Multilayer nonwoven fabric for foam molding

Abstract

Multilayer nonwoven fabrics for foam molding that have excellent resistance to the separation of layers, have reinforcing effects and urethane leakage prevention performance, and are producible without the occurrence of fiber dust on the surface. In the multilayer nonwoven fabric for foam molding, a reinforcing layer is stacked on at least one side of a dense layer, the dense layer includes a meltblown nonwoven fabric layer (A) and spunbonded nonwoven fabric layers (B) that are stacked on both sides of the layer (A), and the meltblown nonwoven fabric layer (A) and the spunbonded nonwoven fabric layers (B) are partially thermocompression bonded with each other.

1 . A multilayer nonwoven fabric for foam molding in which a reinforcing layer is stacked on at least one side of a dense layer, wherein
 the dense layer comprises a meltblown nonwoven fabric layer (A) and spunbonded nonwoven fabric layers (B) that are stacked on both sides of the meltblown nonwoven fabric layer (A), and the meltblown nonwoven fabric layer (A) and the spunbonded nonwoven fabric layers (B) are partially thermocompression bonded with each other, and wherein the dense layer and the reinforcing layer are stacked with each other by needle punching.   
     
     
         2 . The multilayer nonwoven fabric for foam molding according to  claim 1 , wherein the meltblown nonwoven fabric layer (A) which constitutes the dense layer has a fiber diameter in the range of 0.1 to 5 μm. 
     
     
         3 . The multilayer nonwoven fabric for foam molding according to  claim 1 , wherein the meltblown nonwoven fabric layer (A) which constitutes the dense layer has a basis weight in the range of 0.1 to 5 g/m 2 . 
     
     
         4 . The multilayer nonwoven fabric for foam molding according to  claim 1 , wherein the spunbonded nonwoven fabric layers (B) which constitute the dense layer have a fiber diameter in the range of 10 to 20 μm. 
     
     
         5 . The multilayer nonwoven fabric for foam molding according to  claim 1 , wherein the spunbonded nonwoven fabric layers (B) which constitute the dense layer have a basis weight in the range of 10 to 20 g/m 2 . 
     
     
         6 . The multilayer nonwoven fabric for foam molding according to  claim 1 , wherein the dense layer has a bulk density in the range of 0.05 to 0.5 g/cm 3 . 
     
     
         7 . The multilayer nonwoven fabric for foam molding according to  claim 1 , wherein the basis weight of the dense layer is in the range of 10 to 60 g/m 2 . 
     
     
         8 . The multilayer nonwoven fabric for foam molding according to  claim 1 , wherein the reinforcing layer is a spunbonded nonwoven fabric layer (C) having a fiber diameter of 12 to 50 μm and a basis weight of 10 to 50 g/m 2 . 
     
     
         9 . The multilayer nonwoven fabric for foam molding according to  claim 1 , wherein the multilayer nonwoven fabric has an air permeability of 25 to 160 (cm 3 /cm 2 /sec). 
     
     
         10 . The multilayer nonwoven fabric for foam molding according to  claim 1 , wherein the multilayer nonwoven fabric has a basis weight of 20 to 160 g/m 2 . 
     
     
         11 . The multilayer nonwoven fabric for foam molding according to  claim 1 , wherein the meltblown nonwoven fabric layer (A) and the spunbonded nonwoven fabric layers (B) are each formed of a propylene polymer. 
     
     
         12 . The multilayer nonwoven fabric for foam molding according to  claim 1 , wherein a foamed urethane is further stacked on the reinforcing layer side of the multilayer nonwoven fabric. 
     
     
         13 . A vehicle seat which comprises the multilayer nonwoven fabric for foam molding of  claim 12 . 
     
     
         14 . A chair which comprises the multilayer nonwoven fabric for foam molding of  claim 12 . 
     
     
         15 . A process for producing multilayer nonwoven fabrics for foam molding, comprising stacking spunbonded nonwoven fabric layers (B) to both sides of a meltblown nonwoven fabric layer (A), partially thermocompression bonding the layers with each other to produce a dense layer, stacking a reinforcing layer on at least one side of the dense layer, and entangling the layers.