JP3553757B2

JP3553757B2 - Laminated brushed nonwoven fabric

Info

Publication number: JP3553757B2
Application number: JP4802197A
Authority: JP
Inventors: 万亀男永田; 啓樹永山; 好一根本; 浩菅原; 仁伊藤; 和明岩本
Original assignee: Nissan Motor Co Ltd
Current assignee: Nissan Motor Co Ltd
Priority date: 1997-03-03
Filing date: 1997-03-03
Publication date: 2004-08-11
Anticipated expiration: 2017-03-03
Also published as: JPH10245759A

Description

【０００１】
【発明の属する技術分野】
本発明は、表面にパイル、好ましくはコード調やディロア調等に柄出しされたパイルを形成してなる起毛調不織布、特に、ラテックスを用いることなく、主として構成繊維の交絡相互接着によってパイルの毛抜けが防止された、カーペット、天井、ドアトリム等の成形性が重要視される内装材に主として利用される安定な寸法形態に成形可能な起毛調不織布に関する。
【０００２】
【従来の技術】
従来の起毛不織布としては、例えば図１、図２、若しくは図３に示すようなものが知られている。図１は、不織布基布２の表面にコード調やディロア調などの柄出しされたパイル１を有し、パイル部分を固定するためラテックスが含浸された含浸層３よりなる起毛不織布であり、特開昭５２−５３９８０号、同６１−１３２６６７号各公報等に開示されている。また、図２には、特に車両内装用として成形可能とするために図１のラテックス含浸層３の裏面に更にポリプロピレンシート、ポリアミドシートや炭酸カルシウム等の無機物質を含んだエチレン／酢酸ビニル共重合体（ＥＶＡ）等の熱可塑性樹脂シート４をラミネートした例を示し、特開昭５９−１４０１７５号、同５７−２０５２５１号、同５９−２０４９８２号各公報等に開示されている。更に、図３にはこれらのラテックスを用いないものとして、パイル部１及び不織布基布部２に同量の芯鞘構造を持つ熱融着繊維を配合した例を示し、特願平７−９９１２５号に提案されている。
【０００３】
【発明が解決しようとする課題】
しかしながら、これら従来の起毛不織布は毛抜けを防止するためのラテックス含浸を必須とするので製造工程が複雑になりコスト高となる他、重量増加の原因となり車両用に用いる場合は、軽量化の要求とは相容れないという問題点があった。又、軽量化、構造の単純化を図るために、熱可塑性樹脂シートのラミネートを省いたり、減量化した場合、成型性、形状保持性が損なわれるため、当初目的である構造の単純化、軽量化と相反して、ラテックス含浸量を増加させて、上記所望の性能を得ることが必要となるため本来の目的を達成することが困難となる。
【０００４】
また、パイル部及び基布部が単層構造からなり全体に同一の熱融着バインダーを配合した場合、バインダー量が少ないと成形性を確保できず、形状保持が困難となり、また、バインダー量を多く配合すると成形時にパイル部の毛倒れが生じてしまい、表面の風合いを確保することが困難であった。
【０００５】
更に、パイル部及び基布部が単層構造からなり全体に同一の難燃処理を施した繊維もしくは難燃剤を含有させた場合、これらの素材は色調が限られるため、表皮材料としては色調調整が非常に困難なものとなっていた。
【０００６】
本発明は、このような従来の問題点に着目してなされたもので、ラテックス含浸を必要とすることなくパイルの抜けを防止できる積層された起毛調不織布を、簡略化された工程を以て低コストで提供することを目的とする。更に又、従来用いられてきた熱可塑性樹脂シートを大幅に軽量化することが可能であると共に、表面の良好な風合い、色調調整の容易性、優れた品質と成形性及び形状保持性を兼備する起毛調不織布を提供することを目的とする。
【０００７】
【課題を解決するための手段】
上記の目的を達成する本発明の積層された起毛調不織布は、その表面全面に亙って構成繊維の少なくとも一部が突出したパイルを形成してなり、繊維配合が互いに異なるパイル部の不織布と基布部の不織布とが積層され更に基布部の裏面に目付５０〜４００ｇ／ｍ² の熱可塑性樹脂シートよりなるバッキング層がラミネートされてなり、上記パイル部の不織布は２〜５０デニールの高融点ポリエステル系ステープル繊維を７６〜９８重量％と鞘成分が低融点コポリエステルよりなる芯鞘型コンジュゲート構造を有する１〜２０デニールの熱融着性ステープル繊維を２〜２４重量％含む繊維配合からなり、また上記基布部の不織布は２〜５０デニールの高融点ポリエステル系ステープル繊維を０〜７５重量％と鞘成分が低融点コポリエステルよりなる芯鞘型コンジュゲート構造を有する１〜２０デニールの熱融着性ステープル繊維を２０〜９５重量％と難燃処理の施されたポリエステル系のステープル繊維を５〜７０重量％含む繊維配合からなり、前記低融点コポリエステルの溶融点と高融点のポリエステルの溶融点との間の温度で不織布を加熱した後、プレス機に投入して冷却することにより、構成繊維と上記コポリエステルとの接点が融着し成形可能であることを特徴とする。
【０００８】
上記低融点コポリエステルは、１００〜２３０℃の範囲の融点を有することが好ましい。また本発明の不織布は好ましくは、積層された状態において５〜２０ｍｍの厚みと２００〜８００ｇ／ｍ^２の目付を有し、更に好ましくはパイル部を構成する不織布及び基布部を構成する不織布は共に１００〜７００ｇ／ｍ^２の目付を有する。
【０００９】
【発明の実施の形態】
以下、本発明の構成をその作用と共に詳述する。
【００１０】
本発明の起毛調不織布は、不織布原反を構成する繊維として、高融点のポリエステルステープル繊維と、鞘部に低融点コポリエステルを用いた芯鞘構造の熱融着型コンジュゲートステープル繊維とを含み、また、パイル部を構成する不織布とそれに積層された基布部を構成する不織布とは互いに繊維配合を異にする。又、基布部の不織布は、難燃処理を施したポリエステル系のステープル繊維を更に含んでなる。この積層された不織布は、上記高融点ポリエステルの溶融点と低融点コポリエステルの溶融点の間の範囲内の温度で加熱した後、プレス機に投入して冷却することにより成形可能である。
【００１１】
一般に起毛不織布を構成する繊維としては、ポリエステル繊維、ナイロン繊維、ポリプロピレン繊維等が用いられるが、本発明の起毛調不織布を構成する繊維としてはポリエステル繊維が最も好ましい。ナイロン繊維は原料コストが高いことによる経済的な理由で好ましくなく、ポリプロピレン繊維は、毛倒れし易く且つ耐摩耗性の点で劣る他、加熱圧縮成形後も型崩れし易いという点で好ましくない。
【００１２】
本発明の起毛調不織布を構成する不織布原反に用いる高融点のポリエステル繊維としては、特に限定されないが、ポリエチレンテレフタレート又はそれに準ずる成分を有するポリエステルが安価で入手し易いことから最も好ましい。一方、芯鞘構造を有する熱融着型繊維の鞘部に用いられる低融点コポリエステルとしては、テレフタル酸、イソフタル酸、アジピン酸等の酸成分とエチレングリコール、プロピレングリコール、ジエチレングリコール、トリエチレングリコール、ポリエチレングリコール、ポリプロピレングリコール等のジオール成分、又はラクトンを開環して共重合したコポリエステル等を用いることが可能である。芯部に用いるポリエステルとしては、特に限定はされないが、ポリエチレンテレフタレート又はそれに準ずる成分を有するポリエステルが安価で最も好ましい。低融点ポリエステルの融点は、１００〜２３０℃の範囲であることが好ましく、更に好ましくは１０５〜２１０℃の範囲である。融点が１００℃未満では、紡糸の際に単糸間融着によりタッキングが起こる問題があるほか、マルチフィラメント間の融着によって解繊が困難になるという問題点が生ずる。融点が２３０℃超では、高融点成分との融点差が小さくなり、加熱時に低融点成分だけでなく高融点成分も軟化又は溶融する可能性が生じ、塊となって繊維としての形状を失い、見栄え上問題となる場合があるほか、加熱温度が上昇し成形が困難になる。
【００１３】
高融点ポリエステルの繊度としては２〜５０デニールの範囲が好ましく、更に好ましくは４〜２０デニールである。２デニール未満になると不織布化の工程におけるカード通過性に問題が生じ、品質の良好な不織布原反が得られなくなる可能性があり、５０デニール超ではパイルの肌理が粗くなるので好ましくない。高融点ポリエステル繊維の横断面形状としては、円形の他、偏平型、Ｙ型、中空型等特に制限はなく、また、サイド・バイ・サイド型のコンジュゲート繊維を用いることも可能である。芯鞘構造を有する熱融着型ポリエステルの繊度としては１〜２０デニールの範囲が好ましく、更に好ましくは、２〜１５デニールである。２デニール未満では上に示したと同様の理由で、また２０デニール超では繊維本数の減少に伴って繊維間の接着点も減少し、加熱成形しても充分な形状保持性が得られないため好ましくない。原反に所定の色を着色するために上記ポリエステルの双方または一方を紡糸段階の顔料添加により着色する原着タイプの繊維とすることも可能であり、また、耐光剤、難燃剤、その他の改質剤を添加することも可能である。
【００１４】
本発明の起毛調不織布において、原反を構成する繊維としてはパイル部、基布部共に上記高融点ポリエステル繊維と熱融着型のポリエステル繊維とを混合して用いるが、パイル部においては熱融着型のポリエステル繊維が２〜２４重量％の範囲で含まれていることが好ましく、更に好ましくは５〜２０重量％で用いる。２重量％未満では、繊維間の接着点が少なくなるため、使用中にパイル部からの毛抜けが頻繁に発生する他、加熱成形しても充分な形状保持性が得られないため好ましくなく、２４重量％超ではコストアップを招く他、繊維間の接着点が増えるためにコード調、ディロア調の柄が加熱成形後に変化し、また、成形加熱後、毛倒れ等が生じる可能性があり、見栄え上問題が生じる可能性が増大する。又、基布部においては熱融着型のポリエステル繊維が２０〜９５重量％の範囲で含まれていることが好ましく、更に好ましくは４０〜９５重量％で用いる。２０重量％未満では、繊維間接着点が少なくなるため、所望の剛性を得ることが困難になり、成形加工性、形状保持性を確保することが困難となる。基布部の熱融着繊維は成形加工性及び形状保持性を得るためのものであり、配合量が増加すればコストアップを招くが、所望の性能が得られるため上限は特に設けない。
【００１５】
本発明の起毛調不織布の成形前の原反としては、厚みが５〜２０ｍｍ、より好ましくは８〜１５ｍｍの範囲である。厚みが５ｍｍ未満では加熱成形後の十分な形状保持性が得られないため好ましくなく、２０ｍｍ超ではフォークニードルによるコード調、ディロア調等の柄出しが困難になる。又、積層された状態での原反の目付は２００〜８００ｇ／ｍ^２で、より好ましくは２５０〜５００ｇ／ｍ^２の範囲である。原反の目付が２００ｇ／ｍ^２未満では十分な形状保持性が得られないばかりか十分な厚みが得られないため、成形後に透けた部分が発生する可能性もあり好ましくない。８００ｇ／ｍ^２超ではフォークニードルによるコード調、ディロア調等の柄出しが困難になる。
【００１６】
【実施例】
以下に本発明の実施例について詳述するが、本発明はこれによって限定されるものではない。実施例中の耐摩耗試験は、テーバー摩耗試験機Ｈ−３８を用い、１Ｋｇ、５００回転でパイル保持性を判定した。
【００１７】
（実施例１）
不織布の配合としては、パイル部は、グレーに原着した１０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：８０重量％、同様にグレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：２０重量％とし、目付を３００ｇ／ｍ^２とした。更に基布部は、繊維配合をグレーに原着した１０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：５０重量％、同様にグレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：３５重量％、リン系化合物を共重合させ、黒に原着した４デニール５１ｍｍカット長の難燃処理を施したポリエステルステープル繊維：１５重量％とし、目付を１００ｇ／ｍ^２とした。次にこれらの繊維をブレンド、カーディング、クロスレイヤー、ニードルパンチ工程を経て、不織布原反を得た。更に得られた原反の片側からフォークニードルを貫通させパイル部を形成した後、シャーリング処理してディロア調の柄出しを行い、厚み１０ｍｍの起毛不織布を得た。この不織布にバッキング層として目付２５０ｇ／ｍ^２のポリエチレン樹脂シートをラミネート加工し、起毛調積層不織布を得た。得られた起毛調積層不織布原反を１８０℃に加熱し、成形型の装着されたプレス機に投入し成形体を得た。成形後の形状保持性は良好で、テーバー摩耗試験結果も良好であり、ディロア調の風合いも保たれ、色調も所望のものが得られた。
【００１８】
（実施例２）
不織布の配合としては、パイル部はブラウンに原着した１０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：９５重量％、同様にブラウンに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：５重量％とし、目付を１５０ｇ／ｍ^２とした。更に基布部は、繊維配合をブラウンに原着した６デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：５０重量％、同様にブラウンに原着した２デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１７０℃のコポリエステル）：３５重量％、リン系化合物を共重合させた非原着（白色）４デニール５１ｍｍカット長の難燃処理を施したポリエステルステープル繊維：１５重量％とし、目付を１５０ｇ／ｍ^２とした。次にこれらの繊維をブレンド、カーディング、クロスレイヤー、ニードルパンチ工程を経て、不織布原反を得た。更に得られた原反の片側からフォークニードルを貫通させパイル部を形成した後、シャーリング処理してディロア調の柄出しを行い、厚み１０ｍｍの起毛不織布を得た。この不織布にバッキング層として目付１００ｇ／ｍ^２のポリエチレン樹脂シートをラミネート加工し、起毛調積層不織布を得た。得られた起毛調積層不織布原反を２０５℃に加熱し、成形型の装着されたプレス機に投入し成形体を得た。成形後の形状保持性は良好で、テーバー摩耗試験結果も良好であり、ディロア調の風合いも保たれ、色調も所望のものが得られた。
【００１９】
（実施例３）
不織布の配合としては、パイル部は、グレーに原着した１５デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：７６重量％、同様にグレーに原着した３デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：２４重量％とし、目付を４００ｇ／ｍ^２とした。更に基布部は、繊維配合をグレーに原着した１０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：４５重量％、同様にグレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：５０重量％、リン系化合物を共重合させた非原着（白色）４デニール５１ｍｍカット長の難燃処理を施したポリエステルステープル繊維：５重量％とし、目付を４００ｇ／ｍ^２とした。次にこれらの繊維をブレンド、カーディング、クロスレイヤー、ニードルパンチ工程を経て、不織布原反を得た。更に得られた原反の片側からフォークニードルを貫通させパイル部を形成した後、シャーリング処理してディロア調の柄出しを行い、厚み２０ｍｍの起毛不織布を得た。この不織布にバッキング層として目付４００ｇ／ｍ^２のポリエチレン樹脂シートをラミネート加工し、起毛調積層不織布を得た。得られた起毛調積層不織布原反を１８０℃に加熱し、成形型の装着されたプレス機に投入し成形体を得た。成形後の形状保持性は良好で、テーバー摩耗試験結果も良好であり、ディロア調の風合いも保たれ、色調も所望のものが得られた。
【００２０】
（実施例４）
不織布の配合としては、パイル部は、グレーに原着した１０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：９０重量％、同様にグレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：１０重量％とし、目付を１００ｇ／ｍ² とした。更に基布部は、繊維配合をグレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：９５重量％、グレーに原着した４デニール５１ｍｍカット長の難燃処理を施したポリエステルステープル繊維：５重量％とし、目付を１００ｇ／ｍ² とした。次にこれらの繊維をブレンド、カーディング、クロスレイヤー、ニードルパンチ工程を経て、不織布原反を得た。更に得られた原反の片側からフォークニードルを貫通させパイル部を形成した後、シャーリング処理してディロア調の柄出しを行い、厚み５ｍｍの起毛不織布を得た。この不織布にバッキング層として目付４００ｇ／ｍ² のポリエチレン樹脂シートをラミネート加工し、起毛調積層不織布を得た。得られた起毛調積層不織布原反を１８０℃に加熱し、成形型の装着されたプレス機に投入し成形体を得た。成形後の形状保持性は良好で、テーバー摩耗試験結果も良好であり、ディロア調の風合いも保たれ、色調も所望のものが得られた。
【００２１】
（実施例５）
不織布の配合としては、パイル部は、グレーに原着した１０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：７６重量％、同様にグレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：２４重量％とし、目付を２５０ｇ／ｍ² とした。更に基布部は、繊維配合をグレーに原着した１０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：５重量％、同様にグレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：２５重量％、グレーに原着した４デニール５１ｍｍカット長の難燃処理を施したポリエステルステープル繊維：７０重量％とし、目付を２００ｇ／ｍ² とした。次にこれらの繊維をブレンド、カーディング、クロスレイヤー、ニードルパンチ工程を経て、不織布原反を得た。更に得られた原反の片側からフォークニードルを貫通させパイル部を形成した後、シャーリング処理してディロア調の柄出しを行い、厚み１２ｍｍの起毛不織布を得た。この不織布にバッキング層として目付５０ｇ／ｍ² のポリエチレン樹脂フィルムをラミネート加工し、起毛調積層不織布を得た。得られた起毛調積層不織布原反を１８０℃に加熱し、成形型の装着されたプレス機に投入し成形体を得た。成形後の形状保持性は良好で、テーバー摩耗試験結果も良好であり、ディロア調の風合いも保たれ、色調も所望のものが得られた。
【００２２】
（実施例６）
不織布の配合としては、パイル部は、グレーに原着した１０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：８０重量％、同様にグレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：２０重量％とし、目付を２２０ｇ／ｍ² とした。更に基布部は、繊維配合をグレーに原着した２デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：７５重量％、同様にグレーに原着した１５デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：２０重量％、グレーに原着した４デニール５１ｍｍカット長の難燃処理を施したポリエステルステープル繊維：５重量％とし、目付を２００ｇ／ｍ² とした。次にこれらの繊維をブレンド、カーディング、クロスレイヤー、ニードルパンチ工程を経て、不織布原反を得た。更に得られた原反の片側からフォークニードルを貫通させパイル部を形成した後、シャーリング処理してディロア調の柄出しを行い、厚み１３ｍｍの起毛不織布を得た。この不織布にバッキング層として目付４００ｇ／ｍ² のポリエチレン樹脂シートをラミネート加工し、起毛調積層不織布を得た。得られた起毛調積層不織布原反を１８０℃に加熱し、成形型の装着されたプレス機に投入し成形体を得た。成形後の形状保持性は良好で、テーバー摩耗試験結果も良好であり、ディロア調の風合いも保たれ、色調も所望のものが得られた。
【００２３】
（比較例１）
不織布の配合としては、パイル部は、グレーに原着した１０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：９８重量％、同様にグレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：２重量％とし、目付を３００ｇ／ｍ² とした。更に基布部は、繊維配合をグレーに原着した１０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：５０重量％、同様にグレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：５０重量％とし、目付を１００ｇ／ｍ² とした。次にこれらの繊維をブレンド、カーディング、クロスレイヤー、ニードルパンチ工程を経て、不織布原反を得た。更に得られた原反の片側からフォークニードルを貫通させパイル部を形成した後、シャーリング処理してディロア調の柄出しを行い、厚み１０ｍｍの起毛不織布を得た。得られた起毛不織布原反を１８０℃に加熱し、成形型の装着されたプレス機に投入し成形体を得た。成形後の形状保持性は十分でなく、テーバー摩耗試験結果も毛抜けが多く見栄え上好ましくないことが判明した。
【００２４】
（比較例２）
不織布の配合としては、パイル部は、グレーに原着した１０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：８０重量％、同様にグレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：２０重量％とし、目付を１００ｇ／ｍ² とした。更に基布部は、繊維配合をグレーに原着した１０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：４５重量％、同様にグレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：５０重量％、グレーに原着した４デニール５１ｍｍカット長の難燃処理を施したポリエステルステープル繊維：５重量％とし、目付を８０ｇ／ｍ² とした。次にこれらの繊維をブレンド、カーディング、クロスレイヤー、ニードルパンチ工程を経て、不織布原反を得た。更に得られた原反の片側からフォークニードルを貫通させパイル部を形成した後、シャーリング処理してディロア調の柄出しを行い、厚み５ｍｍの起毛不織布を得た。この不織布にバッキング層として目付３５ｇ／ｍ² のポリエチレン樹脂フィルムをラミネート加工し、起毛調積層不織布を得た。得られた起毛調積層不織布原反を１８０℃に加熱し、成形型の装着されたプレス機に投入し成形体を得た。成形後の形状保持性は十分でなく、テーバー摩耗試験結果も毛抜けが多く、また透けた部分も発生し、見栄え上好ましくないことが判明した。
【００２５】
（比較例３）
不織布の配合としては、パイル部は、グレーに原着した６０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：８０重量％、同様にグレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：２０重量％とし、目付を３００ｇ／ｍ² とした。更に基布部は、繊維配合をグレーに原着した１０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：４５重量％、同様にグレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：４０重量％、グレーに原着した４デニール５１ｍｍカット長の難燃処理を施したポリエステルステープル繊維：１５重量％とし、目付を１００ｇ／ｍ² とした。次にこれらの繊維をブレンド、カーディング、クロスレイヤー、ニードルパンチ工程を経て、不織布原反を得た。更に得られた原反の片側からフォークニードルを貫通させパイル部を形成した後、シャーリング処理してディロア調の柄出しを行い、厚み１５ｍｍの起毛不織布を得た。この不織布にバッキング層として目付３００ｇ／ｍ² のポリエチレン樹脂シートをラミネート加工し、起毛調積層不織布を得た。得られた起毛調積層不織布原反を１８０℃に加熱し、成形型の装着されたプレス機に投入し成形体を得た。成形後、テーバー摩耗試験結果も毛抜けが多く、また表面の主繊維の繊度が大きいため、見栄え上好ましくないことが判明した。
【００２６】
（比較例４）
不織布の配合としては、パイル部は、グレーに原着した１０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：９０重量％、同様にグレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：１０重量％とし、目付を３００ｇ／ｍ² とした。更に基布部は、繊維配合をグレーに原着した１０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：７５重量％、同様にグレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：２０重量％、グレーに原着した４デニール５１ｍｍカット長の難燃処理を施したポリエステルステープル繊維：５重量％とし、目付を１００ｇ／ｍ² とした。次にこれらの繊維をブレンド、カーディング、クロスレイヤー、ニードルパンチ工程を経て、不織布原反を得た。更に得られた原反の片側からフォークニードルを貫通させパイル部を形成した後、シャーリング処理してディロア調の柄出しを行い、厚み１２ｍｍの起毛不織布を得た。この不織布にバッキング層として目付３０ｇ／ｍ² のポリエチレン樹脂フィルムをラミネート加工し、起毛調積層不織布を得た。得られた起毛調積層不織布原反を１８０℃に加熱し、成形型の装着されたプレス機に投入し成形を行ったが、形状保持性は十分でなく、所望の成形体を得ることが困難であった。
【００２７】
（比較例５）
不織布の配合としては、パイル部、基布部ともに、ブラウンに原着した１０デニール５１ｍｍカット長の円形横断面の通常ポリエステルステープル繊維：７０重量％、グレーに原着した４デニール５１ｍｍカット長の芯鞘構造を有する熱融着型のポリエステルステープル繊維（鞘部、融点１１０℃のコポリエステル）：１５重量％、グレーに原着した４デニール５１ｍｍカット長の難燃処理を施したポリエステルステープル繊維：１５重量％とし、目付を３００ｇ／ｍ² とした。次にこれらの繊維をブレンド、カーディング、クロスレイヤー、ニードルパンチ工程を経て、不織布原反を得た。更に得られた原反の片側からフォークニードルを貫通させパイル部を形成した後、シャーリング処理してディロア調の柄出しを行い、厚み１０ｍｍの起毛不織布を得た。この不織布にバッキング層として目付４００ｇ／ｍ² のポリエチレン樹脂シートをラミネート加工し、起毛調積層不織布を得た。得られた起毛調積層不織布原反を１８０℃に加熱し、成形型の装着されたプレス機に投入し成形体を得た。得られた成形体は表面に難燃繊維のグレー色が斑ら模様として存在し、所望の色調を得ることが困難であることが判明した。
【００２８】
【発明の効果】
以上詳述したように、本発明の起毛調不織布は、不織布原反を構成する繊維として、高融点のポリエステルステープル繊維と、芯鞘構造を有し鞘部に低融点コポリエステルが用いられている熱融着型のコンジュゲートステープル繊維とが含まれており、又、パイル部と基布部を構成する繊維配合が異なる不織布が積層された構成を有し、特に、色調の調整困難な難燃処理繊維又は難燃剤含有繊維を基布部に用いたこにより表面の色調調整を簡便容易にし、更に、低目付、即ち５０〜４００ｇ／ｍ² のラミネートされた熱可塑性樹脂シートバッキング層を持つ起毛調不織布においても色調の自由度を大きくすることが可能である。更に又本発明の起毛不織布は、融点の低いコポリエステルの溶融点と融点の高いポリエステルの溶融点の範囲内の温度で加熱した後、プレス機に投入して冷却することにより成形可能であり、加熱・成形により熱融着繊維繊維の作用によってパイルが基布に強固に捕捉・固定されるため、パイルを基布に固定するためにラテックスを用いる必要がない。更に、パイル部と基布部の配合を変えることにより、表面風合いを損なうことなしに、成形性・形状保持性を兼ね備えることが可能となった。このため、製造工程の簡略化に伴うコスト低減と、更に製品の軽量化が達成されるという格段の効果を奏する。
【図面の簡単な説明】
【図１】従来公知の起毛不織布の層構成を示す垂直断面図である。
【図２】従来公知の起毛不織布の別の層構成を示す垂直断面図である。
【図３】従来公知の起毛不織布の別の層構成及び本発明の起毛調不織布の典型例を示す垂直断面図である。
【符号の説明】
１コード調、ディロアの柄部分
２基布層
３ラテックス含浸層
４熱可塑性樹脂シート[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a brushed nonwoven fabric obtained by forming a pile, preferably a pile patterned in a cord tone or a deloy tone, on the surface, and in particular, the hair of the pile is mainly formed by entanglement and mutual adhesion of constituent fibers without using latex. The present invention relates to a raised nonwoven fabric which can be formed into a stable dimensional form mainly used for interior materials such as carpets, ceilings, door trims and the like in which formability is regarded as important.
[0002]
[Prior art]
As a conventional brushed nonwoven fabric, for example, the one shown in FIG. 1, FIG. 2, or FIG. 3 is known. FIG. 1 shows a brushed nonwoven fabric having an impregnated layer 3 impregnated with latex to fix a pile portion, which has a patterned pile 1 having a cord tone or a Delore tone on the surface of a nonwoven fabric base fabric 2. These are disclosed in JP-A-52-53980 and JP-A-61-132667. FIG. 2 shows that the latex-impregnated layer 3 shown in FIG. 1 further has an ethylene / vinyl acetate copolymer containing an inorganic substance such as a polypropylene sheet, a polyamide sheet, or calcium carbonate on the back surface thereof so that it can be molded particularly for a vehicle interior. Examples of laminating thermoplastic resin sheets 4 such as a united (EVA) are disclosed in JP-A-59-140175, JP-A-57-205251, JP-A-59-204982, and the like. Further, FIG. 3 shows an example in which the same latex-fused fiber having the same core-sheath structure is blended in the pile portion 1 and the nonwoven fabric base portion 2 without using these latexes. No. has been proposed.
[0003]
[Problems to be solved by the invention]
However, these conventional brushed nonwoven fabrics require latex impregnation to prevent hair loss, which complicates the manufacturing process and increases the cost. In addition, when used for vehicles, weight reduction is required. There was a problem that was incompatible with. In addition, if the lamination of the thermoplastic resin sheet is omitted or reduced in order to reduce the weight and simplify the structure, the moldability and shape retention will be impaired. Contrary to this, it is necessary to increase the latex impregnation amount to obtain the above-mentioned desired performance, so that it is difficult to achieve the original purpose.
[0004]
Further, when the pile portion and the base fabric portion have a single-layer structure and the same heat-sealing binder is compounded as a whole, if the amount of the binder is small, the moldability cannot be secured, the shape retention becomes difficult, and the amount of the binder is reduced. If it is mixed too much, the pile parts will fall down during molding, making it difficult to secure the texture of the surface.
[0005]
Furthermore, when the pile portion and the base fabric portion have a single-layer structure and contain fibers or flame retardants that have been subjected to the same flame-retardant treatment, the color tone of these materials is limited. Was very difficult.
[0006]
The present invention has been made in view of such conventional problems, and a laminated brushed nonwoven fabric capable of preventing the pile from coming off without requiring latex impregnation is provided at a low cost with a simplified process. The purpose is to provide. Furthermore, it is possible to greatly reduce the weight of a thermoplastic resin sheet conventionally used, and at the same time, it has good surface texture, easy color tone adjustment, excellent quality, moldability and shape retention. An object of the present invention is to provide a brushed nonwoven fabric.
[0007]
[Means for Solving the Problems]
The laminated brushed nonwoven fabric of the present invention that achieves the above object forms a pile in which at least a part of the constituent fibers protrudes over the entire surface thereof, and a nonwoven fabric of a pile portion in which the fiber composition is different from the nonwoven fabric. The nonwoven fabric of the base cloth portion is laminated, and the basis weight is 50 to 400 g / m on the back surface of the base cloth portion. ^Two The nonwoven fabric in the pile portion is a core-sheath comprising 76 to 98% by weight of a 2 to 50 denier high-melting polyester staple fiber and a sheath component of a low-melting copolyester. The woven fabric of the base fabric portion is composed of 2 to 50 denier high-melting-point polyester staple fibers having a denatured conjugate structure and containing 2 to 24% by weight of heat-fusible staple fibers of 1 to 20 denier. 20 to 95% by weight of 1 to 20 denier heat-fusible staple fiber having a core-sheath conjugate structure in which the sheath component is made of a low melting point copolyester. Polyester staple fiber with flame retardant treatment By heating the nonwoven fabric at a temperature between the melting point of the low-melting point copolyester and the melting point of the high-melting point polyester, and then putting the mixture into a press and cooling it. The contact point between the constituent fiber and the copolyester is fused and can be molded.
[0008]
The low melting point copolyester preferably has a melting point in the range of 100 to 230C. Further, the nonwoven fabric of the present invention preferably has a thickness of 5 to 20 mm and 200 to 800 g / m 2 in a laminated state. ² The nonwoven fabric forming the pile portion and the nonwoven fabric forming the base fabric portion are more preferably 100 to 700 g / m2. ² With a basis weight of
[0009]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, the configuration of the present invention will be described in detail together with its operation.
[0010]
The brushed nonwoven fabric of the present invention includes, as fibers constituting the raw nonwoven fabric, a polyester staple fiber having a high melting point, and a heat-fusible conjugate staple fiber having a core-sheath structure using a low melting point copolyester in a sheath portion. The nonwoven fabric forming the pile portion and the nonwoven fabric forming the base fabric portion laminated on the pile portion have different fiber compositions. Also, the non-woven fabric of the base fabric part is Polyester staple fiber with flame retardant treatment . The laminated nonwoven fabric can be molded by heating at a temperature in the range between the melting point of the high-melting polyester and the melting point of the low-melting copolyester, and then putting it into a press and cooling.
[0011]
Generally, polyester fibers, nylon fibers, polypropylene fibers, and the like are used as the fibers constituting the brushed nonwoven fabric, but polyester fibers are most preferable as the fibers constituting the brushed nonwoven fabric of the present invention. Nylon fibers are not preferred for economic reasons due to high raw material costs, and polypropylene fibers are not preferred because they are liable to fall down and are inferior in abrasion resistance and easily collapse after heating and compression molding.
[0012]
The high-melting polyester fiber used for the raw nonwoven fabric constituting the brushed nonwoven fabric of the present invention is not particularly limited, but polyethylene terephthalate or a polyester having a component equivalent thereto is most preferable because it is inexpensive and easily available. On the other hand, as the low melting point copolyester used for the sheath portion of the heat-fusible fiber having a core-sheath structure, terephthalic acid, isophthalic acid, acid components such as adipic acid and ethylene glycol, propylene glycol, diethylene glycol, triethylene glycol, It is possible to use a diol component such as polyethylene glycol or polypropylene glycol, or a copolyester obtained by ring-opening and copolymerizing a lactone. The polyester used for the core is not particularly limited, but polyethylene terephthalate or a polyester having a component equivalent thereto is inexpensive and most preferable. The melting point of the low-melting polyester is preferably in the range of 100 to 230 ° C, more preferably in the range of 105 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 is higher than 230 ° C., the melting point difference between the high melting point component and the high melting point component becomes small, and there is a possibility that not only the low melting point component but also the high melting point component is softened or melted during heating, and loses its shape as a lump as a fiber, In addition to a problem in appearance, the heating temperature increases and molding becomes difficult.
[0013]
The fineness of the high melting point polyester is preferably in the range of 2 to 50 denier, more preferably 4 to 20 denier. If it is less than 2 denier, a problem may occur in the card passing property in the process of forming the nonwoven fabric, and a good quality nonwoven fabric may not be obtained. If it is more than 50 denier, the texture of the pile is undesirably rough. The cross-sectional shape of the high melting point polyester fiber is not particularly limited, such as a flat type, a Y type, and a hollow type, besides a circle, and a side-by-side type conjugate fiber can also be used. The fineness of the heat-fusible polyester having a core-sheath structure is preferably in the range of 1 to 20 denier, more preferably 2 to 15 denier. If it is less than 2 denier, it is preferable for the same reason as described above, and if it exceeds 20 denier, the bonding point between fibers also decreases with the decrease in the number of fibers, and sufficient shape retention cannot be obtained even by heat molding. Absent. It is also possible to use a so-called dyed fiber in which both or one of the above-mentioned polyesters is colored by adding a pigment in the spinning step in order to color the raw fabric in a predetermined color. It is also possible to add a filler.
[0014]
In the brushed tone nonwoven fabric of the present invention, as the fibers constituting the raw fabric, the high-melting polyester fiber and the heat-fusible polyester fiber are mixed and used for both the pile portion and the base fabric portion. It is preferable that the wearable polyester fiber is contained in the range of 2 to 24% by weight, more preferably 5 to 20% by weight. If it is less than 2% by weight, the number of bonding points between the fibers is reduced, so that the hairs often come off from the pile portion during use, and it is not preferable because sufficient shape retention cannot be obtained even by heat molding. If the content is more than 24% by weight, the cost may increase, and the number of bonding points between the fibers may increase, so that the cord-like pattern and the Diroa-like pattern may change after heat molding. The likelihood of appearance problems increases. The base cloth preferably contains 20 to 95% by weight of the heat-fusible polyester fiber, and more preferably 40 to 95% by weight. If the content is less than 20% by weight, it is difficult to obtain desired rigidity because the number of bonding points between fibers is reduced, and it is difficult to ensure moldability and shape retention. The heat-fused fiber of the base fabric is for obtaining moldability and shape retention, and an increase in the blending amount leads to an increase in cost. However, since desired performance is obtained, no upper limit is particularly set.
[0015]
The raw material of the raised nonwoven fabric of the present invention before molding has a thickness of 5 to 20 mm, more preferably 8 to 15 mm. If the thickness is less than 5 mm, sufficient shape retention after heat molding cannot be obtained, so that it is not preferable. If the thickness is more than 20 mm, patterning such as chord tone and derogation with a fork needle becomes difficult. Also, the basis weight of the raw material in the laminated state is 200 to 800 g / m ² And more preferably 250 to 500 g / m ² Range. The basis weight of the raw material is 200g / m ² If it is less than 10, not only sufficient shape retention cannot be obtained, but also sufficient thickness cannot be obtained, so that a transparent portion may be formed after molding, which is not preferable. 800 g / m ² If it is super, it will be difficult to print patterns such as chords and dirowers with a fork needle.
[0016]
【Example】
Hereinafter, examples of the present invention will be described in detail, but the present invention is not limited thereto. In the abrasion resistance test in the examples, the pile retention was determined at 1 kg and 500 rotations using a Taber abrasion tester H-38.
[0017]
(Example 1)
As for the composition of the non-woven fabric, the pile portion is a normal polyester staple fiber having a circular cross section of 10 denier 51 mm cut length and 80% by weight, and a 4 denier 51 mm cut length core sheath structure similarly deposited on gray. Heat-fusible polyester staple fiber (sheath, copolyester having a melting point of 110 ° C.) having: 20% by weight and a basis weight of 300 g / m 2 ² And Further, the base fabric portion has a 10-denier 51 mm cut length ordinary polyester staple fiber having a circular cross section of 50% by weight, and a 4 denier 51 mm cut length core-sheath structure similarly grayed. Heat fusible polyester staple fiber (sheath, copolyester having a melting point of 110 ° C.): 35% by weight, copolymerized with a phosphorus-based compound, and subjected to flame-retardant treatment of 4 denier 51 mm cut length soaked in black Polyester staple fiber: 15% by weight, basis weight 100 g / m ² And Next, these fibers were blended, carded, cross-layered, and needle-punched to obtain a raw nonwoven fabric. Further, a pile portion was formed by penetrating a fork needle from one side of the obtained raw material, and then subjected to shirring treatment to obtain a pattern of a deloy tone, thereby obtaining a brushed nonwoven fabric having a thickness of 10 mm. The nonwoven fabric has a basis weight of 250 g / m2 as a backing layer. ² Was laminated to obtain a brushed tone laminated nonwoven fabric. The obtained brush-finished 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 Taber abrasion test result was also good, and the desired texture was obtained while maintaining the texture of the Deloyer tone.
[0018]
(Example 2)
As for the composition of the non-woven fabric, the pile portion has a 10-denier 51 mm cut length ordinary polyester staple fiber with a circular cross section of 95% by weight, and a 4 inch denier 51 mm cut length core-sheath structure similarly deposited on brown. Heat-fusible polyester staple fiber (sheath, copolyester having a melting point of 110 ° C.): 5% by weight and a basis weight of 150 g / m 2 ² And Further, the base cloth portion has a 6-denier 51 mm cut length ordinary polyester staple fiber having a circular cross section of 50% by weight, and a 2 sheath denier 51 mm cut length cored on brown similarly. Heat-fused polyester staple fiber (sheath, copolyester having a melting point of 170 ° C.): 35% by weight, non-originated (white) 4-denier copolymerized with a phosphorus-based compound, subjected to a flame-retardant treatment with a cut length of 51 mm. Polyester staple fiber: 15% by weight, and the basis weight is 150 g / m. ² And Next, these fibers were blended, carded, cross-layered, and needle-punched to obtain a raw nonwoven fabric. Further, a pile portion was formed by penetrating a fork needle from one side of the obtained raw material, and then subjected to shirring treatment to obtain a pattern of a deloy tone, thereby obtaining a brushed nonwoven fabric having a thickness of 10 mm. The nonwoven fabric has a basis weight of 100 g / m as a backing layer. ² Was laminated to obtain a brushed tone laminated nonwoven fabric. The obtained brush-finished laminated nonwoven fabric raw material was heated to 205 ° C. and put into a press equipped with a mold to obtain a molded body. The shape retention after molding was good, the Taber abrasion test result was also good, and the desired texture was obtained while maintaining the texture of the Deloyer tone.
[0019]
(Example 3)
As for the composition of the non-woven fabric, the pile portion is a regular polyester staple fiber having a circular cross section of 15 denier and 51 mm cut length, which is originally colored in gray: 76% by weight. Similarly, a 3 denier 51 mm cut length core sheath structure which is similarly deposited in gray. Heat fusible polyester staple fiber (sheath part, copolyester having a melting point of 110 ° C.) having a weight of 24 g / m 2 and a basis weight of 400 g / m 2 ² And Further, the base cloth portion has a normal polyester staple fiber having a circular cross section of 10 denier 51 mm cut length in which the fiber composition is grayed: 45% by weight, and a 4 denier 51 mm cut length core sheath structure also similarly grayed out. Heat-fused polyester staple fiber (sheath, copolyester having a melting point of 110 ° C.): 50% by weight, non-originated (white) 4-denier copolymerized with a phosphorus-based compound, subjected to a flame retardant treatment with a cut length of 51 mm. Polyester staple fiber: 5% by weight and a basis weight of 400 g / m ² And Next, these fibers were blended, carded, cross-layered, and needle-punched to obtain a raw nonwoven fabric. Further, a pile portion was formed by penetrating a fork needle from one side of the obtained raw material, and a shirring treatment was performed to obtain a pattern of a dielore-like pattern to obtain a brushed nonwoven fabric having a thickness of 20 mm. This nonwoven fabric has a basis weight of 400 g / m as a backing layer. ² Was laminated to obtain a brushed tone laminated nonwoven fabric. The obtained brush-finished 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 Taber abrasion test result was also good, and the desired texture was obtained while maintaining the texture of the Deloyer tone.
[0020]
(Example 4)
As for the composition of the nonwoven fabric, the pile portion is a normal polyester staple fiber having a circular cross section of 10 denier and a cut length of 51 mm, which is originally colored in gray: 90% by weight. Heat-fusible polyester staple fiber (sheath part, copolyester having a melting point of 110 ° C.) having 10% by weight and a basis weight of 100 g / m 2 ^Two And Further, the base fabric portion is a heat-fused polyester staple fiber (sheath portion, copolyester having a melting point of 110 ° C.) having a core-sheath structure with a cut length of 4 denier and 51 mm in which the fiber composition is grayed: 95% by weight, gray 4 denier 51 mm cut length polyester staple fiber treated with flame retardant cut at 5% by weight, with a basis weight of 100 g / m ^Two And Next, these fibers were blended, carded, cross-layered, and needle-punched to obtain a raw nonwoven fabric. Further, a pile portion was formed by penetrating a fork needle from one side of the obtained raw material, and a shirring treatment was performed to obtain a pattern of a Deloitte tone, thereby obtaining a brushed nonwoven fabric having a thickness of 5 mm. This nonwoven fabric has a basis weight of 400 g / m as a backing layer. ^Two Was laminated to obtain a brushed tone laminated nonwoven fabric. The obtained brush-finished 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 Taber abrasion test result was also good, and the desired texture was obtained while maintaining the texture of the Deloyer tone.
[0021]
(Example 5)
As for the composition of the non-woven fabric, the pile portion is a normal polyester staple fiber having a circular cross section of 10 denier and 51 mm cut length, which is originally colored in gray: 76% by weight, and similarly, a 4 denier 51 mm cut length core sheath structure which is originally deposited in gray. Heat-bondable polyester staple fiber (sheath, copolyester having a melting point of 110 ° C.) having a weight of 24 g / m 2 and a basis weight of 250 g / m 2 ^Two And Further, the base fabric portion has a 10-denier 51 mm cut length ordinary polyester staple fiber having a circular cross section with a fiber mixture of 5% by weight, and a 4 denier 51 mm cut length core-sheath structure similarly grayed. Polyester staple fiber of heat fusion type (sheath, copolyester having a melting point of 110 ° C.): 25% by weight, flame-retardant polyester staple fiber having a cut length of 4 denier 51 mm and gray: 70% by weight , Basis weight 200g / m ^Two And Next, these fibers were blended, carded, cross-layered, and needle-punched to obtain a raw nonwoven fabric. Further, a pile portion was formed by penetrating a fork needle from one side of the obtained raw material, and a shirring treatment was performed to obtain a pattern of a dielore tone, thereby obtaining a brushed nonwoven fabric having a thickness of 12 mm. This nonwoven fabric has a basis weight of 50 g / m as a backing layer. ^Two Was laminated to obtain a brushed tone laminated nonwoven fabric. The obtained brush-finished 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 Taber abrasion test result was also good, and the desired texture was obtained while maintaining the texture of the Deloyer tone.
[0022]
(Example 6)
As for the composition of the non-woven fabric, the pile portion is a normal polyester staple fiber having a circular cross section of 10 denier 51 mm cut length and 80% by weight, and a 4 denier 51 mm cut length core sheath structure similarly deposited on gray. Heat fusible polyester staple fiber (sheath part, copolyester having a melting point of 110 ° C.): 20% by weight and a basis weight of 220 g / m 2 ^Two And Further, the base fabric portion has a 2-sheath 51 mm cut length ordinary polyester staple fiber having a circular cross section of 75% by weight and a 15 denier 51 mm cut length core sheath structure also made of gray. Heat fusible polyester staple fiber (sheath, copolyester having a melting point of 110 ° C.): 20% by weight, flame-retardant 4 denier 51 mm cut length polyester staple fiber deposited on gray: 5% by weight , Basis weight 200g / m ^Two And Next, these fibers were blended, carded, cross-layered, and needle-punched to obtain a raw nonwoven fabric. Further, a pile portion was formed by penetrating a fork needle from one side of the obtained raw material, and a shirring treatment was performed to obtain a pattern of a Delorian tone, thereby obtaining a brushed nonwoven fabric having a thickness of 13 mm. This nonwoven fabric has a basis weight of 400 g / m as a backing layer. ^Two Was laminated to obtain a brushed tone laminated nonwoven fabric. The obtained brush-finished 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 Taber abrasion test result was also good, and the desired texture was obtained while maintaining the texture of the Deloyer tone.
[0023]
(Comparative Example 1)
As for the composition of the non-woven fabric, the pile portion is a regular polyester staple fiber having a circular cross section of 10 denier and 51 mm cut length, which is originally colored in gray: 98% by weight. Heat fusible polyester staple fiber (sheath part, copolyester having a melting point of 110 ° C.) having 2% by weight and a basis weight of 300 g / m 2 ^Two And Further, the base fabric portion has a 10-denier 51 mm cut length ordinary polyester staple fiber having a circular cross section of 50% by weight, and a 4 denier 51 mm cut length core-sheath structure similarly grayed. Heat fusible polyester staple fiber (sheath, copolyester having a melting point of 110 ° C.): 50% by weight and a basis weight of 100 g / m 2 ^Two And Next, these fibers were blended, carded, cross-layered, and needle-punched to obtain a raw nonwoven fabric. Further, a pile portion was formed by penetrating a fork needle from one side of the obtained raw material, and then subjected to shirring treatment to obtain a pattern of a deloy tone, thereby obtaining a brushed nonwoven fabric having a thickness of 10 mm. The obtained brushed 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 sufficient, and the results of Taber abrasion test revealed that many hairs fell out and were not preferable in appearance.
[0024]
(Comparative Example 2)
As for the composition of the non-woven fabric, the pile portion is a normal polyester staple fiber having a circular cross section of 10 denier 51 mm cut length and 80% by weight, and a 4 denier 51 mm cut length core sheath structure similarly deposited on gray. Heat fusible polyester staple fiber (sheath part, copolyester having a melting point of 110 ° C.): 20% by weight and a basis weight of 100 g / m 2 ^Two And Further, the base cloth portion has a normal polyester staple fiber having a circular cross section of 10 denier 51 mm cut length in which the fiber composition is grayed: 45% by weight, and a 4 denier 51 mm cut length core sheath structure also similarly grayed out. Heat-fusible polyester staple fiber (sheath, copolyester having a melting point of 110 ° C.): 50% by weight, flame-retardant polyester staple fiber with a cut length of 4 denier 51 mm cut on gray: 5% by weight 80 g / m ^Two And Next, these fibers were blended, carded, cross-layered, and needle-punched to obtain a raw nonwoven fabric. Further, a pile portion was formed by penetrating a fork needle from one side of the obtained raw material, and a shirring treatment was performed to obtain a pattern of a Deloitte tone, thereby obtaining a brushed nonwoven fabric having a thickness of 5 mm. This nonwoven fabric has a basis weight of 35 g / m as a backing layer. ^Two Was laminated to obtain a brushed tone laminated nonwoven fabric. The obtained brush-finished 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 sufficient, and the Taber abrasion test results showed that there was a lot of hair loss and that a transparent portion was formed, which was unfavorable in appearance.
[0025]
(Comparative Example 3)
As for the composition of the nonwoven fabric, the pile portion is a normal polyester staple fiber having a circular cross section of 60 denier and 51 mm cut length, which is originally gray and 80% by weight. Heat-fusible polyester staple fiber (sheath, copolyester having a melting point of 110 ° C.) having: 20% by weight and a basis weight of 300 g / m 2 ^Two And Further, the base fabric portion has a 10-denier 51 mm cut length ordinary polyester staple fiber having a circular cross section with a fiber mixture of 45% by weight, and a 4 denier 51 mm cut length core-sheath structure similarly grayed. Heat-fusible polyester staple fiber (sheath, copolyester having a melting point of 110 ° C.): 40% by weight, flame-retardant polyester staple fiber having a cut length of 4 denier 51 mm cut on gray: 15% by weight , The basis weight is 100 g / m ^Two And Next, these fibers were blended, carded, cross-layered, and needle-punched to obtain a raw nonwoven fabric. Further, a pile portion was formed by penetrating a fork needle from one side of the obtained raw material, and then subjected to shirring treatment to obtain a pattern of a Deloitte tone, thereby obtaining a brushed nonwoven fabric having a thickness of 15 mm. The nonwoven fabric has a basis weight of 300 g / m as a backing layer. ^Two Was laminated to obtain a brushed tone laminated nonwoven fabric. The obtained brush-finished laminated nonwoven fabric was heated to 180 ° C. and put into a press equipped with a mold to obtain a molded body. After the molding, the Taber abrasion test result also revealed that the hair had many sheddings and that the fineness of the main fibers on the surface was large, so that the appearance was not preferable.
[0026]
(Comparative Example 4)
As for the composition of the nonwoven fabric, the pile portion is a normal polyester staple fiber having a circular cross section of 10 denier and 51 mm cut length, which is originally colored in gray: 90% by weight, and similarly, a 4 denier 51 mm cut length core sheath structure which is similarly deposited in gray. Heat-bondable polyester staple fiber (sheath part, copolyester having a melting point of 110 ° C.) having 10% by weight and a basis weight of 300 g / m 2 ^Two And Further, the base fabric part has a 10-denier 51 mm cut length ordinary polyester staple fiber having a circular cross section with a fiber composition of gray, 75% by weight, and a 4 denier 51 mm cut length core-sheath structure similarly grayed. Heat fusible polyester staple fiber (sheath, copolyester having a melting point of 110 ° C.): 20% by weight, flame-retardant 4 denier 51 mm cut length polyester staple fiber deposited on gray: 5% by weight , The basis weight is 100 g / m ^Two And Next, these fibers were blended, carded, cross-layered, and needle-punched to obtain a raw nonwoven fabric. Further, a pile portion was formed by penetrating a fork needle from one side of the obtained raw material, and a shirring treatment was performed to obtain a pattern of a dielore tone, thereby obtaining a brushed nonwoven fabric having a thickness of 12 mm. The nonwoven fabric has a basis weight of 30 g / m as a backing layer. ^Two Was laminated to obtain a brushed tone laminated nonwoven fabric. The obtained brush-finished laminated nonwoven fabric was heated to 180 ° C. and put into a press equipped with a molding die for molding. However, the shape retention was not sufficient, and it was difficult to obtain a desired molded body. Met.
[0027]
(Comparative Example 5)
The blending of the nonwoven fabric is as follows. For both the pile portion and the base fabric portion, a 10-denier 51 mm cut length ordinary polyester staple fiber with a brown cross section, 70% by weight, and a 4 denier, 51 mm cut length core with a gray deposit Heat-fused polyester staple fiber having a sheath structure (sheath portion, copolyester having a melting point of 110 ° C.): 15% by weight, flame-retardant polyester staple fiber having a cut length of 4 denier and 51 mm cut on gray: 15 Weight% and the basis weight is 300 g / m ^Two And Next, these fibers were blended, carded, cross-layered, and needle-punched to obtain a raw nonwoven fabric. Further, a pile portion was formed by penetrating a fork needle from one side of the obtained raw material, and then subjected to shirring treatment to obtain a pattern of a deloy tone, thereby obtaining a brushed nonwoven fabric having a thickness of 10 mm. This nonwoven fabric has a basis weight of 400 g / m as a backing layer. ^Two Was laminated to obtain a brushed tone laminated nonwoven fabric. The obtained brush-finished laminated nonwoven fabric was heated to 180 ° C. and put into a press equipped with a mold to obtain a molded body. It was found that the obtained molded article had a gray color of the flame-retardant fiber on the surface as a spotted pattern, and it was difficult to obtain a desired color tone.
[0028]
【The invention's effect】
As described in detail above, the brushed nonwoven fabric of the present invention has a high melting point polyester staple fiber and a low melting point copolyester having a core-sheath structure as a fiber constituting a nonwoven fabric fabric. It contains a heat-fusible conjugate staple fiber and has a structure in which nonwoven fabrics with different fiber compositions constituting the pile portion and the base fabric portion are laminated. By using the treated fiber or the flame retardant-containing fiber in the base fabric part, the color tone of the surface can be easily and easily adjusted, and the weight per unit area is low, that is, 50 to 400 g / m. ^Two It is also possible to increase the degree of freedom in color tone in a brushed nonwoven fabric having a laminated thermoplastic resin sheet backing layer. Furthermore, the brushed nonwoven fabric of the present invention can be molded by heating at a temperature within the range of the melting point of the low-melting copolyester and the melting point of the high-melting polyester, and then putting it into a press and cooling, Since the pile is firmly captured and fixed to the base fabric by the action of the heat-fused fiber fibers by heating and molding, it is not necessary to use latex to fix the pile to the base fabric. Further, by changing the composition of the pile portion and the base fabric portion, it is possible to provide both moldability and shape retention without impairing the surface texture. For this reason, there is a remarkable effect that the cost is reduced due to the simplification of the manufacturing process and the weight of the product is further reduced.
[Brief description of the drawings]
FIG. 1 is a vertical sectional view showing a layer structure of a conventionally known brushed nonwoven fabric.
FIG. 2 is a vertical sectional view showing another layer configuration of a conventionally known raised nonwoven fabric.
FIG. 3 is a vertical sectional view showing another layer configuration of a conventionally known brushed nonwoven fabric and a typical example of a brushed nonwoven fabric of the present invention.
[Explanation of symbols]
1 Chord tone, Diroa handle
2 Base fabric layer
3 Latex impregnated layer
4 thermoplastic resin sheet

Claims

In a raised nonwoven fabric in which at least a part of the constituent fibers of the nonwoven fabric protrudes over the entire surface of the nonwoven fabric, a nonwoven fabric of a pile portion and a nonwoven fabric of a base fabric portion having different fiber compositions are laminated. Further, a backing layer made of a thermoplastic resin sheet having a basis weight of 50 to 400 g / m ² is laminated on the back surface of the base fabric, and the nonwoven fabric of the pile portion is formed of 2 to 50 denier high-melting polyester staple fiber of 76 to 98 denier. A fiber composition containing 2 to 24% by weight of 1 to 20 denier heat-fusible staple fiber having a core-sheath type conjugate structure in which a sheath component is composed of a low melting point copolyester and a non-woven fabric of the base cloth portion. Is a core-sheath type conjugate comprising 0 to 75% by weight of a high melting point polyester staple fiber having 2 to 50 deniers and a sheath component of a low melting point copolyester. Becomes 1 to 20 denier heat-fusible staple fibers having over preparative structure 20 to 95% by weight polyester staple fibers subjected to the flame retardant treatment of a fiber blend containing 5-70% by weight, said low melting point copolyester After heating the nonwoven fabric at a temperature between the melting point of the polyester and the melting point of the polyester with a high melting point, put it in a press and cool it, so that the contact points between the constituent fibers and the copolyester can be fused and molded. A laminated brushed nonwoven fabric characterized by the following.

The laminated brushed nonwoven fabric of claim 1 wherein said low melting copolyester has a melting point in the range of 100-230 ° C.

3. The laminated brushed nonwoven fabric of claim 2 wherein said low melting point copolyester has a melting point in the range of 105-210C.

Laminated brushed tone nonwoven of any one of claims 1 to 3 having a basis weight thickness and 200 to 800 g / m ² of 5~20mm in a state in which the nonwoven fabric is laminated.

It laminated brushed tone nonwoven according to claim 4 having a basis weight and 250~500g / m ² Thickness of 8~15mm in a state in which the nonwoven fabric is laminated.

The laminated brushed nonwoven fabric according to any one of claims 1 to 5, wherein the high melting point polyester staple fiber has a fineness of 4 to 20 denier.

The brushed nonwoven fabric according to any one of claims 1 to 5, wherein the heat-fusible staple fibers have a fineness of 2 to 15 denier.

Laminated brushed tone nonwoven of any one of claims 1 to 7, a nonwoven fabric constituting the nonwoven fabric and the base fabric portions constituting the pile portion has a both 100~700g / m ² of basis weight.

9. The brushed nonwoven fabric according to claim 8, wherein both the nonwoven fabric forming the pile portion and the nonwoven fabric forming the base fabric portion have a basis weight of 100 to 400 g / m < ² >.

The nonwoven fabric of the pile portion is composed of a fiber blend containing 80 to 95% by weight of the high-melting polyester staple fiber and 5 to 20% by weight of the heat-fusible staple fiber, and the nonwoven fabric of the base fabric portion has a high melting point. 2. A fiber composition comprising 0 to 60% by weight of polyester staple fiber, 40 to 95% by weight of heat-fusible staple fiber, and 5 to 50% by weight of polyester staple fiber which has been subjected to a flame retardant treatment. 10. The brushed nonwoven fabric according to any one of items 1 to 9.

The brushed nonwoven fabric according to any one of claims 1 to 10, wherein the pile is formed on a front surface of the nonwoven fabric using a fork needle from the back surface, and further, a tip portion thereof is trimmed by a shearing process. .

The laminated brushed nonwoven fabric according to claim 11, wherein the pile tip portion is trimmed with a predetermined height difference by a shearing process, and is patterned in a cord tone or a diroa tone.

The nonwoven fabric forming the pile portion and the base fabric portion has a continuous laminated structure, or after the nonwoven fabric of the pile portion and the nonwoven fabric of the base fabric portion are separately prepared, needling or heat bonding or both. The laminated brushed nonwoven fabric according to any one of claims 1 to 12, wherein the laminated brushed nonwoven fabric has an integrated laminated structure.

It laminated brushed tone nonwoven of any one of claims 1 to 13 having a basis weight of the thermoplastic resin sheet laminated to the back surface of the base cloth portion is 100 to 400 g / m ^2.