JP2922454B2 - Manufacturing method of pile nonwoven skin material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a nonwoven fabric skin material of an interior material used for an interior material of a vehicle and formed in accordance with an uneven shape of a ceiling, a door, a pillar or the like.

[0002]

2. Description of the Related Art Most of interior materials for automobiles and the like are made by heating and plasticizing a thermoplastic resin, molding the resin in accordance with an arrangement place, and attaching a skin material such as a nonwoven fabric to the surface to improve the design. Was secured.

[0003] There is also a method in which a skin material is adhered to a thermoplastic resin by molding the resin and then bonding the skin material with an adhesive. However, at the same time as the molding, an anchor is formed by utilizing the plasticity of the thermoplastic resin. Adhering is advantageous in terms of cost, and nonwoven fabric skin materials have often been used for this purpose.

[0004] The nonwoven skin material is tangled with a required density and depth by needling a web of specific fibers stacked to a required thickness with a needle plate on which a large number of needles are implanted. Since it is formed into a woven cloth, it is relatively easy to stretch and can easily follow the complicated shape of the interior material, it is often used for interior materials of automobiles (Japanese Patent Publication No. 2-3390). And Japanese Patent Publication No. 1-60576).

[0005] This non-woven fabric skin material produces a three-dimensional appearance and texture by forming raised hair (pile) on the surface layer by needling, and constitutes an important design element as the skin material.

[0006]

However, when the nonwoven skin material on which the pile is formed in this way is also anchored at the same time as the molding of the thermoplastic resin, heat and pressing force simultaneously act on the nonwoven skin material. The pile is crushed, and the root of the pile is heat-fixed while the hair is in a fallen state. In essence, the design of the surface of the nonwoven fabric is produced mainly by the three-dimensional appearance of the pile, so if the pile is overlaid many times, the appearance becomes flat and the design is greatly impaired.

The pile density, that is, the number of piles per unit area, also greatly affects the design of the fibrous skin material. The pile density of the nonwoven fabric is the sticking density of needles, but is currently 800 times / cm ^2. However, the nonwoven fabric skin material is disadvantageous in comparison with a moquette or the like in terms of productivity and texture of the nonwoven fabric.

[0008] The nonwoven fabric is a gas permeable material having micropores formed. When anchoring is performed simultaneously with molding, air trapped between the thermoplastic resin and the skin material is discharged from the micropores of the nonwoven fabric. Although it is necessary, particularly when a resin having low viscosity is used, the resin softened and melted together with the ventilation may leach out and impair the design.

[0009] The present invention has been made in view of such a point,
The purpose of the method is to provide a method for producing a non-woven skin material which has a strong pile recovery ability against heat and pressure, and has a high pile density, which can prevent leaching of a molten resin and improve design properties. Is to offer.

[0010]

In order to achieve the above object, the present invention relates to a method in which a special needle is added to a surface nonwoven fabric in advance.
A needling is further performed to form a pile on the surface, a heat-shrinkable non-woven fabric is interposed between the non-woven fabric of the surface layer and the non-woven fabric of the back layer, and three layers are overlapped .
Ri to form a pile on the surface layer of the surface of the nonwoven fabric subjected to needling, heated to the heat-shrinkable nonwoven fabric was manufacturing method of the pile not <br/> fabric skin material to heat shrinkage.

[0011] Needle on the surface non-woven fabric with a special needle in advance
To form a base pile on the surface,
A heat-shrinkable non-woven fabric between the surface non-woven fabric and the backing non-woven fabric
And three layers are superimposed, and special is made from the nonwoven side of the back layer.
Needle by needle and pile on the surface of non-woven fabric
, The fibers of each layer are entangled with each other to bond the layers together, and the back layer is placed in the surface veil.
And heat-shrinkable non-woven pile appear and form a pattern.
To improve the design and the texture and hand.
It can maintain good touch and has excellent design properties
In addition, the texture and the touch can be improved. Then, by heating, the heat-shrinkable nonwoven fabric of the intermediate layer shrinks, and at the same time, the nonwoven fabrics of the surface layer and the back layer also shrink, thereby reducing the overall area.

Therefore, the root of the pile is the heat shrinkage of the intermediate layer.
It is tightened and stable by the non-woven fabric, and even when pressed down by heat or pressure when adhering to a thermoplastic resin, it has resistance and can recover hairiness.

Further, since the entire area is reduced after forming the pile, the pile density is increased and the design can be improved. The micropores are further reduced due to the shrinkage of the heat-shrinkable nonwoven fabric, so that the resin can be prevented from leaching at the time of sticking to the thermoplastic resin.

[0014] With the manufacturing method of the pile nonwoven surface material according to claim 1, wherein the nonwoven fabric of the surface layer of the nonwoven fabric and the back layer are different from each other, the surface layer of the base pile by needling the advance surface of the nonwoven fabric After forming, the heat-shrinkable nonwoven fabric of the intermediate layer and the nonwoven fabric of the back layer are overlapped and needling is performed, thereby forming a pile of the nonwoven fabric of the back layer different from the surface layer on the surface layer surface and combining it with the base pile of the surface layer. A pattern can be formed.

[0015] The heat shrinkable nonwoven fabric, by a method of manufacturing a pile nonwoven surface material according to claim 1 or 2, wherein the spunbonded nonwoven fabric having a heat-shrinkable made of polyester resin fibers, interposed intermediate layer spunbonded nonwoven fabric to be found when it is heated to 100 ° C., since it has a 10-30% heat-shrinkable, is heat treated to contract, to stabilize the state by fixing the base of the pile, and the pile density To improve the design.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment according to the present invention will be described with reference to FIGS. FIG. 1 is an explanatory view showing a process for producing the present nonwoven fabric skin material.

First, in the step of forming the nonwoven fabric of each layer having a three-layer structure, first, raw cotton 8 weighed to a predetermined weight is conveyed by a belt conveyor 10 or the like (FIG. 1) and sent to a mixing machine 11 for mixing. The mixture is uniformly dispersed and mixed by the machine 11 (Fig. 1
Then, the fibers are drawn by a carding machine 12 to form a web 9 having uniform fiber orientations (carding step in FIG. 1), and a plurality of webs 9 thus formed are stacked (FIG. 1). Lapping process), tamped with needle by needle punch machine 13 (Fig. 1
Needle punching step): Form a nonwoven fabric.

In this embodiment, three types of nonwoven fabrics 1, 2, 3 are formed: a surface layer, an intermediate layer, and a back layer. The surface nonwoven fabric 1 and the back layer nonwoven fabric 3 are made of different fibers, and the color of the surface layer nonwoven fabric 1 is black and the color of the back layer nonwoven fabric 3 is white. The fiber web of the surface nonwoven fabric 1 and the backing nonwoven fabric 3 is preferably polyester or polypropylene, and has a fiber diameter of 1.5 to 1.5.
It is preferable that the fiber length is 4 denier and the fiber length is 50 mm or more.

The non-woven fabric 2 of the intermediate layer is a polyester spun-bonded non-woven fabric, and is formed by jetting air onto fibers spun from a spinning nozzle and simultaneously cooling and stretching the fibers.

Since the spunbonded nonwoven fabric thus formed is solidified by freezing the strain therein, when heated to a certain temperature, thermal shrinkage occurs due to the property that the frozen strain recovers. The spunbonded nonwoven fabric 2 used in the present embodiment, when heated to 100 ° C.,
It causes heat shrinkage of 0 to 30%.

The three types of nonwoven fabrics 1, 2, and 3 are shown in FIG.
Is supplied to a pile unloading machine 14 shown in FIG. Piling machine 14
An endless brush belt 16 having bristles 15 implanted on its surface is rotated, and pile punch machines 17 and 18 are disposed on the upstream and downstream sides of the brush belt 16 that rotates upward.

The pile punching machines 17 and 18 apply a plurality of special needles implanted on a needle plate at a predetermined needle density to the brush belt 16.
The nonwoven fabric conveyed above is pierced at a predetermined depth to form a loop-shaped pile on the brush belt 16 side (FIG. 2).
reference).

As shown in FIG. 1, first, the surface layer nonwoven fabric 1 is carried into the pile punching machine 17 on the upstream side, and needling is performed, and a base pile 1a of white fibers is formed on the surface of the surface layer nonwoven fabric 1.

The surface nonwoven fabric 1 on which the base pile 1a is formed is loaded on the brush belt 16 as it is and carried into the next downstream pile punching machine 18, during which the spunbonded nonwoven fabric 2 is placed on the surface nonwoven fabric 1. The spunbonded nonwoven fabric 2 is overlaid with the backing nonwoven fabric 3 and is carried into the pile punching machine 18 on the downstream side.

When the needling is performed at a predetermined depth by the pile punching machine 17 on the three-layered nonwoven fabric in the order of the surface nonwoven fabric 1, the spunbonded nonwoven fabric 2, and the backing nonwoven fabric 3, , 2 and 3 are entangled with each other and joined together, and the black fibers of the backing nonwoven fabric 3 are projected to the surface of the surface nonwoven fabric 1 to form a pile 3a, and the already formed white base pile is formed. 1a is mixed with a black pile 3a.

FIG. 2 schematically shows this state in an enlarged manner. As shown in FIG. 2, three layers of nonwoven fabrics 1, 2 and 3 are combined and a loop-shaped pile 1a made of fibers of the surface nonwoven fabric 1 is formed on the surface of the surface nonwoven fabric 1. And a loop-shaped pile 3a of fibers of the backing nonwoven fabric 3 protrudes.

The nonwoven fabric after the pile punching step is sent to the heating furnace 19 next. In heating furnace 19, 20
Hot air treatment is performed at 0 ° C. for about 180 seconds (FIG. 1). Due to this heat treatment, the spunbonded nonwoven fabric 2 of the intermediate layer thermally shrinks, and at the same time, the nonwoven fabrics 1 and 3 on both sides sandwiching the spunbonded nonwoven fabric 2 are also reduced in size.

As shown schematically in FIG. 3, the three layers of nonwoven fabrics 1, 2, 3 are reduced by 10 to 30% to increase the pile densities of the piles 1a, 3a, and to increase the piles 1a, 3
The root of a is firmly fixed by the reduction of the nonwoven fabric, and the state is stabilized. The micropores formed in the nonwoven fabrics 1, 2, 3 are further reduced by the reduction of the nonwoven fabrics 1, 2, 3.

In the nonwoven fabric skin material 4 thus formed, as shown in FIG. 4, on the surface of the surface nonwoven fabric 1, a shimo-furi pattern in which the black pile 3a is mixed with the white base pile 1a is formed. By making the pile punching of the backing nonwoven fabric 3 by the pile punching machine 17 intermittently, the pile non-woven fabric 3 shown in FIG.
As shown in FIG. 5, a stripe pattern can be formed.

The nonwoven skin material 4 having the pattern formed by the pile as described above is then carried into a stamping mold 20 as shown in FIG. The stamping mold 20 is an upper mold 21
And the lower mold 22 are united, and the thermoplastic resin is heated and plasticized in a cavity between the upper and lower molds to be formed into a predetermined shape, and the molten resin (PP resin,
At 30 ° C., an MI value of 40 g / min) 24 is fed into the cavity.

The non-woven fabric material 4 is disposed between the upper and lower molds with the surface layer facing upward, the mold is clamped at a pressure of 50 kg / cm ² , and the molten resin 24 is supplied into the cavity. It spreads to the back side and forms a predetermined shape, and at the same time, the nonwoven fabric skin material 4 is adhered to the surface, and thus the interior material is manufactured.

The piles 1a and 3a on the surface of the nonwoven skin material 4
Is pressed and heated by the upper mold 21, but the piles 1a, 3
Since the root of a is firmly fixed by the reduction of the nonwoven fabric and the state is stable, the resilience when the mold is opened is large,
Hair can be obtained and the texture and feel can be kept good. In addition, since the pile density is high, the design is excellent.

The micropores formed in the nonwoven fabrics 1, 2, 3 of the nonwoven fabric skin material 4 are further reduced by the reduction of the nonwoven fabrics 1, 2, 3 so that the molten resin can
The problem that 24 oozes out of the micropores is prevented.

In addition to the stamping molding as described above, a method of producing an interior material having a nonwoven skin material 4 adhered to the surface by blow molding is possible. FIG. 7 shows a blow molding die 30 in which a parison of thermoplastic resin (PP resin, plate thickness 1.5 mm, MI value 0.8
g / min) 33, the non-woven fabric skin material 4 is stretched between the parison 33 and one of the molds 31, the mold is clamped, and air is supplied into the parison 33 at an internal pressure of 5 kg / cm ^2. A predetermined shape is formed, and at the same time, the skin material 4 is adhered to the surface of the parison 33, and the interior material is manufactured.

Even if the parison pressure is increased by blow molding, the roots of the piles 1a and 3a of the non-woven fabric skin material 4 are firmly fixed by the reduction of the non-woven fabric, and the state is stable, and there is a resilience. Good design properties can be maintained without occurrence.

[0036]

According to the present invention, the needling of the nonwoven fabric superposed on the three layers from the back layer side entangles the fibers of each layer and bonds the layers together, and forms a pile on the surface layer. And then heating, the heat-shrinkable non-woven fabric of the intermediate layer shrinks, and at the same time the non-woven fabric of the surface layer and the back layer also shrinks, so that the root of the pile is tightened and stable, and adheres to the thermoplastic resin. In this case, even if pressed down by heat or pressure, it is resistant and can restore hairiness.

Further, since the entire area is reduced after the formation of the pile, the pile density is increased and the design can be improved. The micropores are further reduced due to the shrinkage of the heat-shrinkable nonwoven fabric, so that the resin can be prevented from leaching at the time of sticking to the thermoplastic resin.

The surface nonwoven fabric and the backing nonwoven fabric are made different from each other, and the surface nonwoven fabric is previously needled to form the surface layer base pile. Then, the heat shrinkable nonwoven fabric of the intermediate layer and the backing nonwoven fabric are overlapped and needling. The pattern can be formed by forming a pile of the nonwoven fabric of the back layer different from the surface layer on the surface layer surface and combining the pile with the base pile of the surface layer.

When a heat-shrinkable spunbonded nonwoven fabric made of polyester-based resin fiber is used as the heat-shrinkable nonwoven fabric, the spunbonded nonwoven fabric interposed in the intermediate layer becomes 1%.
When heated to 00 ° C., since it has a heat shrinkage of 10 to 30%, it is possible to stabilize the state by fixing the root of the pile, and to improve the design property by increasing the pile density.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a step of manufacturing a nonwoven fabric skin material according to one embodiment of the present invention.

FIG. 2 is an enlarged schematic view of a nonwoven fabric skin material after a pile punching step.

FIG. 3 is an enlarged schematic cross-sectional view of a nonwoven skin material after a heat treatment.

FIG. 4 is a schematic view of the nonwoven fabric skin material.

FIG. 5 is a schematic diagram of a nonwoven fabric material on which another pile pattern is formed.

FIG. 6 is a schematic diagram of stamping molding.

FIG. 7 is a schematic diagram of blow molding.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Surface nonwoven fabric, 2 ... Spun bond nonwoven fabric, 3 ... Back layer nonwoven fabric, 4 ... Nonwoven fabric skin material, 8 ... Raw cotton, 9 ... Web, 10
… Belt conveyor, 11… Mixing machine, 12… Carding machine, 13… Needle punch machine, 14… Pile out machine, 15…
Bristle, 16 ... brush belt, 17, 18 ... pile punch machine, 19
… Heating furnace, 20… Stamping mold, 21… Upper mold, 22…
Lower die, 23 gate, 24 molten resin, 30 blow molding die, 31, 32 die, 33 parison.

──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Takashi Yamaguchi 1-4-1 Chuo, Wako-shi, Saitama Pref. Honda Technology Laboratory Co., Ltd. 2 Inside the Toyota Plant of Hayashi Telemp Co., Ltd. (72) Michio Shimazaki 100-2, Kamiyasumachi Machiya-dong, Toyota City, Aichi Prefecture Inside of the Toyota Plant of Hayashi Telemp Co., Ltd. (56) References JP-A-Hei 7-3598 JP-A-2-221449 (JP, A) (58) Fields investigated (Int. Cl. ⁶ , DB name) B32B 1/00-35/00 D04H 1/00-1/74

Claims (3)

(57) [Claims] 1. Use a special needle to pre-need the surface non-woven fabric
Forming a pile surface subjected to ring, the heat shrinkable nonwoven fabric superposed in three layers and interposed between the nonwoven fabric of the same surface of the nonwoven fabric and the back layer, the needling by a special needle from nonwoven side of the backing layer method of manufacturing a pile nonwoven surface material, characterized in that forming a pile to perform surface of the nonwoven fabric surface, to heat shrink the heat shrinkable nonwoven fabric is heated. 2. A according to claim 1, wherein the non-woven fabric of the surface layer of the nonwoven fabric and the backing layer is equal to or is different to each other <br/> physician
Manufacturing method of pile nonwoven skin material. 3. The pile nonwoven fabric skin material according to claim 1, wherein the heat shrinkable nonwoven fabric is a heat shrinkable spunbonded nonwoven fabric made of polyester resin fibers. Production method.