U.S. patent application number 10/582179 was filed with the patent office on 2008-01-31 for elastic nonwoven fabric.
Invention is credited to Yasumasa Hayakawa, Masanori Ogawa, Tsuyoshi Watanabe.
Application Number | 20080026660 10/582179 |
Document ID | / |
Family ID | 34674882 |
Filed Date | 2008-01-31 |
United States Patent
Application |
20080026660 |
Kind Code |
A1 |
Ogawa; Masanori ; et
al. |
January 31, 2008 |
Elastic Nonwoven Fabric
Abstract
The object of the present invention is to improve the elasticity
of a nonwoven fabric manufactured by the spunbonding method. To
attain the object, the present invention provides a nonwoven fabric
manufactured by the spunbonding method, wherein a lot of holes are
formed in the nonwoven fabric by the needle punching method, to
give said nonwoven fabric elasticity. Synthetic resin may be
impregnated into the nonwoven fabric.
Inventors: |
Ogawa; Masanori; (Aichi,
JP) ; Hayakawa; Yasumasa; (Aichi, JP) ;
Watanabe; Tsuyoshi; (Aichi, JP) |
Correspondence
Address: |
Donald S Dowden;Cooper & Dunham
1185 Avenue of the Americas
New York
NY
10036
US
|
Family ID: |
34674882 |
Appl. No.: |
10/582179 |
Filed: |
December 1, 2004 |
PCT Filed: |
December 1, 2004 |
PCT NO: |
PCT/JP04/17851 |
371 Date: |
September 17, 2007 |
Current U.S.
Class: |
442/328 |
Current CPC
Class: |
D04H 3/105 20130101;
Y10T 442/601 20150401 |
Class at
Publication: |
442/328 |
International
Class: |
D04H 3/10 20060101
D04H003/10; D04H 3/16 20060101 D04H003/16 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 8, 2003 |
JP |
2003-408728 |
Claims
1. An elastic nonwoven fabric made of a nonwoven fabric
manufactured by a spunbonding method, wherein a multiplicity of
holes are formed in said nonwoven fabric by a needle punching
method, and synthetic resin is impregnated into said nonwoven
fabric.
2. (canceled)
3. An elastic nonwoven fabric in accordance with claim 1 wherein
said synthetic resin comprises a thermoplastic resin.
4. An interior material for an automotive vehicle, said material
comprising a nonwoven fabric in accordance with claim 1, as a
surface layer material, and a base material having a surface to
which said elastic nonwoven fabric is attached as a surface layer,
then being molded into a prescribed shape.
5. An interior material for an automotive vehicle, said material
comprising a nonwoven fabric in accordance with claim 2, as a
surface layer material, and a base material having a surface to
which said elastic nonwoven fabric is attached as a surface layer,
then being molded into a prescribed shape.
6. An interior material for an automotive vehicle, said material
comprising a nonwoven fabric in accordance with claim 3, as a
surface layer material, and a base material having a surface to
which said elastic nonwoven fabric is attached as a surface layer,
then being molded into a prescribed shape.
7. An elastic nonwoven fabric in accordance with claim 1, wherein
said holes range in number between substantially 10/cm.sup.2 and
100/cm.sup.2.
8. An elastic nonwoven fabric in accordance with claim 1 having a
weight within the range of substantially 30 g/m.sup.2 to 60
g/m.sup.2.
9. an elastic nonwoven fabric in accordance with claim 1, wherein
each of said holes has a diameter within the range of 0.1 mm to 2.4
mm.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to an elastic nonwoven fabric
manufactured by the spunbonding method.
BACKGROUND OF THE INVENTION
[0002] Hitherto, as the surface layer material, a nonwoven fabric
manufactured by the needle punching method has generally been used.
Nevertheless, it is difficult to manufacture a thin nonwoven fabric
by the needle punching method. Therefore, this thin nonwoven fabric
has been manufactured by the spunbonding method. (Patent Literature
JP2002-105832)
DISCLOSURE OF THE INVENTION
[0003] Nevertheless, the nonwoven fabric manufactured by the
spunbonding method has poor elasticity along its length and width,
so that in a case where said nonwoven fabric is used as a surface
layer material, and is attached to the base material and molded
into a prescribed shape, there is a problem in that wrinkles and
cracks may occur in the deep drawn part of the resulting molded
fabric.
Means to Solve Said Problem
[0004] As a means to solve said problem, the present invention
provides an elastic nonwoven fabric made of a nonwoven fabric
manufactured by the spunbonding method, wherein a lot of holes are
formed in said nonwoven fabric by the needle punching method.
[0005] It is preferable that synthetic resin be impregnated into
said nonwoven fabric.
[0006] Further, it is preferable that said synthetic resin be a
thermosetting resin.
[0007] Furthermore, the present invention also provides an interior
material consisting of said elastic nonwoven fabric as a surface
layer material, and a base material to whose surface said elastic
nonwoven fabric is attached as a surface layer, then being molded
into a prescribed shape.
Effect of the Invention
[0008] The elasticity of said nonwoven fabric along its length and
width is improved by a lot of holes formed in said nonwoven fabric
by needle punching. Accordingly, in a case where said elastic
nonwoven fabric is used as a surface layer material, being attached
to a base material, and molded into a prescribed shape, no wrinkles
and no cracks may occur in the deep drawn part of the resulting
molded article.
DETAILED DESCRIPTION OF THE INVENTION AND PREFERRED EMBODIMENTS
[0009] The nonwoven fabric used in the present invention is
manufactured by the spunbonding method, wherein a thermoplastic
resin is melted and extruded from the spinning die to form a lot of
filaments, and the resulting filaments bond to each other in their
melting state. A plural number of said nonwoven fabrics
manufactured by the spunbonding method may be laminated and needle
punched to form a laminated nonwoven fabric, and said laminated
nonwoven fabric may be used as said nonwoven fabric of the present
invention.
[0010] Said thermoplastic resin used as a material of said nonwoven
fabric may include such as polyethylene, polypropylene,
ethylene-propylene copolymer, ethylene-vinyl acetate copolymer,
ethylene-propylene terpolymer, polyvinyl chloride, polyvinylidene
chloride, polystyrene, polyvinyl acetate, fluoroplastics,
thermoplastic polyacrylate, thermoplastic polyester, thermoplastic
polyamide, acrylonitrile-butadiene copolymer, butadiene-styrene
copolymer, acrylonitrile-butadiene-styrene copolymer or the
like.
[0011] Said thermoplastic resin may be used singly or two or more
kinds of said thermoplastic resin may be used together.
[0012] The thickness of said nonwoven fabric is commonly in the
range of between 0.05 mm and 1 mm, with the fineness of fiber
composing said nonwoven fabric being commonly in the range of
between 0.05 dtex and 5 dtex, the unit weight of said nonwoven
fabric commonly being in the range of between 10
g/m.sup.2.about.200 g/m.sup.2.
[0013] A lot of holes are needle punched into said nonwoven fabric
manufactured by the spunbonding. The shape of said holes may vary
circular, elliptical, rectangular, or the like. Not every hole
formed in said nonwoven fabric should necessarily be the same
shape, and said holes may vary between different kinds of
shapes.
[0014] The diameter of each hole should be in the range of between
0.1 mm and 2 mm, but desirably 0.2 mm and 1.5 mm. Herein, the
diameter of the hole means that in the case of a circle, the
diameter is the diameter of the circle, and in the case of a
rectangular hole, the diameter is the length of the longest
diagonal line.
[0015] The number of holes is commonly in the range of between
10/cm.sup.2 and 100/cm.sup.2. Synthetic resin is impregnated into
said nonwoven fabric of the present invention. Said synthetic resin
impregnated into said nonwoven fabric is a thermoplastic resin such
as a phenol group resin, urethane resin, melamine resin, urea
resin, epoxy resin, thermosetting type polyester resin, or the
like. The phenol group resin used in the present invention is
described below.
[Phenol Group Resin]
[0016] Phenol group resin is produced by the condensation reaction
between a phenol group compound, and an aldehyde, and/or aldehyde
donor. To give said phenol group resin water solubility, said
phenol group resin may be sulfomethylated and/or
sulfimethylated.
[0017] Said phenol group resin is impregnated into said nonwoven
fabric as a precondensate. Usually, said precondensate is prepared
as a water solution but if desired, a water soluble organic solvent
may be used. Said water soluble organic solvent is such as alcohol
group solvent such as methanol, ethanol, n-propanol, isopropanol,
n-butanol, isobutanol, s-butanol, t-butanol, n-amyl alcohol,
isoamyl alcohol, n-hexanol, methylamyl alcohol, 2-ethylbutanol,
n-heptanol, n-octanol, trimethylnonyl alcohol, cyclohexanol, benzyl
alcohol, furfuryl alcohol, tetrahydrofurfuryl alcohol, abiethyl
alcohol, diacetone alcohol, or the like, ketone group solvent such
as acetone, methylacetone, ethyl methyl ketone, methyl n-propyl
ketone, methyl n-butyl ketone, isobutyl methyl ketone, diethyl
ketone, di-n-propyl ketone, diisobutyl ketone, acetonylacetone,
methyl oxide, cyclohexanone, methylcyclohexanone, acetophenone,
camphor, or the like, glycol group solvent such as ethylene glycol,
diethylene glycol, triethylene glycol, propylene glycol,
trimethylene glycol, polyethylene glycol, or the like, glycol ether
group solvent such as ethylene glycol monomethyl ether, ethylene
glycol monoethyl ether, ethylene glycol isopropyl ether, diethylene
glycol monomethyl ether, monomethyl triethylene glycol ether, or
the like, ester of said glycol group solvent or derivative thereof
such as ethylene glycol diacetate, diethylene glycol monoethyl
ether acetate, or the like, ether group solvent such as
1,4-dioxane, or the like, and further diethyl cellosolve
diethylcarbitol, ethyl lactate, isopropyl lactate, diglycol
diacetate, dimethyl formamide, or the like.
(Phenol Group Compound)
[0018] The phenolic compound used to produce said phenolic resin
may be monohydric phenol, or polyhydric phenol, or a mixture of
monohydric phenol and polyhydric phenol, but in a case where only
monohydric phenol is used, formaldehyde is apt to be emitted when
or after said resin composition is cured, so that polyhydric phenol
or a mixture of monohydric phenol and polyhydric phenol is
preferably used.
(Monohydric Phenol)
[0019] The monohydric phenols include alkyl phenols such as
o-cresol, m-cresol, p-cresol, ethylphenol, isopropylphenol,
xylenol, 3,5-xylenol, butylphenol, t-butylphenol, nonylphenol, or
the like; monohydric phenol derivatives such as o-fluorophenol,
m-fluorophenol, p-fluorophenol, o-chlorophenol, m-chlorophenol,
p-chlorophenol, o-bromophenol, m-bromophenol, p-bromophenol,
o-iodophenol, m-iodophenol, p-iodophenol, o-aminophenol,
m-aminophenol, p-aminophenol, o-nitrophenol, m-nitrophenol,
p-nitrophenol, 2,4-dinitrophenol, 2,4,6-trinitrophenol, or the
like; monohydric phenols of polycyclic aromatic compounds such as
naphthol, or the like. Each monohydric phenol can be used singly,
or as a mixture thereof.
(Polyhydric Phenol)
[0020] The polyhydric phenols mentioned above, include resorcin,
alkylresorcin, pyrogallol, catechol, alkylcatechol, hydroquinone,
alkylhydroquinone, phloroglucinol, bisphenol, dihydroxynaphthalene,
or the like. Each polyhydric phenol can be used singly, or as a
mixture thereof. Resorcin and alkylresorcin are more suitable than
other polyhydric phenols. Alkylresorcin, in particular, is the most
suitable of polyhydric phenols, because it can react with aldehydes
more rapidly than resorcin.
[0021] The alkylresorcins include 5-methylresorcin,
5-ethylresorcin, 5-propylresorcin, 5-n-butylresorcin,
4,5-dimethylresorcin, 2,5-dimethylresorcin, 4,5-diethylresorcin,
2,5-diethylresorcin, 4,5-dipropylresorcin, 2,5-dipropylresorcin,
4-methyl-5-ethylresorcin, 2-methyl-5-ethylresorcin,
2-methyl-5-propylresorcin, 2,4,5-trimethylresorcin,
2,4,5-triethylresorcin, or the like.
[0022] A polyhydric phenol mixture produced by the dry distillation
of oil shale, which is produced in Estonia, is inexpensive, said
polyhydric phenol mixture including 5-metylresorcin, along with
many other kinds of alkylresorcin, being highly reactive, and
making said polyhydric phenol mixture an especially desirable raw
polyphenol material.
[0023] In the present invention, said phenolic compound and
aldehyde and/or aldehyde donor (aldehydes) are condensed together.
Said aldehyde donor refers to a compound or a mixture which emits
aldehyde when said compound or said mixture decomposes. The
aldehydes include formaldehyde, acetaldehyde, propionaldehyde,
chloral, furfural, glyoxal, n-butylaldehyde, capronaldehyde,
allylaldehyde, benzaldehyde, crotonaldehyde, acrolein,
phenylacetaldehyde, o-tolualdehyde, salicylaldehyde, or the like.
The aldehyde donors include paraformaldehyde, trioxane,
hexamethylenetetramine, tetraoxymethylene, or the like.
[0024] As described above, said phenolic resin is desirably
sulfoalkylated and/or sulfialkylated, to improve the stability of
said water soluble phenolic resin.
(Sulfomethylation Agent)
[0025] The sulfomethylation agents used to improve the stability of
the aqueous solution of phenol resins, include such as water
soluble sulfites prepared by the reaction between sulfurous acid,
bisulfurous acid, or metabisulfirous acid, and alkaline metals,
trimethylamine, quaternary ammonium (e.g. benzyltrimethylammonium);
and aldehyde adducts prepared by the reaction between said water
soluble sulfites and aldehydes.
[0026] The aldehyde adducts are prepared by the addition reaction
between aldehydes and water soluble sulfites as mentioned above,
wherein the aldehydes include formaldehyde, acetaldehyde,
propionaldehyde, chloral, furfural, glyoxal, n-butylaldehyde,
capronaldehyde, allylaldehyde, benzaldehyde, crotonaldehyde,
acrolein, phenylacetaldehyde, o-tolualdehyde, salicylaldehyde, or
the like. For example, hydroxymethane sulfonate, which is one of
the aldehyde adducts, is prepared by the addition reaction between
formaldehyde and sulfite.
(Sulfimethylation Agent)
[0027] The sulfimethylation agents used to improve the stability of
the aqueous solution of phenol resins, include alkaline metal
sulfoxylates of aliphatic or aromatic aldehyde such as sodium
formaldehyde sulfoxylate (a.k.a. Rongalit), sodium benzaldehyde
sulfoxylate, or the like; hydrosulfites (a.k.a. dithionites) of
alkaline metal or alkaline earth metal such as sodium hydrosulfite,
magnesium hydrosulfite, or the like; hydroxyalkanesulfinate such as
hydroxymethanesulfinate, or the like.
(Third Component)
[0028] In the case of producing said phenol resins, if necessary,
additives may be mixed in with said phenol resins as a catalyst or
to adjust the pH. Such additives include acidic compounds and
alkaline compounds. Said acidic compounds include inorganic acid or
organic acid such as hydrochloric acid, sulfuric acid,
orthophosphoric acid, boric acid, oxalic acid, formic acid, acetic
acid, butyric acid, benzenesulfonic acid, phenolsulfonic acid,
p-toluenesulfonic acid, naphthalene-.alpha.-sulfonic acid,
naphthalene-.beta.-sulfonic acid, or the like; esters of organic
acid such as dimethyl oxalate, or the like; acid anhydrides such as
maleic anhydride, phthalic anhydride, or the like; salts of
ammonium such as ammonium chloride, ammonium sulfate, ammonium
nitrate, ammonium oxalate, ammonium acetate, ammonium phosphate,
ammonium thiocyanate, ammonium imidosulfonate, or the like;
halogenated organic compounds such as monochloroacetic acid, the
salt thereof, organic halogenides such as
.alpha.,.alpha.'-dichlorohydrin, or the like; hydrochloride of
amines such as triethanolamine hydrochloride, aniline
hydrochloride, or the like; urea adducts such as the urea adduct of
salicylic acid, urea adduct of stearic acid, urea adduct of
heptanoic acid, or the like; and N-trimethyltaurine, zinc chloride,
ferric chloride, or the like; alkaline compounds including ammonia,
amines; hydroxides of alkaline metal and alkaline earth metal such
as sodium hydroxide, potassium hydroxide, barium hydroxide, calcium
hydroxide, and the like; oxide of alkaline earth metal such as
lime, or the like; salts of alkaline metal such as sodium
carbonate, sodium sulfite, sodium acetate, sodium phosphate, or the
like.
(Method of Producing the Phenol Resins)
[0029] The phenol resins (the precondensation polymers) can be
prepared using the usual method. The usual methods including method
(a) comprising the condensation of a monohydric phenol and/or a
polyhydric phenol and aldehydes; method (b) comprising the
condensation of a precondensation polymer and a monohydric phenol
and/or a polyhyrdric phenol, wherein said precondensation polymer
comprises a monohydric phenol and aldehydes; method (c) comprising
the condensation of a precondensation polymer and a monohydric
phenol and/or a polyhydric phenol, wherein said precondensation
polymer comprises a monohydric phenol, a polyhydric phenol and
aldehydes; method (d) comprising the condensation of a
precondensation polymer consisting of a monohydric phenol and
aldehydes, with a precondensation polymer consisting of a
polyhydric phenol and aldehydes; and method (e) comprising the
condensation of a precondensation polymer consisting of a
monohydric phenol and aldehydes and/or precondensation polymers
consisting of a polyhydric phenol and aldehydes, with a
precondensation polymer consisting of a monohydric phenol and
polyhydric phenol and aldehydes.
[0030] In the present invention, the desirable phenolic resin is
phenol-alkylresorcin cocondensation polymer. Said
phenol-alkylresorcin cocondensation polymer provides a water
solution of said cocondensation polymer (pre-cocondensation
polymer) having good stability, and being advantageous in that it
can be stored for a longer time at room temperature, compared with
a condensate consisting of a phenol only (precondensation polymer).
Further, in a case where said water solution is impregnated into
said nonwoven fabric, after which said nonwoven fabric is precured
to put said phenol resin at its B-stage, said phenol group resin at
its B-stage in said nonwoven fabric may be stable, so that said
nonwoven fabric keeps a good moldability for a longtime. Further,
since alkylresorcin is highly reactive to aldehyde, and catches
free aldehyde to react with it, the content of free aldehyde in the
resin can be reduced. Said phenol-alkylresorcin cocondensation
polymer is also advantageous in that the content of free aldehyde
in said polymer is reduced by the reaction with alkylresorcin.
[0031] The desirable method for producing said phenol-alkylresorcin
cocondensation polymer is first to create a reaction between phenol
and aldehyde to produce a phenolic precondensation polymer, and
then to add alkylresorcin, and if desired, aldehyde, to said
phenolic precondensation polymer to create a reaction.
[0032] In the case of method (a), for the condensation of
monohydric phenol and/or polyhydric phenol and aldehydes, the
aldehydes (0.2 mole to 3 moles) are added to said monohydric phenol
(1 mole), then said aldehydes (0.1 mole to 0.8 mole) are added to
the polyhydric phenol (1 mole) as usual. If necessary, additives
may be added to the phenol resins (the precondensation polymers).
In said method(s), there is a condensation reaction from heating at
55.degree. C. to 100.degree. C. for 8 to 20 hours. The addition of
aldehydes may be made at one time at the beginning of the reaction,
or several separate times throughout the reaction, or said
aldehydes may be dropped in continuously throughout the
reaction.
[0033] In the case of sulfomethylation and/or sulfimethylation, the
sulfomethylation agents and/or sulfimethylation agents may be added
to the precondensation polymers at an arbitrary time.
[0034] The addition of the sulfomethylation agents and/or
sulfimethylation agents may be made any time, such as before,
during, or after condensation. The total amount of said
sulfomethylation agent and/or sulfimethylation agent added is
usually in the range of between 0.001 and 1.5 moles per 1 mole of
phenol. In a case where said amount added is less than 0.001 mole,
the hydrophile of the resulting sulfomethylated and/or
sulfimethylated phenolic resin is not adequate, and in a case where
said amount added is more than 1.5 moles, the water resistance of
the resulting sulfomethylated and/or sulfimethylated phenolic resin
degrades. To provide excellent curing properties in the resulting
precondensate and excellent physical properties in the cured resin,
said amount to be added is preferably in the range of between 0.01
and 0.8 mole per 1 mole of phenol.
[0035] The sulfomethylation agents and/or sulfimethylation agents
for sulfomethylation and/or sulfimethylation react with the
methylol groups and/or aromatic groups, so that the sulfomethyl
group and/or sulfimethyl group are introduced to the
precondensation polymers.
[0036] The solution of precondensation polymers of sulfomethylated
and/or sulfimethylated phenol resins is stable even in a wide range
of acidic condition (e.g. pH=1.0) or alkaline condition, so that
the solution can be cured in any conditions such as acid, neutral
or alkaline. In the case of curing the precondensate under acidic
condition, there is a decrease in the remaining methylol groups, so
that no formaldehydes from the decomposed cured phenol resins
appear.
[0037] Further, if necessary, the phenol resins and/or
precondensation polymers thereof may be copolycondensed with amino
resin monomers such as urea, thiourea, melamine, thiomelamine,
dicyandiamine, guanidine, guanamine, acetoguanamine,
benzoguanamine, 2,6-diamino-1,3-diamine, or the like.
[0038] Further, curing agents such as an aldehyde and/or an
aldehyde donor or an alkylol triazine derivative, or the like, may
be added to said phenolic precondensation polymer (including
precocondensation polymer).
[0039] As said aldehyde and/or aldehyde donor, the same aldehyde
and/or aldehyde donor as used in the production of said phenolic
precondensation polymer is (are) used, and an alkylol triazine
derivatives are produced by the reaction between urea group
compound, amine group compound, and aldehyde and/or aldehyde donor.
Said urea group compound used in the production of said alkylol
triazined derivatives may be such as urea, thiourea, and alkylurea
such as methylurea, an alkylthiourea such as methylthiourea;
phenylurea, naphthylurea, halogenated phenylurea, nitrated
alkylurea, or the like, or a mixture of two or more kinds of said
urea group compounds. A particularly, desirable urea group compound
may be urea or thiourea. As the amine group compounds, aliphatic
amine such as methyl amine, ethylamine, propylamine,
isopropylamine, butylamine, amylamine or the like, benzylamine,
furfuryamine, ethanolamine, ethylenediamine, hexamethylenediamine
hexamethylenetetramine, or the like, as well as ammonia are
illustrated, and said amine group compound is used singly or two or
more amine group compounds may be used together.
[0040] The aldehyde and/or aldehyde donor used for the production
of said alkylol triazine derivative is (are) the same as the
aldehyde and/or aldehyde donor used for the production of said
phenolic precondensation polymer.
[0041] To synthesize said alkylol triazine derivatives, commonly
0.1 to 1.2 moles of said amine group compound(s) and/or ammonia,
and 1.5 to 4.0 moles of aldehyde and/or aldehyde donor are combined
to react with 1 mole of said urea group compound.
[0042] In said reaction, the order in which said compounds are
added is arbitrary, but preferably, first the required amount of
aldehyde and/or aldehyde donor is (are) put in a reactor, then the
required amount of amine group compound(s) and/or ammonia is (are)
gradually added to said aldehyde and/or aldehyde donor, the
temperature being kept at below 60.degree. C., after which the
required amount of said urea group compound(s) is (are) added to
the resulting mixture, then said mixture is agitated and heated at
80 to 90.degree. C. for 2 to 3 hours so as react together. Usually,
37% by mass of formalin is used as said aldehyde and/or aldehyde
donor, but some of said formalin may be replaced with
paraformaldehyde to increase the concentration of the reaction
product.
[0043] Further, in a case where hexamethylenetetramine is used, the
solid content of the reaction product obtained is much higher. The
reaction between said urea group compound, said amine group
compound and/or ammonia and said aldehyde and/or aldehyde donor is
commonly performed in a water solution, but said water may be
partially or wholly replaced by one or more kinds of alcohol(s)
such as methanol, ethanol, isopropanol, n-butanol, ethylene glycol,
diethylene glycol, or the like, and one or more kinds of other
water soluble solvent(s) such as a ketone group solvent like
acetone, ethyl methyl ketone, or the like can also be used as
solvents.
[0044] The amount of said curing agent to be added is, in the case
of an aldehyde and/or aldehyde donor, in the range of between 10
and 100 parts by mass to 100 parts by mass of said phenolic
precondensation polymer (precopolycondensation polymer), and in the
case of alkylol triazine, 10 to 500 parts by mass to 100 parts by
mass of said phenolic precondensation polymer
(precopolycondensation polymer).
[0045] Said synthetic resin is commonly prepared as a solution and
one or more kind(s) of third component(s) may be added to said
solution. Said third component is, for example, water-soluble
polymer and natural gums such as poly(vinyl alcohol), sodium
alginate, starch, starch derivatives, glue, gelatin, blood powder,
methylcellulose, carboxymethylcellulose, polyacrylate,
polyacrylamide or the like; fillers and surfactants such as calcium
carbonate, magnesium carbonate, barium sulfate, calcium sulfite,
calcium phosphate, calcium hydroxide, magnesium hydroxide, aluminum
hydroxide, magnesium oxide, titanium oxide, iron oxide, zinc oxide,
alumina, silica, diatom earth, dolomite, gypsum, talc, clay,
asbestos, mica, calcium silicate, bentonite, white carbon, carbon
black, iron powder, aluminum powder, glass powder, stone powder,
synthetic resin powder, blast furnace slag, fly ash, cement,
zirconia powder, wood flour, wheat flour, walnut flour, coconut
flour, ground rice, or the like; higher fatty acid such as stearic
acid, palmitic acid, or the like; higher alcohol such as palmityl
alcohol, stearyl alcohol, or the like; carboxylic ester such as
butyl stearate, glycerol, monostearate or the like; carboxylic
amide; natural wax and synthetic wax such as carnauba wax, or the
like; pigment, dye, burning retardant, flame retardant,
insecticide, antiseptic agent, age resister, ultraviolet absorber,
fluorescent dye, surfactant, foaming agent, oil repellent agent, or
the like.
[0046] In a case where said thermosetting resin is impregnated into
said nonwoven fabric, said nonwoven fabric may be dried after the
impregnation of said resin, to put said resin in said nonwoven
fabric at its B-stage.
[0047] A powder or film of hot-melt adhesive may be applied or
laminated onto said nonwoven fabric. Said hot-melt adhesive is, for
example, a polyolefin resin such as polyethylene, polypropylene,
ethylene-vinyl acetate copolymer, or a modified polyolefin resin,
polyvinyl chloride, polyurethane, polyester, ester copolymer,
polyamide, polyamide copolymer, cellulose derivative,
polyvinylether, or the like.
[0048] Said elastic nonwoven fabric (1) of the present invention
has a lot of holes (2) from needle punching, as shown in FIG. 1, so
that the elasticities along the length and width of said nonwoven
fabric are improved by said holes, and accordingly, said nonwoven
fabric is easily attached to other material without forming
wrinkles, even in a case where said nonwoven fabric is attached to
parts having an uneven surface,
[0049] Said parts to which said nonwoven fabric is attached have a
desirable appearance. Said elastic nonwoven fabric (1) is used for
a surface layer (2) of an interior (3).
[0050] Said nonwoven fabric of the present invention is
manufactured by the spunbonding method, but in the present
invention, a nonwoven fabric manufactured by the melt-blow method
or the calendar treatment can be used.
[Interior]
[0051] An interior can be manufactured by attaching said elastic
nonwoven fabric of the present invention to a base material as a
surface layer, then molding said base material onto which said
elastic nonwoven fabric is attached, into a prescribed shape.
[0052] As said base material, knitted or woven fabric, nonwoven
fabric, felt and laminated fabrics thereof, foamed plastics having
connected cells, sintered plastic beads, or the like are used. Said
fabric is made of a synthetic fiber such as polyester fiber,
polyethylene fiber, polypropylene fiber, polyamide fiber, acrylic
fiber, polyurethane fiber, polyvinyl chloride fiber, polyvinylidene
chloride fiber, acetate fiber, or the like, botanical fiber such as
pulp, cotton, coconut fiber, hemp, bamboo fiber, kenaf fiber, or
the like, inorganic fiber such as glass fiber, carbon fiber,
ceramics fiber, asbestos fiber, or the like, or recycled fiber from
the scrap of the products made of said fiber, or a fiber mixture
containing two or more kinds of said fibers.
[0053] Said foamed plastic is made of plastic such as polyurethane
(flexible polyurethane, rigid polyurethane), polyethylene,
polypropylene, polyamide, polyester, polyvinyl chloride, or the
like.
[0054] A synthetic resin may be impregnated into said base
material. Said synthetic resin includes thermoplastic resins such
as polyethylene, polypropylene, ethylene-propylene copolymer,
ethylene-vinyl acetate copolymer, polyvinyl chloride,
polyvinylidene chloride, polystyrene, polyvinyl acetate, fluoride
resin, thermoplastic acrylic resin, thermoplastic polyester resin,
thermoplastic polyamide resin, acrylonitrile-butadiene copolymer,
butadiene-styrene copolymer, acrylonitrile-butadiene-styrene
copolymer, or the like, and thermosetting resin such as urethane
resin, melamine resin, urea resin, thermosetting acrylic resin,
phenol resin, resorcinol resin, alkylresorcinol resin, epoxy resin,
thermosetting polyester, or the like.
[0055] In a case where said thermosetting resin is impregnated,
said base material into which said thermosetting resin is
impregnated is preferably dried, to put said thermosetting resin at
its B-stage.
[0056] To attach said surface layer made of said elastic nonwoven
fabric to said base material, said surface layer is put on said
base material, after which said base material is hot-pressed or
heated, and then cold-pressed.
[0057] In the case of molding said base material onto which said
surface layer is attached, said base material is preferably molded
at the same time that said surface layer is attached to said base
material.
[0058] In a case where said base material is molded concurrently to
when said surface layer is attached, said surface layer is attached
to said base layer with enough elasticity to give the resulting
molded interior a good appearance.
[0059] The resulting interior may be used for automobile parts such
as the door trim, dashboard, head lining, hood insulator, engine
cover, or the like, or as an automobile heat insulating material
and sound proof material, building material, wall material,
building heat insulating material, building sound proof material,
or the like.
[0060] The present invention is explained in the EXAMPLES described
below, and further, the present invention is not limited to the
specific EXAMPLES described below.
EXAMPLE 1
[0061] A nonwoven fabric made of a polyester fiber (fineness: 3.5
dtex, unit weight: 40 g/m.sup.2) was manufactured by the
spunbonding method.
[0062] To form a lot of holes in said nonwoven fabric, said
nonwoven fabric was pressed by a needle roller on whose surface a
lot of needles were randomly arranged, each needle having a maximum
diameter of 1 mm. The resulting nonwoven fabric had a lot of holes,
the diameter of each of said holes being in the range of between
0.1 mm and 0.3 mm, with 15 holes being formed per 1 cm.sup.2 of
said nonwoven fabric.
[0063] Further, a phenol-formaldehyde precondensate (solid content
30% by mass) was impregnated into said hole punched nonwoven fabric
in an amount of 30% by mass as solid content. After impregnating
with said precondensate, said nonwoven fabric was dried at
150.degree. C. for 3 minutes for precuring, to obtain an elastic
nonwoven fabric.
EXAMPLE 2
[0064] An elastic nonwoven fabric was manufactured in the same
manner as in EXAMPLE 1, with the exception that a lot of holes were
formed, each hole having a diameter in the range of between 0.1 mm
and 0.3 mm, with 50 such holes being formed per 1 cm.sup.2 of said
nonwoven fabric.
EXAMPLE 3
[0065] An elastic nonwoven fabric was manufactured in the same
manner as in EXAMPLE 1, with the exception that a lot of holes were
formed, each hole having a diameter in the range of between 0.1 mm
and 0.3 mm, with 100 holes being formed per 1 cm.sup.2 of said
nonwoven fabric.
COMPARISON 1
[0066] An elastic nonwoven fabric was manufactured in the same
manner as in EXAMPLE 1, with the exception that a lot of holes were
formed, each hole having a diameter in the range of between 0.1 mm
and 0.3 mm, with 8 holes being formed per 1 cm.sup.2 of said
nonwoven fabric.
COMPARISON 2
[0067] An elastic nonwoven fabric was manufactured in the same
manner as in EXAMPLE 1, with the exception that a lot of holes were
formed, each hole having a diameter in the range of between 0.1 mm
and 0.3 mm, with 110 holes being formed per 1 cm.sup.2 of said
nonwoven fabric.
Test
[0068] Said elastic nonwoven fabrics (1) manufactured in EXAMPLES 1
to 3, and COMPARISONS 1 and 2, were each used as surface layers
(1A).
[0069] A phenol-formaldehyde precondensate was coated onto a glass
wool sheet (7) as a base material, and said glass wool mat (7)
(unit weight: 800 g/m.sup.2, thickness: 50 mm) on which said
phenol-formaldehyde precondensate was coated was then precured, and
each surface layer (1A) was put on said precured base material (7),
and each precured base material (7) upon which each surface layer
(1A) was put was then respectively molded with a mold (3)
consisting of an upper mold (4) and a lower mold (5), as shown in
FIG. 2, at 200.degree. C. for 60 seconds, to manufacture a molded
article (6) (thickness 5 mm), as shown in FIG. 3.
[0070] The appearance of each molded article (6) was observed
optically. The results are shown in Table 1.
TABLE-US-00001 TABLE 1 Number of Holes Appearance of Molded
Sheet(6) Molded Sheet(6) (per 1 cm.sup.2) (Surface Layer in
particular (1A)) EXAMPLE 1 15 No wrinkles, no peeling, good
appearance EXAMPLE 2 50 No wrinkles, no peeling, good appearance
EXAMPLE 3 100 No wrinkles, no peeling, good appearance COMPARISON 1
8 Wrinkles occur on the corner part(9) of the molded sheet
COMAPRISON 2 110 Peeling of nonwoven fabric on the incline
part(8)
EXAMPLE 4
[0071] A nonwoven fabric made of a polypropylene fiber (fineness:
0.1 dtex unit weight: 30 g/m.sup.2) was manufactured by the
spunbonding method.
[0072] To form a lot of holes in said nonwoven fabric, said
nonwoven fabric was pressed by a needle roller on whose surface a
lot of needles were randomly arranged, each needle having a maximum
diameter of 1 mm. The resulting nonwoven fabric had a lot of holes,
the diameters of said holes being in the range of between 0.8 mm
and 1.2 mm, with 25 holes being formed per 1 cm.sup.2 of said
nonwoven fabric.
[0073] Further, a phenol-formaldehyde precondensate (solid content:
40% by mass) was impregnated into said holepunched nonwoven fabric
in an amount of 25% by mass as a solid. After impregnating with
said precondensate, said nonwoven fabric was dried at 150.degree.
C. for 3 minutes for precuring, to obtain an elastic nonwoven
fabric.
[0074] Said nonwoven fabric, used as a surface layer, was put on a
base material, said base material being manufactured by coating a
phenol formaldehyde precondensate onto a glass wool mat (unit
weight 600 g/m.sup.2, thickness: 40 mm) and precuring said glass
wool mat upon which said phenol formaldehyde precondensate was
coated. Said base material upon which said surface layer was put
was then molded at 210.degree. C. for 45 seconds into a prescribed
shape by the hot-press method, to obtain a molded article. Said
molded article has no wrinkles and no other defects in
appearance.
EXAMPLE 5
[0075] A nonwoven fabric made of a polyester fiber (fineness: 2.0
dtex, unit weight: 60 g/m.sup.2) was manufactured by the
spunbonding method. To form a lot of holes in said nonwoven fabric,
said nonwoven fabric was pressed by a needle roller on whose
surface a lot of needles were randomly arranged, each needle having
a maximum diameter of 1 mm. The resulting nonwoven fabric had a lot
of holes, the diameters of said holes being in the range of between
0.5 mm and 0.8 mm, with 18 holes being formed per 1 cm.sup.2 of
said nonwoven fabric.
[0076] Further, a phenol-alkylresorcine-formaldehyde precondensate
used in EXAMPLES 4 (solid content: 40% by mass) was impregnated
into said holepunched nonwoven fabric in an amount of 30% by mass
as a solid, after which a polyamide group hot-melt adhesive powder
(200 mesh pass, melting point 130.degree. C.) was sprayed on the
reverse side of said nonwoven fabric. Following this, said nonwoven
fabric was heated at 150.degree. C. for 2 minutes, to obtain an
elastic nonwoven fabric on whose reverse side said hot-melt
adhesive powder was applied.
COMPARISON 3
[0077] An elastic nonwoven fabric was manufactured in the same
manner as in EXAMPLE 5, with the exception that a lot of holes,
each having a diameter in the range of between 2.1 mm and 2.4 mm,
were formed in said nonwoven fabric.
COMPARISON 4
[0078] A nonwoven fabric (unit weight: 60 g/m.sup.2) made of a
fiber mixture containing 90% by mass of said polyester fiber used
in EXAMPLE 5, and 10% by mass of a low melting point polyester
fiber (fineness: 2.0 dtex, softening point: 110.degree. C.) was
manufactured by needle punching (unit weight: 60 g/m.sup.2).
[0079] Said phenol-alkylresorcine-formaldehyde precondensate used
in EXAMPLE 5 (40% by mass as a solid) was impregnated into said
nonwoven fabric in an amount of 30% by mass as a solid, after which
said polyamide group hot-melt adhesive powder used in EXAMPLE 5 was
sprayed onto said nonwoven fabric, into which said precondensate
was impregnated.
[0080] Following this, said nonwoven fabric was dried at
150.degree. C. for 2 minutes, to obtain an elastic nonwoven fabric
upon which said hot-melt adhesive powder was applied.
[0081] Each elastic nonwoven fabric manufactured in EXAMPLE 5 and
COMPARISONS 3 and 4 were used for a surface layer. Each surface
layer was put on a glass wool mat onto which a phenol formaldehyde
precondensate was coated and precured (unit weight: 1000 g/m.sup.2,
thickness 70 mm), and said glass wool mat, upon which said nonwoven
fabric was put, was molded into a prescribed shape by the hot-press
method at 200.degree. C. for 50 seconds, to obtain a molded
article. The appearance of each molded article was observed
optically. The results are shown in Table 2.
TABLE-US-00002 TABLE 2 Appearance of molded article Sample (surface
layer in particular) EXAMPLE 5 No wrinkles, no peeling, no snags in
the surface layer, very good appearance COMPARISON 3 Snags in the
uneven part of the molded base material COMPARISON 4 Good
moldability, but noticeable fluff in the surface layer of the thick
area of the molded base part
[0082] Since nonwoven fabric manufactured by the traditional
spunbonding method has poor elasticity along its length and width,
it is recognized that wrinkles easily occur in the surface layer of
the uneven area of the base material when said nonwoven fabric is
attached to said base material as a surface layer, and further,
that said surface layer is easy to remove from the uneven part of
said base material (defective bonding).
[0083] Further, nonwoven fabric manufactured by the needle punching
method has a good elasticity along its length and width, so that
said nonwoven fabric (surface layer) attaches well to the base
material, but, since fluffs occur on the surface of said nonwoven
fabric, the appearance of the resulting molded article is
imperfect.
[0084] The molded article using said elastic nonwoven fabric of the
present invention as a surface layer has an excellent appearance
and good moldability.
POSSIBILITY OF INDUSTRIAL USE
[0085] The elastic nonwoven fabric of the present invention can be
used for the surface layer of an automobile interior, for such as
the door trim, head lining, hood insulator, engine cover, or the
like, as a surface layer for an automobile heat insulating
material, or sound proof material, a surface layer for building
material, wall material, building heat insulating material,
building sound proof material, or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0086] FIG. 1 is a perspective view of the elastic nonwoven
fabric.
[0087] FIG. 2 is a sectional view illustrating the mold.
[0088] FIG. 3 is a sectional side view of the molded article.
[0089] 1. nonwoven fabric [0090] 2. hole
* * * * *