Multilayer nonwoven fabric for foam molding, method of producing multilayer nonwoven fabric for foam molding, urethane-foam molded complex using multilayer nonwoven fabric, vehicle seat, and chair

Patent metadata

Field	Value
Publication number	US-9694558-B2
Application number	US-201414916436-A
Country	US
Kind code	B2
Filing date	Sep 5, 2014
Priority date	Sep 6, 2013
Publication date	Jul 4, 2017
Grant date	Jul 4, 2017

Abstract

Disclosed is a multilayer nonwoven fabric for foam molding containing a dense layer and a reinforcing layer provided on at least one side of the dense layer, the reinforcing layer is a staple fiber nonwoven fabric containing thermoplastic resin staple fibers (A) having a fiber diameter of more than 20 μm, in an amount of 5% by mass to 50% by mass, and hermoplastic resin staple fibers (B) having a fiber diameter of 20 μm or less, in an amount of 95% by mass to 50% by mass, and conjugate polyester-based staple fibers (C) are contained in an amount of 10% by mass to 40% by mass, the dense layer is a nonwoven fabric having bulk density in a range of from 0.05 g/cm 3 to 0.3 g/cm 3 , and the dense layer and the reinforcing layer are entangled with each other by needle punching.

First claim

The invention claimed is:

1. A multilayer nonwoven fabric for foam molding, comprising:
a dense layer; and
a reinforcing layer provided on at least one side of the dense layer, wherein the reinforcing layer is a staple fiber nonwoven fabric containing:
thermoplastic resin staple fibers (A) having a fiber diameter of more than 20 μm, in an amount of 5% by mass to 50% by mass, and
thermoplastic resin staple fibers (B) having a fiber diameter of 20 μm or less, in an amount of 95% by mass to 50% by mass,

wherein a total of the thermoplastic resin staple fibers (A) and the thermoplastic resin staple fibers (B) is 100% by mass, the thermoplastic resin staple fibers (A) or the thermoplastic resin staple fibers (B) contain conjugate polyester-based staple fibers (C) formed containing two or more resins having different melting points, and the conjugate polyester-based staple fibers (C) are contained in the reinforcing layer in an amount of 10% by mass to 40% by mass,
wherein the dense layer is a nonwoven fabric having bulk density in a range of from 0.05 g/cm 3 to 0.3 g/cm 3 , and
wherein the dense layer and the reinforcing layer are entangled with each other by needle punching.

2. The multilayer nonwoven fabric for foam molding according to claim 1 , wherein a thickness of the fabric is from 1.6 mm to 5.0 mm.

3. The multilayer nonwoven fabric for foam molding according to claim 1 , wherein a thickness of the fabric after being held at 110° C. and 4.9 Pa for 5 minutes is 1.2 mm or more.

4. The multilayer nonwoven fabric for foam molding according to claim 1 , wherein a fiber diameter of at least a portion of the conjugate polyester-based staple fibers (C) is 20 μm or less.

5. The multilayer nonwoven fabric for foam molding according to claim 1 , wherein a melting point of at least one resin that forms the conjugate polyester-based staple fibers (C) is in a range of from 110° C. to 190° C.

6. The multilayer nonwoven fabric for foam molding according to claim 1 , wherein the dense layer includes a nonwoven fabric that is partially thermocompression-bonded, air through processed, resin bonded, or calendered.

7. The multilayer nonwoven fabric for foam molding according to claim 1 , wherein the dense layer is a nonwoven fabric constituted of continuous fibers.

8. The multilayer nonwoven fabric for foam molding according to claim 1 , wherein the thermoplastic resin staple fibers (A) and the thermoplastic resin staple fibers (B) are at least one kind of staple fibers selected from the group consisting of polyester-based staple fibers and polyolefin-based staple fibers.

9. The multilayer nonwoven fabric for foam molding according to claim 1 , wherein the thermoplastic resin staple fibers (A) and the thermoplastic resin staple fibers (B) are polyester-based staple fibers.

10. The multilayer nonwoven fabric for foam molding according to claim 1 , wherein the dense layer includes a continuous fiber nonwoven fabric that is partially thermocompression-bonded.

11. The multilayer nonwoven fabric for foam molding according to claim 1 , wherein a basis weight of the dense layer is in a range of from 10 g/m 2 to 35 g/m 2 .

12. The multilayer nonwoven fabric for foam molding according to claim 1 , wherein an air permeability of the dense layer is in a range of from 70 cm 3 /cm 2 /sec to 200 cm 3 /cm 2 /sec.

13. The multilayer nonwoven fabric for foam molding according to claim 1 , wherein the dense layer comprises a multilayer structure containing:
a melt-blown nonwoven fabric layer (M) that is constituted of continuous fibers, and
a spunbonded nonwoven fabric layer (S) constituted of continuous fibers, and provided on both sides of the melt-blown nonwoven fabric layer (M); and
the melt-blown nonwoven fabric layer (M) and each spunbonded nonwoven fabric layer (S) are partially thermocompression-bonded with each other.

14. The multilayer nonwoven fabric for foam molding according to claim 1 , wherein the multilayer nonwoven fabric has an air permeability at a pressure difference of 125 Pa of from 25 cm 3 /cm 2 /sec to 160 cm 3 /cm 2 /sec.

15. The multilayer nonwoven fabric for foam molding according to claim 1 , wherein the multilayer nonwoven fabric has a basis weight of from 20 g/m 2 to 160 g/m 2 .

16. The multilayer nonwoven fabric for foam molding according to claim 1 , wherein the multilayer nonwoven fabric has an air permeability at a pressure difference of 125 Pa of 25 cm 3 /cm 2 /sec to 140 cm 3 /cm 2 /sec.

17. The multilayer nonwoven fabric for foam molding according to claim 1 , wherein a basis weight of the reinforcing layer is in a range of from 40 g/m 2 to 150 g/m 2 .

18. A method of producing the multilayer nonwoven fabric for foam molding according to claim 1 , comprising providing the reinforcing layer on at least one side of the dense layer, and, subsequently, entangling the reinforcing layer and the dense layer with each other by needle punching.

19. The method of producing the multilayer nonwoven fabric for foam molding according to claim 18 , wherein the dense layer is formed by providing the spunbonded nonwoven fabric layer (S) on both sides of the meltblown nonwoven fabric layer (M), and, subsequently, carrying out partial thermocompression-bonding, air through processing, resin bonding, or calendering.

20. A urethane-foam molded complex in which a urethane foam layer is provided on an outer surface of the reinforcing layer of the multilayer nonwoven fabric for foam molding according to claim 1 .

21. The urethane-foam molded complex according to claim 20 , wherein the reinforcing layer and the urethane foam layer are integrated with each other.

22. A vehicle seat comprising the multilayer nonwoven fabric for foam molding according to claim 1 .

23. A chair comprising the multilayer nonwoven fabric for foam molding according to claim 1 .

24. A vehicle seat comprising the urethane-foam molded complex according to claim 20 .

25. A chair comprising the urethane-foam molded complex according to claim 20 .

Assignees

• Mitsui Chemicals Inc

Inventors

• Ichikawa Taro
• Saza Norihito

Classifications

• D04H1/498

  entanglement of layered webs · CPC title

• B32B2260/046

  Synthetic resin · CPC title

• B32B2479/00

  Furniture · CPC title

• B32B5/26 Primary

  another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} · CPC title

• B32B2307/724

  Permeability to gases, adsorption · CPC title