NONWOVEN FABRIC LAMINATE FOR FOAM MOLDING, URETHANE FOAM MOLDING COMPOSITE INCLUDING SAID NONWOVEN FABRIC LAMINATE, AND METHOD FOR MANUFACTURING NON-WOVEN FABRIC LAMINATES FOR FOAM MOLDING

摘要

A nonwoven fabric laminate for foam molding includes a reinforcing layer on at least one side of a dense layer. The dense layer is a nonwoven fabric including polyester continuous fibers with a fiber diameter of 10 to 30 μm and having a bulk density of not less than 0.1 g/cm³, the fibers being fusion bonded together by a hot air treatment. The reinforcing layer is a nonwoven fabric including polyester staple fibers with a fiber diameter of 10 to 30 μm. The dense layer and the reinforcing layer are stacked and interlocked with each other by needle punching. The nonwoven fabric laminates for foam molding can maintain denseness in the sheets even after being heated, spread and compressed. The nonwoven fabrics display excellent conformability to the shape of a mold during a shaping process involving heating, spreading and compressing and thus can be formed into complicated shapes.