Laminate

Abstract

To provide a laminate comprising a skin layer and a layer containing a fibrous material with controlled thickness.SOLUTION: A fibrous laminate 1 comprising a skin layer 3, a first layer 5 laminated in contact with the skin layer 3 and containing a fibrous first material 51 that includes a flame retardant, and a second layer 6 laminated in contact with the first layer 5 and containing a fibrous second material 61 having a smaller amount of flame retardant than the first material 51, wherein the skin layer 3 and the first layer 5 are thermally fused.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to a laminate comprising a skin layer and a fibrous layer. [Background technology]

[0002] Patent Document 1 discloses a vehicle floor carpet comprising a carpet layer and a felt layer laminated on the back surface of the carpet layer. In this vehicle floor carpet, the felt layer is formed from fibers with a lower melting point than the base fabric of the carpet layer. The carpet layer and the felt layer are integrally bonded by frame lamination. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 11-348061 Summary of the Invention [Problem to be solved by the invention]

[0004] During the manufacturing process of such laminates, the felt layer is heated and melted by a burner. The flame emits light and heat when gases are burned in the fire. The flame usually fluctuates. This fluctuating motion is thought to be caused by the flow of surrounding air and gases toward the flame. This can cause the felt layer to melt too much in parts, resulting in a thin thickness and making it difficult to control the thickness.

[0005] In such a fibrous laminate, it is preferable that the thickness of the laminate be controlled. It is an object of the present disclosure to provide a laminate comprising a layer containing a fibrous material of controlled thickness and a skin layer. [Means for solving the problem]

[0006] A laminate according to one embodiment of the present disclosure includes a surface layer and a first layer laminated in contact with the surface layer. The first layer includes a fibrous first material containing a flame retardant. The laminate further includes a second layer laminated in contact with the first layer. The second layer includes a fibrous second material having a lower amount of flame retardant than the first material. [Effects of the Invention]

[0007] The laminate according to one embodiment of the present disclosure can reduce variations in the thickness of the fiber layers due to heat melting and heat fusion, thereby reducing material loss, and therefore the overall thickness of the laminate can be controlled to a desired thickness. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view of a cushion seat for a vehicle. [Figure 2] Cross-sectional view of a surface laminate of a cushion seat for a vehicle seat [Figure 3] FIG. 4 is an explanatory diagram showing a method for manufacturing a fibrous layer in which a first layer and a second layer are laminated. [Figure 4] 4A and 4B are explanatory diagrams showing a method for manufacturing a skin laminate in which a skin layer and a fibrous layer are laminated together. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, a laminate 1 according to an embodiment of the present disclosure will be described with reference to the drawings. Note that, unless otherwise specified, a numerical range indicated by "to" includes both the lower limit and the upper limit. For example, the expression "1 to 5" includes both the lower limit "1" and the upper limit "5." In other words, "1 to 5" has the same meaning as "1 or more and 5 or less."

[0010] 1, in this embodiment, the laminate 1 is used, for example, as a headrest cover for a vehicle seat, an armrest cover for a vehicle seat, a cushion seat cover for a vehicle seat, other bag-like covers, and a covering material for a vehicle interior member. In general, the headrest, armrest, and cushion seat 100 include a metal frame, a cushion material 90 surrounding the metal frame, and a cover surrounding the cushion material 90.

[0011] 2, the laminate 1 includes a skin layer 3 and a fibrous layer 4 laminated in contact with the skin layer 3. The fibrous layer 4 includes a fibrous first layer 5 laminated in contact with the skin layer 3, and a fibrous second layer 6 laminated in contact with the first layer 5.

[0012] The surface layer 3 is a fiber sheet or a resin sheet. Examples of fiber sheets include fabrics, cloth, woven fabrics, knitted fabrics, moldable knits, and nonwoven fabrics. Examples of resin sheets include artificial leather, suede-like synthetic leather, synthetic leather, and thermoplastic elastomer (TPO) sheets. However, the present disclosure is not limited to these. Examples of woven fabrics include plain weave, twill weave, jacquard, and dobby. Examples of pile fabrics include moquette. Examples of knitted fabrics include tricot, double raschel, and circular knit. From the viewpoint of industrial use, the raw material for these surface layers 3 is preferably a thermoplastic resin. Examples of thermoplastic resins include nylon, polyester, and olefin.

[0013] The fibrous layer 4 is a layer containing a fibrous material laminated in contact with the skin layer 3. The fibrous layer 4 includes a first layer 5 containing a fibrous first material 51 and a second layer 6 containing a fibrous second material 61 laminated in contact with the first layer 5. The fibrous first material 51 contains a substance that imparts flame retardancy. Examples of substances that impart flame retardancy include flame retardants that are blended into polymers, substances that react with and bond to polymers, and flame retardants that are attached to the surface of fibers, nonwoven fabrics, etc. by post-processing. When the first layer 5 is flame-fused, a portion of the first material 51 melts and solidifies, adhering to the skin material 31. In this case, to prevent overmelting of the first material 51, the amount of flame retardant added to the first material 51 is, for example, 0.5 to 3 g / m. 2 The amount of phosphorus atoms and halogen atoms as substances that impart flame retardancy is, for example, 0.05% by weight to 5% by weight. The first layer 5 has a thickness of 0.5 mm to 2 mm and a basis weight of 10 to 300 g / m 2 The first layer 5 includes a fibrous first material 51. Furthermore, the first layer 5 may also include, for example, a state in which non-fibrous melt-solidified first material 51 or the like is wrapped around the fibers.

[0014] Examples of the type of fibrous body 41 constituting the fibrous body layer 4 include felt and nonwoven fabrics in which fibers are intertwined without being woven. The fibrous body 41 is composed of a large number of fibers. In this embodiment, the fibrous body 41 is a nonwoven fabric. The fibrous body 41 is formed by intertwining fibers of a first layer 5 containing a fibrous first material 51 containing a flame retardant with fibers of a second layer 6 containing a fibrous second material 61 having a smaller amount of flame retardant than the first material 51, forming a nonwoven fabric. The first layer 5 contains more of the fibrous first material 51 than the second layer 6.

[0015] The type of resin used in the fibrous material of the fibrous body 41 is a thermoplastic resin. Thermoplastic resins are broadly divided into general-purpose plastics and engineering plastics (general-purpose engineering plastics and super engineering plastics). Thermoplastic resins can be further classified into nylon, polyester, olefin, and the like. For example, polyamide 6 (PA6) and polyamide 66 (PA66) are classified as nylon. For example, polyethylene terephthalate (PET) and polybutylene terephthalate (PBT) are classified as polyester. For example, polyethylene (PE), polypropylene (PP), and the like are classified as polyolefin.

[0016] <Same type of thermoplastic resin> It is preferable that both the skin layer 3 and the first layer 5 contain the same type of thermoplastic resin, which increases the adhesive strength of the laminate 1 after heat fusion bonding.

[0017] Here, examples of the same type of thermoplastic resin include nylon 6, nylon 66, and the same type of polyamide having an amide bond. Examples of polyester include polyesters that are polymers having an ester bond, such as PET, PBT, PTT, and PEN. Examples of polyolefins include polyolefins such as polyethylene, polypropylene, and TPO (Thermoplastic Olefinic Elastomer). Specifically, for example, if the skin layer 3 and the first layer 5 are made of nylon 6 fiber and nylon 66 fiber, respectively, then both layers are nylon and the same type of thermoplastic resin. Also, for example, if the skin layer 3 and the first layer 5 are made of PBT fiber and PET fiber, respectively, then both layers are polyester and the same type of thermoplastic resin. Furthermore, for example, if the skin layer 3 and the first layer 5 are made of TPO skin and polypropylene fiber, respectively, then both layers are polyolefin and the same type of thermoplastic resin.

[0018] Next, the fibers used in the fiber layer 4 or the fiber sheet of the skin layer 3 may be any type of fiber, but chemical fibers are preferred from the viewpoint of industrial applicability. Among chemical fibers, semi-synthetic fibers and synthetic fibers are particularly preferred, with synthetic fibers being especially preferred. Among these, thermoplastic synthetic fibers are preferred, which are produced by heating and melting a raw polymer, extruding it through a spinning nozzle, and then cooling it to form fibers.

[0019] Examples of synthetic fibers include nylon fibers (polyamide fibers), polyester fibers, polypropylene fibers, polyethylene fibers, polyurethane fibers, and acrylic fibers. Polyamide fibers include nylon 6 fibers, nylon 66 fibers, and polyamide fibers with amide bonds. Polyester fibers include polyethylene terephthalate (PET) fibers, as well as polybutylene terephthalate (PBT) fibers in which the ethylene of PET is replaced with butylene, polytrimethylene terephthalate (PTT) fibers in which the ethylene is replaced with trimethylene, and polyethylene naphthalate (PEN) fibers. Polyolefin fibers include polypropylene fibers, general-purpose polyethylene fibers, and ultra-high-strength polyethylene fibers. These fibers may contain various additives, modifiers, and colorants as needed, and may also be dyed.

[0020] The skin layer 3 and the first layer 5 may be made of the same type of fiber. The same type of fiber refers to fibers of the same type as those broadly categorized as described above. Specifically, the same type of fiber refers to, for example, chemical fibers, excluding inorganic fibers and natural fibers. Of the chemical fibers, preferably, both the skin layer 3 and the first layer 5 are synthetic fibers. Specifically, for example, both the skin layer 3 and the first layer 5 may be made of a combination of synthetic nylon fibers (nylon 6 fibers, nylon 66 fibers) and polyester fibers (PET fibers, PBT fibers, PTT fibers).

[0021] The nonwoven fabric may be of various types. For example, the method for accumulating fibers may be any of dry, wet, spunbond, and meltblown methods. The fibers may be bonded together by chemical, thermal, or mechanical bonding.

[0022] The second layer 6 includes a fibrous second material 61 and is laminated in contact with the first layer 5. The second material 61 may or may not include a flame retardant. The second material 61 may contain a smaller amount of flame retardant than the first material 51. From the viewpoint of preventing overmelting of the first material 51 when the first layer 5 is flame-fused, it is preferable that the first material 51 contains a larger amount of flame retardant than the second material 61. It is more economical for the second material 61 not to contain an excessive amount of flame retardant, but the second material 61 may contain a flame retardant as needed. The second layer 6 has a thickness of 0.5 mm to 20 mm and a basis weight of 10 to 400 g / m. 2 The second material 61 is preferably an elastic material that can be compressed and restored to its original shape, since it provides cushioning. The thickness of the second layer 6 is, for example, greater than that of the first layer 5 from the viewpoint of cushioning. Since the first material 51 contains a large amount of a flame-retardant material, the thickness of the first layer 5 may be less than that of the second layer 6 from the viewpoint of economy.

[0023] From the viewpoint of handling during manufacturing, it is preferable to laminate the first layer (first material) and the second layer (second material) in advance before laminating them with the skin layer 3. The lamination method of the first layer 5 and the second layer 6 may be any of the thermal bonding method, chemical bonding method, steam jet method, and spunlace method (hydroentanglement method). Among these, the needle punch method, in which the fibers are mechanically bonded by piercing with a barbed needle, is preferred because it can maintain the cushioning properties of the laminate 1.

[0024] The laminate 1 (skin laminate) is manufactured as follows: A first layer 5 including a fibrous first material 51 containing a flame retardant-imparting substance and a second layer 6 including a fibrous second material 61 are laminated to obtain a (multi-layer) fiber body 41. Then, a process is performed in which the surface of the first layer side of the multi-layer fiber body in which the first material 51 and the second material 61 are laminated is heated and melted, and pressed onto the skin layer 3, thereby laminating the skin layer 3 and the (multi-layer) fiber body 41. The laminate 1 (skin laminate) is manufactured by the above-mentioned processes.

[0025] The method for producing the fibrous body 41 will be described in more detail with reference to FIG. 3(a) and (b), a fibrous material is prepared in which a first layer 5 and a second layer 6 are superimposed. The fibrous material includes a first layer 5 including a fibrous first material 51 and a second layer 6 including a fibrous second material 61.

[0026] As shown in Figure 3(a), with the first layer 5 stacked on the second layer 6, the fibrous first material 51 and the fibrous second material 61 are intertwined by repeatedly moving a needle punch 71, for example, along the stacking direction (see the black arrow in Figure 3(a)). This allows for the production of a fibrous body 41 in which the first layer 5 and the second layer 6 are integrated while the first material 51 and the second material 61 remain fibrous, as shown in Figure 3(b). Note that the barbed needles of the needle punch 71 are omitted from Figure 3(a).

[0027] As a result, the fibers of the first material 51 and the second material 61 are intertwined and bonded to each other in the fibrous body 41, and the fibers are intertwined and laminated in the form of a single sheet. In this manner, in this embodiment, the second layer 6 is joined to the first layer 5 by mechanical bonding rather than by adhesive.

[0028] FIG. 4 shows the lamination process of the skin layer 3 and the first layer 5 or the fibrous layer 4. The fibrous body 41 and the skin material 31 are continuously supplied from a fibrous body supply roll 84 and a skin material supply roll 83. The surface of the first layer 5 of the fibrous body 41 is heated and melted by the flame of a flame device 89. The skin material 31 is placed on the flame-melted surface of the first layer 5, which has been melted by the flame, and passed between pressure rolls 87. After melting, the first material 51 comes into contact with the skin material 31 and cools and solidifies. This forms a laminate 1 (skin laminate) in which the first layer 5 of the fibrous body 41 and the skin material 31 are flame-fused together. This laminate 1 is taken up by a skin laminate roll 81.

[0029] The flame device 89 is composed of a gas burner or the like, and the flame temperature is preferably 600 to 1300°C. The first layer 5 is flame-melted by the flame to a thickness of about 0.1 to 1.0 mm. The gap between the pressure rolls 87 is preferably slightly (about 0.6 to 2 mm) narrower than the product thickness (thickness of the laminated sheet).

[0030] In this embodiment 1, the first material 51 used is a flame-retardant nonwoven fabric made of polypropylene fibers spun from a polymer raw material to which a halogen-based flame retardant is added as a flame-retardant imparting substance. The second material 61 is a nonwoven fabric made of polyester fibers (PET fibers) that do not contain a flame-retardant imparting substance. Therefore, the second material 61 contains less flame retardant than the first material 51. The skin material 31 is a polyester-based PET fiber fabric. In the present embodiment 1, the flame-retardant nonwoven fabric of polypropylene fibers is flame-fused and pressure-bonded to the skin material 31. The flame-retardant nonwoven fabric is flame-fused to adhere to the skin material 31 without being over-melted, and does not peel off.

[0031] <Providing flame retardancy> The combustion process of polymeric organic materials generally involves the following steps: combustion of flammable gases, heat generation, heat conduction, thermal decomposition of the organic materials, and diffusion of the flammable gases. The mechanism of flame retardancy involves acting on at least one step of this combustion cycle.

[0032] In this embodiment, the flame retardancy imparted to the first material 51 is preferably one that reduces the burning rate, and is preferably one that self-extinguishes even if ignited. Furthermore, the first material 51 containing the flame retardant is preferably one that is heat-sealed and bonded to the skin material 31. Specifically, for example, the first material 51 is heat-sealed during frame lamination and is pressure-bonded together with the skin material 31. This preferably prevents the first layer 5 and the skin material 31 from peeling off and maintains adhesion.

[0033] The flame retardancy of the first layer (first material) is achieved by focusing on slowing the burning rate among various flame retardants and flame retardant properties. That is, the first layer 5 includes a fibrous first material 51 containing a flame retardant imparting substance that confers flame retardancy. By laminating the first layer 5 and the skin layer 3 by heat fusion, overmelting during heat fusion is reduced.

[0034] The flame retardant imparting substance in the present application includes compounds that impart flame retardancy, such as halogen-based flame retardants, phosphorus-based flame retardants, halogen compounds contained therein, phosphorus compounds, etc., which are organic flame retardants among various flame retardants. Specific examples of the flame retardant imparting substances include the following:

[0035] Phosphorus-based flame retardants include phosphorus compounds such as aromatic phosphate esters, red phosphorus, and polymers derived from these. Aromatic phosphate esters include various phosphoric acid esters (phosphates), phosphorous acid esters (phosphites), phosphonic acid esters (phosphonates), and triphenyl phosphate (TPP). Phosphate esters containing halogen atoms and phosphorus atoms are also included. Examples include phosphate esters such as tris(dibromopropyl)phosphate, tris(dichloropropyl)phosphate, polybrominated triphenyl phosphate, and resorcinol bis(diphenyl phosphate). Phosphite esters such as triphenyl phosphite, tris(2,4-dichlorophenyl)phosphite, and tris(2,4-dibromophenyl)phosphite are also included. Organic phosphorus compounds such as vinyl alkyl phosphonates and allyl haloalkyl phosphonates are also included.

[0036] Examples of halogen-based flame retardants include tetrabromobisphenol A (TBBPA), ethylene bis(tetrabromophthalimide) (EBTBPI), bis(pentabromophenyl)ethane (BPBPE), decabromodiphenyl ether (DBDPE, DBDPO), hexabromobenzene, TBBA-bis(dibromopropyl ether), hexabromocyclododecane (HBCD), and brominated cycloalkanes. Other examples include bromine compounds such as tris(brominated neopentyl)phosphates, such as tris(tribromoneopentyl)phosphate, tris(dibromoneopentyl)phosphate, and tris(monobromoneopentyl)phosphate, as well as chlorine compounds such as chlorinated paraffins.

[0037] In addition to the above, antimony compounds such as antimony trioxide and antimony pentoxide may be used as auxiliary agents. Also, stabilizers such as hindered amine compounds and N-methyl type high molecular weight hindered amine stabilizers may be used in combination.

[0038] The first material 51 contains a flame retardant-imparting substance that imparts flame retardancy, such as a substance such as a flame retardant. The first material 51 containing a flame retardant-imparting substance includes a case where the substance that imparts flame retardancy is contained inside the fibers of the first material 51, and a case where the flame retardant is attached to the fiber surface of the fibrous first material 51. In other words, not only can the flame retardant-imparting substance be contained inside each fibrous fiber, but the flame retardant can also be attached to the outside of each fiber.

[0039] Specifically, methods for imparting flame retardancy to the fibrous body 41 can be broadly divided into methods for producing flame-retardant fibers and methods for post-processing with a flame-retardant substance. Methods for producing flame-retardant fibers include blending a flame-retardant substance into the raw material components of a fiber yarn when producing the yarn, and copolymerizing the raw material components of the fiber with a flame-retardant substance.

[0040] Furthermore, if necessary, the spun fiber fabric may be post-treated with a flame retardant to impart flame retardancy, for example, various halogen-based phosphoric acid esters, phosphorous acid esters, phosphonic acid esters, aromatic phosphoric acid esters such as triphenyl phosphate, red phosphorus, and polymers derived therefrom, and other phosphorus compounds may be attached to the fiber fabric in post-treatment.

[0041] The post-processing method with a flame retardant imparting substance is a method of treating fibers or woven or knitted fabrics to impart flame retardancy to the fiber fabric during dyeing or finishing (resin processing). For example, there is a method of dispersing the flame retardant imparting substance in water and attaching it to the fiber fabric, or a method of emulsifying the flame retardant imparting substance in water and attaching it to the fiber fabric. For example, a flame retardant made by dispersing a halogen-based compound, such as a brominated cycloalkane such as hexabromocyclododecane, in water with a dispersant is applied to a fiber fabric. Another method involves applying a flame retardant made by emulsifying and dispersing a liquid phosphate ester, such as resorcinol bis(diphenyl phosphate), in water with a surfactant to a synthetic fiber fabric.

[0042] The flame retardant-imparting substance is blended into the polymer during the polymer production or spinning stage. For example, the flame retardant is added to the polymer in an amount of 0.5 to 5% by weight, preferably 1 to 4.5% by weight. A bromine-based compound can be used as the flame retardant-imparting substance. A typical melt spinning process and drawing process are then used to spin the flame-retardant fiber. The fibrous body 41 contains atoms that impart flame retardancy, such as phosphorus and halogens, based on the flame retardant-imparting substance. The atoms that contribute to flame retardancy in the fibrous body 41 are present in an amount of, for example, 0.3 to 4.2% by weight, preferably 0.6 to 3.8% by weight.

[0043] The method for copolymerizing the raw material components of the fiber with the flame retardant imparting substance is as follows. Flame-retardant polymers are synthesized by adding a copolymerizable monomer (flame-retardant substance) containing phosphorus, a compound that confers flame retardancy, to the reaction system during the polymer manufacturing stage. Flame-retardant polymers are randomly copolymerized within the main chain of the polymer (polyester). Because the flame-retardant substance is copolymerized within the polyester main chain, the flame retardancy is semi-permanent, even if the material is worn or rubbed. Examples of flame-retardant substances include the trifunctional monomer trimethyl phosphate and phosphorus-based bifunctional monomers.

[0044] In the second embodiment, the first material 51 used is a flame-retardant nonwoven fabric made of polyester fiber instead of the flame-retardant nonwoven fabric made of polypropylene fiber used in the first embodiment. The other materials used are the skin material 31 and the second layer 6 (second material 61). The first material 51 is a flame-retardant nonwoven fabric made of polyester fiber (PET fiber) spun by adding a phosphorus-based monomer as a flame-retardant substance to a polyester-based polymer raw material. The second material 61 is a nonwoven fabric made of polyester fiber (PET fiber) that does not contain a flame-retardant substance. Therefore, the second material 61 has a smaller amount of flame retardant than the first material 51. The skin material 31 is a polyester-based PET fiber fabric. Both the first material 51 and the second material 61 are polyester fiber.

[0045] In the second embodiment, a flame-retardant nonwoven fabric made of polyester fibers is flame-fused and pressure-bonded to the skin material 31. The flame-retardant nonwoven fabric adheres to the skin material 31 by flame fusion without being over-melted, and does not peel off. Furthermore, since the skin layer 3, the first layer 5, and the second layer 6 are all made of the same type of fiber and the same type of thermoplastic resin, adhesion is good. This also improves recyclability at the time of disposal.

[0046] Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the above embodiments, and various modifications are possible without departing from the spirit of the invention. In particular, the examples described in this specification can be arbitrarily combined as necessary. [Explanation of symbols]

[0047] 1: Laminate (skin layer / first layer / second layer) 3: Epidermal layer, 31: Epidermal material 4: Fiber layer, 41: Fiber (first layer / second layer) 5: 1st layer, 51: 1st material 6: 2nd layer, 61: 2nd material 71: Needle punch 81: Skin laminate roll 83: Covering material supply roll 84: Fiber supply roll 87: Pressure roll 89: Flame device 90: Cushioning material 100: Seat cushion

Claims

1. The epidermis layer, a first layer laminated in contact with the skin layer and including a fibrous first material containing a flame retardant; a second layer laminated in contact with the first layer and including a fibrous second material having a smaller amount of flame retardant than the first material; Equipped with Laminate.

2. The skin layer and the first layer are heat-sealed. The laminate according to claim 1 .

3. The fibers of the first layer and the fibers of the second layer are intertwined with each other. The laminate according to claim 2 .

4. The thickness of the first layer is smaller than the thickness of the second layer. The laminate according to claim 2 or 3.

5. the skin layer and the first layer comprise the same type of thermoplastic resin; The laminate according to claim 1 .

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