Fiber sheets, surface materials, and interior components

Abstract

This disclosure provides a novel sheet. [Solution] One aspect of the invention is a fiber sheet comprising a dense layer formed on the surface of the fiber sheet, in which the fibers contained in the fiber sheet are bound together and the fibers are denser than those inside the fiber sheet, and the surface of the dense layer is provided with a heated surface that includes a molten and solidified portion in which the fibers are melted and solidified.

Description

Technical Field

[0001] The present disclosure relates to a fiber sheet, a skin material, and an interior member.

Background Art

[0002] Conventionally, various sheets have been developed (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

[0013] , etc.)

Summary of the Invention

Problems to be Solved by the Invention

[0004] The present disclosure provides a novel sheet.

Means for Solving the Problems

[0005] One aspect of the invention is a fiber sheet including a dense layer formed on the surface layer of the fiber sheet, in which fibers included in the fiber sheet are bound to each other and the fibers are denser than inside the fiber sheet, and a heated surface including a melt-solidified portion where the fibers are melt-solidified is provided on the surface of the dense layer.

Brief Description of the Drawings

[0006] [Figure 1] Cross-sectional view of the fiber sheet [Figure 2] Cross-sectional photograph of the fiber sheet [Figure 3] Enlarged view of the binding portion between fibers [Figure 4] Enlarged photograph of the binding portion between fibers [Figure 5] Enlarged view of the melt-solidified portion of the heated surface [Figure 6] Cross-sectional view of an interior member in which the base material is covered with a skin material [Figure 7] Cross-sectional view of a fibrous sheet being heated by hot air. [Figure 8] Cross-sectional view of a pressed fiber sheet. [Figure 9] Cross-sectional view of a fiber sheet that has been pressed to form a heated surface including a molten and solidified area on the surface of the dense layer. [Modes for carrying out the invention]

[0007] [First Embodiment] Figures 1 and 2 show a fiber sheet 10 according to the first embodiment. The fiber sheet 10 of this embodiment is made of a nonwoven fabric containing resin fibers.

[0008] As shown in Figure 1, a dense layer 21 is formed on the surface of the fiber sheet 10, in which the fibers are denser than in the interior of the fiber sheet 10 (the part inside the surface layer). In this embodiment, the dense layer 21 is provided only on one side of the fiber sheet 10 (the first surface 10A side). In this embodiment, the entire other side of the fiber sheet 10 (the second surface 10B side) (i.e., the part excluding the dense layer 21) is a base layer 22 with a lower fiber density than the dense layer 21.

[0009] As shown in Figures 3 and 4, the dense layer 21 has multiple bonding portions 12 formed in which the fibers 11 constituting the fiber sheet 10 are bonded together. In the dense layer 21, the fiber density is higher than that of the base layer 22 due to this bonding of the fibers 11 together.

[0010] As shown in Figures 1 and 2, a heated surface 21M is formed on the surface (first surface 10A) of the dense layer 21. A molten and solidified portion 13 (see Figure 5) is formed on the heated surface 21M where the fibers 11 have melted and solidified. In this embodiment, the binding portions 12 are formed by the melting and solidification of the fibers 11, and at least a portion of the multiple binding portions 12 are arranged on the heated surface 21M as a molten and solidified portion 13.

[0011] In this embodiment, a gap S is provided between the molten and solidified portions 13 on the heated surface 21M of the dense layer 21 (see Figure 5). In the multiple bonding portions 12 on the heated surface 21M of the dense layer 21, protruding portions 14 are formed, which are made up of molten and solidified fibers 11 and extend outwards from the fibers 11 to narrow the gap S between the fibers 11.

[0012] The fibers 11 constituting the fiber sheet 10 preferably contain a thermoplastic resin. In particular, it is preferable that at least the surface portion of the fiber 11 contains a thermoplastic resin. In the example of this embodiment, as shown in Figure 3, the fiber 11 has a core-sheath structure having a core portion 17 and a cylindrical sheath portion 18 surrounding the core portion 17. In such a core-sheath structure, it is preferable that at least the sheath portion 18 contains a thermoplastic resin (for example, the sheath portion 18 is made of a thermoplastic resin). By including a thermoplastic resin in the sheath portion 18, the sheath portions 18 of the fiber 11 can be melted and solidified by heating to form a bonding portion 12 in which the sheath portions 18 are joined together.

[0013] The core portion 17 and the sheath portion 18 of the fiber 11 may both be made of thermoplastic resin (for example, both may be made of polyolefin resin). In the example of this embodiment, the core portion 17 contains polypropylene resin (for example, is made of polypropylene resin), and the sheath portion 18 contains polyethylene resin (for example, is made of polyethylene resin). However, the resin constituting the fiber 11 is not limited to these examples. The resin constituting the fiber 11 may be, for example, polyethylene terephthalate (PET) resin or polyester resin. Furthermore, the fiber 11 may contain a thermosetting resin. For example, the sheath portion 18 may be made of thermoplastic resin and the core portion 17 may be made of thermosetting resin.

[0014] When the fiber 11 has a core - sheath structure, it is preferable that the resin of the core part 17 has a higher melting point than the resin of the sheath part 18. In this configuration, for example, by heating the fiber 11 to a temperature between the melting point of the core part 17 and the melting point of the sheath part 18, while leaving the core part 17 of the fiber 11 and maintaining the form of the fiber 11, the sheath parts 18 can be melted and solidified to form the binding part 12.

[0015] Printing may be performed on the heated surface 21M of the dense layer 21. In the example of this embodiment, ink adheres to the heated surface 21M. As described above, when voids S (see FIG. 5) that open between the molten - solidified parts 13 are provided between the fibers 11 of the dense layer 21 on the heated surface 21M, it becomes possible to attach the ink from the heated surface 21M of the dense layer 21 to the inside. Thereby, it becomes possible to make it easier for the ink to be fixed to the dense layer 21.

[0016] A primer for fixing the ink may be applied to the heated surface 21M. In the example of this embodiment, since the voids S that open to the heated surface 21M are provided between the fibers 11, the primer can be applied from the heated surface 21M of the dense layer 21 to the inside. Thereby, it becomes possible to make it easier for the primer to be fixed to the dense layer 21 and to make it easier for the ink to be further fixed. As described above, when the fiber 11 is made of a polyolefin - based resin, it is considered that the ink is difficult to adhere (difficult to stick) to the heated surface 21M. In contrast, in the example of this embodiment, since the primer is applied to the heated surface 21M, it becomes possible to make it easier for the ink to adhere to the heated surface 21M. Also, by applying the primer to the heated surface 21M, it is possible to suppress the peeling of the ink and improve the abrasion resistance of the heated surface 21M. Examples of the primer include, for example, a modified polyolefin primer (for example, an acid - modified polyolefin primer).

[0017] The fiber diameter of the fibers 11 of the fiber sheet 10 is preferably 6.8 dtex or less, more preferably 6.7 dtex or less, and even more preferably 2.2 dtex or more and 6.7 dtex or less. The finer the fiber diameter, the more possible it is to enhance the smoothness of the heated surface 21M.

[0018] Also, in the fiber sheet 10 of the non-woven fabric, the basis weight is preferably 0.04 g / cm 2 or more and 0.08 g / cm 2 or less.

[0019] Next, the usage examples of the fiber sheet 10 will be described. The fiber sheet 10 may be used alone or in a laminate laminated with other sheets (for example, fiber sheets). The fiber sheet 10 having such a single-layer structure or laminated structure may be used, for example, as the skin material 30 (see FIG. 6) or for fabrics such as clothes.

[0020] The fiber sheet 10 may be used, for example, as the skin material 30 covering an article such as the base material 40 (see FIG. 6). FIG. 6 shows an interior member 50 as a member in which the skin material 30 is fixed in a state of covering the base material 40 (for example, a plate-like body). The interior member 50 may be for a vehicle such as a car or for a building. The interior member 50 may be used, for example, for an instrument panel or a glove box of a vehicle. For example, when the skin material 30 is fixed to the curved surface of the base material 40 in the interior member 50, by providing the dense layer 21 and the heated surface 21M only on one side of the fiber sheet 10, it becomes easier to give flexibility to the fiber sheet 10 and it becomes possible to make the skin material 30 follow the curved surface of the base material 40 in the interior member 50.

[0021] As shown in Figure 6, the interior member 50 may have a light-emitting member 60 between the base material 40 and the surface material 30. In this configuration, the surface material 30 (fiber sheet 10) is translucent, allowing light from the light-emitting member 60 to be seen through the surface material 30. For example, if the surface material 30 consists of a fiber sheet 10, and the fiber sheet 10 has voids S (see Figure 5) that penetrate the fiber sheet 10 between the fibers 11, then light from the light-emitting member 60 can be seen through the voids S. The surface material 30 may also be made of a translucent material (for example, transparent or semi-transparent) so that light from the light-emitting member 60 can be transmitted through it. In these configurations, by allowing light from the light-emitting member 60 to be transmitted through the surface material 30 (fiber sheet 10), the decorative properties of the interior member 50 can be enhanced. In addition, by providing molten and solidified portions on the fibers 11 of the heated surface 21M, the smoothness of the heated surface 21M can be enhanced. This makes it easier to print on the heated surface 21M, thereby enhancing the aesthetic appeal of the heated surface 21M. For example, a wood grain pattern or similar design may be printed on the heated surface 21M.

[0022] As mentioned above, the basis weight of the fiber sheet 10 is 0.04 to 0.08 g / cm². 2 This makes it easier to form voids S that allow light from the light-emitting member 60 to pass through appropriately. When the basis weight of the fiber sheet 10 is within this range, it becomes a surface material with appropriate cushioning properties. Furthermore, when the basis weight is within the above range, it becomes possible to easily conform to the curved surface of the interior member 50. Note that a higher basis weight makes it possible to improve the smoothness of the heated surface 21M.

[0023] In the interior component 50, for example, the fiber sheet 10 of the surface material 30 and the base material 40 may be joined together with an adhesive. A hot melt adhesive may be used as such an adhesive. For example, if the surface material 30 (fiber sheet 10) is made of a polyolefin thermoplastic resin (for example, having the core-sheath structure described above) and the base material 40 is made of a polyolefin resin (for example, polypropylene resin), then a polyolefin hot melt adhesive is preferred as the hot melt adhesive. Conventionally, for example, a component (for example, an interior component) has been developed in which a surface material is made of a surface material in which a surface layer such as polyvinyl chloride is laminated on a base layer such as polyurethane resin, and a base material such as ABS resin is covered with this surface material. However, such components made of different resins and including thermosetting resins were difficult to recycle. In contrast, as described above, by making the entire component (for example, an interior component 50) in which the fiber sheet 10 and the base material 40 are joined together with an adhesive, it becomes possible to facilitate recycling. Examples of hot-melt adhesives made from polyolefin resins include those containing both a polyolefin resin and an acid-modified polyolefin resin. An acid-modified polyolefin resin is, for example, obtained by graft polymerization of an unsaturated carboxylic acid or its derivative onto a polypropylene resin.

[0024] The fiber sheet 10 is manufactured, for example, as follows. First, a fiber sheet-like body 10S (see Figure 7) is prepared by forming a sheet of fiber aggregates that have been defibrated and loosened into a cotton-like state. This fiber sheet-like body 10S does not have a binding portion 12 formed, nor does it have a dense layer 21 formed. The fiber 11 is made of thermoplastic resin, and may have a core-sheath structure in which, for example, the core portion 17 is made of polypropylene resin and the sheath portion 18 is made of polyethylene resin (see Figure 3).

[0025] Next, the fibrous sheet 10S is heated (see Figure 7). In this embodiment, hot air is blown onto the fibrous sheet 10S. The hot air is blown from the first surface 10A side (from the top in the example shown in Figure 7) of the fibrous sheet 10S. When the fibers 11 of the fibrous sheet 10S are heated by the hot air in this way, at least the surface portion of the fibers 11 melts. Then, the molten fibers 11 stick together, and as these fibers 11 cool and solidify, a plurality of bonding portions 12 (see Figure 3) are formed. Heating with hot air heats the fibrous sheet 10S in a natural state without compression, causing the fibers 11 to bond together, thereby forming a soft and cushioned fibrous sheet 10F. At least a portion of the plurality of bonding portions 12 are located on the first surface 10A.

[0026] Next, the fiber sheet 10F, on which the bonded portion 12 is formed, is pressed. In this pressing process, the fiber sheet 10S is sandwiched and pressed between the upper die 71 and lower die 72 of the press mold shown in Figure 8 (see Figure 9). In this embodiment, the upper die 71 is heated, while the lower die 72 is not. By pressing in this manner, the first surface 10A of the fiber sheet 10S (in this embodiment, the surface facing the upper die 71) is heated, the fibers 11 on the first surface 10A melt, and the heated surface 21M is formed. In addition, the heat from the upper die 71 during pressing causes the fibers 11 on the first surface 10A side of the fiber sheet 10F to further increase the number of bonded portions 12. As a result, a dense layer 21 is formed on the first surface 10A side of the fiber sheet 10F, with a higher fiber density than the second surface 10B side (base layer 22) on the other side. When the fiber sheet 10F is removed from the press mold and cooled, a molten and solidified portion 13 (see Figure 5) is formed on the heated surface 21M, where the fibers 11 have melted and solidified. In addition, some of the multiple bonding portions 12 are arranged on the heated surface 21M as the molten and solidified portion 13. This results in a fiber sheet 10 having the molten and solidified portion 13 on the heated surface 21M. In this embodiment, heating and pressing the upper mold 71 makes it possible to make the first surface 10A (heated surface 21M) flatter. In this embodiment, the fiber sheet 10 has voids S (see Figure 5) between the fibers 11 on the heated surface 21M, and for example, it has breathability.

[0027] For example, printing is performed on the heated surface 21M of the fiber sheet 10. In this case, ink is applied to the heated surface 21M of the fiber sheet 10. In this configuration, if the ink does not adhere well to the heated surface 21M (for example, if the fiber 11 is made of polyolefin resin), it is preferable to apply a primer to the heated surface 21M in advance to facilitate ink adhesion. Applying the primer by spray makes it easier to apply from the heated surface 21M to the interior of the dense layer 21. Inkjet printing also makes it easier to adhere the ink from the heated surface 21M to the interior of the dense layer 21. This concludes the explanation of the manufacturing method of the fiber sheet 10.

[0028] As described above, the fiber sheet 10 of this embodiment is a sheet with a configuration unlike any other. According to this embodiment, for example, it is possible to provide a sheet with an unprecedented texture. Furthermore, according to this embodiment, it is also possible to provide a sheet with an unprecedented appearance. In the fiber sheet 10 of this embodiment, the heated surface 21M is provided with molten and solidified portions 13 and protruding portions 14 in which the fibers 11 have melted and solidified, making it possible to make the surface smoother compared to a fiber sheet without these portions. This makes it easier to adhere ink to the heated surface 21M. It also makes it easier to adhere primer to the heated surface 21M.

[0029] [Other embodiments] In the above embodiment, the dense layer 21 was provided only on the surface layer on the first surface 10A side of the fiber sheet 10, but the dense layer 21 may also be provided on the surface layers on both the front and back sides of the fiber sheet 10. In this case, for example, a base layer 22 with a lower fiber density than the dense layer 21 is provided in the center of the fiber sheet 10 in the thickness direction. This configuration can be obtained, for example, in the above embodiment by blowing hot air from both the front and back sides of the fiber sheet 10S to form the bonding portion 12, and then heating both the upper die 71 and the lower die 72 of the press mold to press the fiber sheet 10S.

[0030] In the above embodiment, gaps S were provided between the molten and solidified portions 13 on the heated surface 21M of the dense layer 21, but gaps S are not required, and the heated surface 21M does not need to be permeable.

[0031] The molten and solidified portion 13, where the fibers 11 have melted and solidified, may be provided in parts other than the binding portion 12 (parts that are not bound to other fibers 11) (see Figure 5). In this configuration as well, the molten and solidified portion 13 may be provided with protruding portions 14 that extend from the fibers 11 to narrow the gaps between the fibers 11.

[0032] In the above embodiment, a primer for fixing the ink was applied to the heated surface 21M of the dense layer 21, but surface treatment such as corona treatment may be performed on the heated surface 21M to fix the ink.

[0033] In the above embodiment, the binding portion 12 was formed by the melting and solidification of the fibers 11, but the binding portion 12 may also be formed by bonding the fibers 11 together with an adhesive.

[0034] In the above embodiment, the fibers 11 of the fiber sheet 10 may contain metal (for example, low-melting-point metal fibers). Even in this case, the fibers 11 melt and solidify to form a binding portion 12 or a molten-solidified portion 13, and a dense layer 21 and a heated surface 21M can be formed.

[0035] <Note> The following describes the features extracted from the above embodiments and examples, explaining their effects and other aspects as necessary.

[0036] For example, the following set of features, relating to "fiber sheets, surface materials, and interior components," can be considered to have been conceived with the objective of "providing a novel sheet," given the background technology that "various sheets have been developed conventionally (see, for example, Japanese Patent Application Publication No. 2020-066184 (paragraph

[0013] , etc.))." Furthermore, there has been a demand for novel fiber sheets, novel surface materials, and novel interior components. In addition, there has also been a demand for novel manufacturing methods for these materials.

[0037] [Feature 1] A dense layer is formed on the surface of the fiber sheet, in which the fibers contained in the fiber sheet are bound together, and the fibers are denser than those inside the fiber sheet. A fiber sheet having a heated surface on the surface of the dense layer, which includes a molten and solidified portion where the fibers have melted and solidified.

[0038] [Feature 2] The fiber sheet according to feature 1, wherein the dense layer has voids that open between the molten and solidified portions on the heated surface.

[0039] [Feature 3] The multiple bonding portions between the fibers are provided with protruding portions that are formed by the melting and solidification of the fibers and that extend outward from the fibers to narrow the gaps between the fibers. The fiber sheet according to feature 1 or 2, wherein at least a portion of the plurality of bonding portions is included in the heated surface as the molten and solidified portion.

[0040] [Feature 4] The dense layer has ink adhering to it from the heated surface to the interior, as described in Feature 2 of the fiber sheet.

[0041] [Feature 5] The fiber sheet according to feature 4, wherein the dense layer is coated with a primer for fixing the ink from the heated surface to the interior.

[0042] [Feature 6] The fiber sheet is made of a polyolefin-based thermoplastic resin, as described in any one of features 1 to 5.

[0043] [Feature 7] The fiber sheet according to feature 6, wherein the fiber has a core-sheath structure comprising a core containing polypropylene resin and a sheath containing polyethylene resin.

[0044] [Feature 8] A fiber sheet according to any one of the features 1 to 7, wherein the fiber diameter of the aforementioned fiber is 6.7 dtex or less.

[0045] [Feature 9] Weight: 0.04-0.08 g / cm 2 A fiber sheet made of nonwoven fabric, having one of the characteristics described in any one of characteristics 1 to 8.

[0046] [Feature 10] A surface material containing a fiber sheet described in any one of the features 1 through 9.

[0047] An interior component in which a fiber sheet as described in Feature 6 or 7 is bonded to a polyolefin resin substrate with a polyolefin hot melt adhesive.

[0048] The surface material described in Feature 10, An interior member comprising a base material covered with the aforementioned surface material, An interior component comprising a light-emitting member between the base material and the surface material.

[0049] According to the above characteristics, a novel fiber sheet is provided.

[0050] While this specification and drawings disclose specific examples of the technology included in the claims, the technology described in the claims is not limited to these specific examples, but also includes various modifications and changes to these examples, as well as parts of the examples taken individually. [Explanation of symbols]

[0051] 10 Fiber Sheets 10A 1st side 10B 2nd side 10S Fiber Sheet 10F Fiber Sheet 11 Fibers 12. Binding part 13. Molten and solidified section 14 Overhang 17 Core 18 Scabbard part 21 Layer compacta 21M Heated surface 22 Base Layer 30 Skin material 40 Base material 50 Interior components 60 Light-emitting element 71 Upper mold 72 Lower mold

Claims

1. A dense layer is formed on the surface of the fiber sheet, in which the fibers contained in the fiber sheet are bound together, and the fibers are denser than those inside the fiber sheet. A fiber sheet having a heated surface on the surface of the dense layer, which includes a molten and solidified portion where the fibers have melted and solidified.

2. The fiber sheet according to claim 1, wherein the dense layer is provided with voids that open between the molten and solidified portions on the heated surface.

3. The multiple bonding portions between the fibers are provided with protruding portions that are formed by the melting and solidification of the fibers and that extend outward from the fibers to narrow the gaps between the fibers. The fiber sheet according to claim 1, wherein at least a portion of the plurality of binding portions is included in the heated surface as the molten and solidified portion.

4. The fiber sheet according to claim 2, wherein the dense layer has ink adhering to it from the heated surface to the interior.

5. The fiber sheet according to claim 4, wherein a primer for fixing the ink is applied to the dense layer from the heated surface to the interior.

6. The fiber sheet according to claim 5, wherein the fiber is made of a polyolefin-based thermoplastic resin.

7. The fiber sheet according to claim 6, wherein the fiber has a core-sheath structure comprising a core containing polypropylene resin and a sheath containing polyethylene resin.

8. The fiber sheet according to claim 1, wherein the fiber diameter of the fiber is 6.7 dtex or less.

9. Weight: 0.04–0.08 g / cm ２ A fiber sheet according to claim 1, comprising a nonwoven fabric.

10. A surface material comprising a fiber sheet according to any one of claims 1 to 9.

11. An interior component in which the fiber sheet according to claim 6 or 7 is bonded to a polyolefin resin substrate with a polyolefin hot melt adhesive.

12. The surface material according to claim 10, An interior member comprising a base material covered with the aforementioned surface material, An interior component comprising a light-emitting member between the base material and the surface material.

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