackle a plurality of cross layers, supply a colored design layer short fiber web from at least one cross layer including the outermost layer web supply to form a web laminate, and then integrate the whole by needle punching, Furthermore, a pile is formed on the surface using a fork needle or the like, and the tip of the pile is sheared. Trimmed, the production method of the bulky napped nonwoven fabric for automobile interior, characterized in that the heat-set as necessary.