Process for producing moldable non-woven fabrics
AssigneeMitsubishi Yuka Badische Co., Ltd.
InventorNaoyuki Kato
Life of this patent
Estimating the term…
Abstract
A process for producing a moldable non-woven fabric is disclosed, which comprises coating or impregnating a mat made of non-woven fabrics with an aqueous emulsion of a thermoplastic resin having a moldable temperature range of from 80.degree. to 180.degree. C. in such an amount that the resin solids content of the emulsion is 15 to 300 wt % based on the weight of the mat, removing the moisture from the mat by heating, and pressing the mat to adjust the apparent density of the mat to 0.15 to 0.5 g/cm.sup.3. This fabric is useful as an interior material for use in an automobile, for example.
Claims10
A process for producing a moldable non-woven fabric, which comprises:
- coating or impregnating a mat formed from a fiber mixture of from 15-50 wt. % of thermoplastic resin fibers and from 85-50 wt. % of synthetic or natural fibers having a melting point of more than 40.degree. C. higher than the thermoplastic resin of the thermoplastic fibers with an aqueous emulsion of a thermoplastic resin which is moldable over a temperature of 80.degree.-180.degree. C. in an amount such that the resin solids content in the emulsion ranges from 15 to 300 wt. % based on the weight of the non-woven fabric mat;
- heating the emulsion coated or impregnated mat to a temperature greater than the melting point of the resin of the emulsion in order to remove water therefrom;
- and then
- compressing the dried mat at a temperature above the melting point of the resin of the emulsion, thereby obtaining a molded product, thereby obtaining a mat whose density is controlled to within the range of 0.15 to 5 g/cm.sup.3.
Dependencies are inferred from the claim text.