JPH03213548A - Production of nonwoven sheet - Google Patents

Abstract

PURPOSE:To obtain the subject sheet having excellent smoothness and level dyeing property and useful for clothes, etc., by welding a fiber fleece containing a heat-weldable substance with protruded parts of an emboss roll wherein said protruded part of the roll is made of a metallic wire or a card clothing. CONSTITUTION:A fiber fleece containing a heat-weldable substance (e.g. thermoplastic fiber) is heated by contacting with protrusions of an emboss roll to weld said heat-weldable substance at a region corresponding to the protrusion and form a nonwoven sheet having a number of welded points. In the above process, the protruded part of the roll is made of a metallic wire which is a wire having saw-tooth part or a card clothing which is a continuous cloth planted with needles.

Description

[Detailed description of the invention] [Industrial application field]

The present invention relates to a method for manufacturing a nonwoven sheet used for clothing materials, industrial materials, and the like.

[Conventional technology]

Conventionally, various nonwoven sheets have been used for various purposes in place of knitted fabrics. Among non-woven sheets, non-woven sheets with a large number of fusion points (for example, so-called point seal non-woven fabrics) have a flexible texture and do not contain rubber binders, so they are suitable for use in clothing. , used in various fields such as industrial and medical applications. A nonwoven sheet with a large number of fusing points is produced by passing a fiber fleece containing a heat-fusible substance such as a thermoplastic fiber or a thermoplastic film between a heated uneven roll and a smooth roll.
It is manufactured by applying heat and pressure to the area in contact with the convex portions of the uneven roll to fuse the heat-fusible material (
calendar method). In addition, the fiber fleece containing a heat-fusible substance is passed between a textured roll at room temperature and a flat ultrasonic oscillator, and the convexities are treated by the action of ultrasonic waves emitted from the convexities of the textured roll. It is manufactured by applying heat (and some pressure if desired) to the area to fuse the heat-fusible material (ultrasonic method). In both the calendar method and the ultrasonic method, the uneven roll is
An engraved roll is used. However, when an engraved roll is used as the uneven roll, there are the following drawbacks. In other words, if an object harder than the textured roll, such as a piece of metal or wood, accidentally gets mixed into the fiber fleece, the textured roll will be damaged by the metal pieces when the fiber fleece passes through the textured roll. there were. Due to this damage, the convex portions of the uneven roll may be missing or deformed, and it becomes impossible to provide the desired fusion points in the fiber fleece after that. Therefore, it is necessary to regenerate this damaged uneven roll. However, in order to reproduce the roll, it is necessary to first smooth the uneven roll and then engrave it so that it has the desired unevenness, which has the drawback of requiring a large amount of cost and time. Further, the tip of the convex portion of the engraved uneven roll could only have a relatively large area due to the engraving process. Therefore, the area of the fusion points in the nonwoven sheet corresponding to the convex portions of the uneven roll, that is, the area of the concave portions in the nonwoven sheet, naturally increases, making the unevenness of the nonwoven sheet noticeable and giving it an appearance and feel that is lacking in smoothness. Only non-woven sheets were obtained. Furthermore, when such a nonwoven sheet is dyed, there is a drawback that the entire surface is not uniformly dyed. This is because the fusion points are formed into a film, so even if the nonwoven sheet is dyed, the fusion points will not be dyed. Therefore, if the area of the fusion points is large, the undyed portions will be noticeable.

[Problem to be solved by the invention]

Therefore, when creating the uneven roll, the present invention uses a special mechanical part without employing engraving, thereby making the area of the tips of the protrusions relatively small (and
The uneven roll can be easily and inexpensively regenerated even if the convex part is damaged.

[Means for Solving the Problem] That is, the present invention applies heat to a fiber fleece containing a heat-fusible substance by the action of the convex portions of the uneven roll, and causes the heat-fusible material to melt in areas corresponding to the convex portions. A method of manufacturing a non-woven sheet in which adhesive substances are fused to provide a large number of fusion points, wherein the convex portions are formed of metallic wire or clothing. It is something. First, in the present invention, a fiber fleece containing a heat-fusible substance is prepared. Thermoplastic fibers are typically used as the heat-fusible material. Thermoplastic fibers include polyester fibers,
Conventionally known fibers such as polyamide fibers and polypropylene fibers are used. As for the form of this fiber, various conventionally known forms such as continuous filament, stable fiber, and syjito-cut fiber can be used. Further, as the heat-fusible substance, a thermoplastic film, thermoplastic powder, etc. can also be used. As the fiber fleece, one containing the above heat-fusible substance is used. Typically 100% thermoplastic fiber
A fiber fleece consisting of Furthermore, a fiber fleece in which about 10 to 90% of thermoplastic fibers and about 90 to 10% of non-thermoplastic fibers are mixed can also be used. As the non-thermoplastic fibers, rayon fibers, cotton fibers, wool fibers, hemp fibers, etc. are used. Also,
Fiber fleece includes a laminate of a fibrous web made of non-thermoplastic fibers and a thermoplastic film, which is a heat-fusible substance, and a fibrous web made of a blend of non-thermoplastic fibers and thermoplastic fibers and a thermoplastic film. are laminated, thermoplastic films are laminated with the above various fiber webs on both sides, thermoplastic powder is mixed into the fiber web, etc.
A gripped web, a melt-blown web or a lamination of a melt-blown web and the above-mentioned various fibrous webs, a laminate of a spunpond web or a spunbond web and the above-mentioned various fibrous webs, etc. can also be used. As the thermoplastic film, conventionally known polyethylene film, polyester film, polyamide film, etc. are used, and as the thermoplastic powder, conventionally known polyethylene powder, polyamide powder, etc. are used. Next, this fiber fleece is passed between an uneven roll and a smooth roll, etc., and heat is applied to the areas corresponding to the projections by the action of the uneven roll, and the heat-fusible material in the fiber fleece is heated. are fused to form a fusion point. This fusion point allows the constituent fibers in the fiber fleece to bond with each other, resulting in a nonwoven sheet with a certain level of strength. What is important in the present invention is that the convex portions of the uneven roll are formed of metallic wire or clothing. Here, the metallic wire is JIS L0305-1
It is defined in 1120 of 982, and is a linear object having a sawtooth shape. Specifically, it is as shown in FIGS. 1 and 2. FIG. 1 is a front view of a metallic wire, in which the upper part is serrated and the lower part is flat. The length of the sawtooth is -a=0.1 mm, and the pitch of the teeth -b=1.
It is 27 mm. Moreover, FIG. 2 is a cross-sectional view of the metallic wire shown in FIG. 1, and the width of the sawtooth - c = 0
．． In1m. In addition, clothing is JIS L030
5-1982, No. 1118, and is a long article with needles planted in the base fabric. Specifically, width 25
A large number of needles are planted on one side of a rubber or film tape about mm in size. These metallic wires or clothing are supplied on the market as parts of spinning machines, and are easily available and very inexpensive. In order to create a textured roll using the above-mentioned metallic wire or clothing, it is preferable to employ, for example, the following method. That is, the metallic wire or clothing is spirally wound around the drum so that the lower surface of the metallic wire or clothing (the surface without saw teeth or needles) is in contact with the circumferential surface of a cylindrical iron drum. . In this way, a textured roll having protrusions formed by the saw teeth of the metallic wire or the needles of the clothing can be obtained. Therefore, the area of the tip of the convex part of this uneven roll can be made very small, such as 0.01- or less. In order to provide a fusion point in the fiber fleece using a textured roll obtained using a metallic wire, either the calendar method or the ultrasonic method described above can be employed. Further, in order to provide fusion points in the fiber fleece using a textured roll obtained using clothing, an ultrasonic method is mainly employed. This is because the convex portions of the uneven roll are formed of needles, making it difficult to apply large pressure to the fiber fleece. In addition, when obtaining a textured roll using metallic wire or clothing, the metallic wire or clothing is not wound around the entire circumference of the drum, but is wound partially to obtain a textured roll with unevenly distributed protrusions. You can also do it. Furthermore, after winding the metallic wire or clothing around the entire circumference of the drum, the serrations of the metallic wire or the needles of the clothing may be partially broken off and removed to obtain a textured roll with unevenly distributed protrusions. Therefore, by unevenly distributing the convex portions in a certain pattern, it is possible to give the nonwoven sheet various interesting patterns, such as woven patterns. [Example] Example 1 A random fiber fleece having a basis weight of 40 g/rrr and made of polyester continuous filaments having a fiber diameter of 0.5 denier was prepared. This fiber fleece was passed through an ultrasonic oscillator (two times on the front side and two times on the back side, for a total of four times), and the continuous polyester filaments were partially fused to provide a large number of fusion points. This ultrasonic oscillation device consists of an ultrasonic oscillation horn with a frequency of 19.5KH2 on one side, and an uneven roll with a diameter of 300 +++ m obtained by spirally winding a metallic wire around an iron drum on the other side. Note that the metallic wire shown in FIGS. 1 and 2 was used. As a result, in the uneven roll obtained by winding the metallic wire, the area of the tips of the protrusions was 0.01+d,
The number of protrusions was 100/cIil. The nonwoven sheet obtained by the above method had high strength and a supple texture, and exhibited a smooth surface condition with almost no conspicuous fusion points forming a film. Example 2 50 split fibers with a fiber diameter of 2.0 denier and a fiber length of 51 mm
% by weight and 50% by weight of polyester fibers with a fiber diameter of 1.0 denier and a fiber length of 38 mm, with a basis weight of 10 g/rr.
A unidirectional web of f was prepared. A crosslay web (fabric weight: 20 g/nf) having the same fiber composition as the unidirectional web was laminated on both sides of this unidirectional web to obtain a laminated web. Note that this split fiber has a segmented circular shape and has a diameter of 0.
．． 17 denier wedge-shaped polyester microfiber 6
We adopted a material in which books and six 0.17-denier ultrafine polyamide fibers with a wedge-shaped cross section were alternately bonded. Next, an orifice diameter of 0.2 m was added to the above three-layer laminated web.
m, using a nozzle with 1000 orifices/m, twice at a pressure of 75 kg/cnT and 100 kg/ca
Water column flow was applied twice at a pressure of . As a result, the split fibers in the three-layer laminated web were separated into individual ultrafine fibers, and the constituent fibers were tightly entangled with each other, resulting in a fiber fleece that was integrated as a whole. After drying this fiber fleece to remove the moisture in the fleece, it was passed through the same ultrasonic oscillator as in Example I twice (once on the front side and once on the back side) to create a large number of fusion points. Obtained a non-woven sheet with Obtained nonwoven sheet 1
The fabric product was of high quality in terms of strength (modulus), drapability, density, surface abrasion resistance, smoothness, appearance, etc. Example 3 Rayon stable fiber 35ffi with fiber diameter 1.5 denier and fiber length 38 mm! % and high crimp polyester stable fiber with a fiber diameter of 1.5 denier and a fiber length of 51 mm - 65% by weight, with a basis weight of 30 g/
A crosslay web was prepared, subjected to water column flow under the same conditions using the entanglement device used in Example 2, and then dried to obtain an entangled fiber web. On the other hand, a melt-blown web with a basis weight of 20 g/n made of ultrafine polypropylene fibers with an average fiber diameter of 3 microns was heated, and this melt-blown web and the aforementioned entangled fiber web were laminated to obtain a fiber fleece. Example 1
(passed through the ultrasonic oscillator used in

[Copylene ultrafine fibers were partially fused to provide multiple fusion points. The nonwoven sheet obtained in this way has an entangled fiber web and a meltblown web that are completely integrated by a very large number of ultrafine bonding points, and does not suffer from partial delamination or tearing due to external forces. No such phenomenon was observed. This non-woven sheet is equipped with a melt-blown web made of ultra-fine fibers, so 1. It has excellent ability to block bacteria and asbestos powder, etc.
At the same time strength, water and oil repellency, and chemical resistance. Breathability 2: Excellent drapability. Therefore, it can be suitably used as a medical base fabric such as surgical gowns, an industrial base fabric such as work clothes, and a base fabric of short-use garments for events, leisure, travel, etc. [Operation and Effects of the Invention] In the method for producing a nonwoven sheet according to the present invention, unevenness formed with inexpensive metallic wire or clothing is used to provide fusion points in the fiber fleece containing a heat-fusible substance. It uses rolls. Therefore, even if a metal piece or the like accidentally gets mixed into the fiber fleece and the convex part of the uneven roll is damaged,
A damaged uneven roll can be easily and inexpensively regenerated by unwinding the damaged part of the metallic wire or clothing and winding a new metallic wire or clothing. Therefore, compared to recycling conventional engraved rolls, significant savings in cost and time can be achieved. In addition, since the area of the tip of the sawtooth of the metallic wire or the tip of the needle of the clothing is very small, the area of the tip of the convex part of the uneven roll obtained by winding the metallic wire or clothing is also: Very small compared to engraved textured rolls. Therefore, the nonwoven sheet obtained by the method according to the invention: - has a very small area of the individual fusion points;
It provides a smooth appearance and feel, and even when dyed, it has the effect of being able to be dyed with a uniform appearance.

[Brief explanation of drawings]

FIG. 1 is a front view of the metallic wire, and FIG. 2 is a cross-sectional view of the metallic wire shown in FIG. Further, a is the vertical length of the sawtooth, b is the pitch of the sawtooth, and C is the width of the sawtooth.

Claims (1)

[Claims] Heat is applied to the fiber fleece containing a heat-fusible substance by the action of the convex portions of the uneven roll, and the heat-fusible substance is fused in areas corresponding to the convex portions, thereby creating a large number of fusion points. A method for manufacturing a nonwoven sheet, characterized in that the convex portion is formed of metallic wire or clothing.