JPH04194084A - Expandable material - Google Patents

Abstract

PURPOSE:To obtain the subject expandable material having excellent shape- stability and good handleability and capable of improving the working efficiency by applying an adhesive agent composed of a thermoplastic resin to one surface of a compressed nonwoven fabric which increases its thickness by heat- treatment. CONSTITUTION:The objective expandable material is produced by applying an adhesive composed of a thermoplastic resin (e.g. polyethylene or ethylene- vinyl acetate copolymer) to one surface of a compressed nonwoven fabric capable of increasing the thickness by heat-treatment and produced by pressing a nonwoven fabric having high apparent density. When the material is bonded to a cloth to form bulky clothings, filter, brassiere, etc., the product is resistant to separation and shift and to the slippage between the cloth and the material and, accordingly, it has excellent handleability, high working efficiency and extremely large cost merit.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention is applicable to bulky clothing, filters, bra cups,
This invention relates to a bulky material that can be used as a material for shoulder pads, quilts, etc.

[Prior Art] Conventional methods for manufacturing bulky clothing using bulky cotton padding are generally as follows.

■Spreading the padded cotton →■ Cutting the padded cotton into parts larger than the fabric to be sewn →■ Sewing the fabric and batting cotton for each part →■
Form the clothes by sewing the fabrics of the sewn parts together →■
Storage and Transportation of Clothes The filling cotton used to manufacture bulky clothes in this way has a low apparent density, is bulky, and is a non-woven fabric with poor shape stability, so it suffers from various types of E. was.

For example, because the padded cotton is bulky, it is not possible to stack a large number of sheets during spreading, resulting in poor cutting efficiency.
Moreover, it requires a large space for storage and transportation,
There was a cost problem.

In addition, the filled cotton was bulky, had a low apparent density, and had poor morphological stability, making it difficult to handle in each process.

Furthermore, when cutting the padded cotton, it is necessary to cut it to a size larger than the fabric to be sewn, and when sewing the padded cotton and the fabric, it is necessary to cut off the excess portion of the padded cotton, which complicates the manufacturing process. Moreover, there was a large amount of loss due to cutting off the excess portion, which was also an economic problem.

Furthermore, the padded cotton and fabric are likely to separate during the sewing process,
Due to poor workability, the fabric and padding were partially sewn together.
It was necessary to add an additional process to tighten the cotton to prevent it from moving.

However, adding an extra step like this is a matter of jurisdiction, so some attempts have been made to streamline sewing work and improve workability by adding adhesive to the padded cotton and bonding it to the fabric. Even if an attempt is made to bond the filling cotton with the fabric using an adhesive, which has a low apparent density, that is, there are many voids, the contact area between the fibers that make up the filling cotton and the fabric is small. Sufficient adhesive strength with the fabric could not be obtained.

On the other hand, the same problems as above, especially the workability of cutting and sewing,
Cost problems during transportation and storage also arose when manufacturing bra cup materials, shoulder pads, and pillows.

In addition, the thicker the filter, the better the collection efficiency, so it is desirable to increase the thickness. There was a cost problem.

[Problems to be Solved by the Invention] An object of the present invention is to provide a bulk-increasable material that is convenient for workability during the manufacturing process, storage and transportation, and economical efficiency.

[l[! [Means for Solving the Problem] This is a material capable of increasing in bulk, in which a thermoplastic resin adhesive is attached to at least one side of a compressed nonwoven fabric whose thickness increases through heat treatment.

[Function] The bulk-increasable material of the present invention (hereinafter, unless otherwise specified,
The material (simply referred to as "material") is a compressed nonwoven fabric with a thermoplastic resin adhesive (hereinafter simply referred to as "adhesive" unless otherwise specified) adhered to at least one side of the compressed nonwoven fabric.

Since the compressed nonwoven fabric of the present invention is a cloth-like nonwoven fabric with high apparent density, it is easy to handle, improving workability during the sewing process, and has shape stability, allowing for accurate cutting. Since there is no loss and space is not taken up, storage and transportation costs can be kept low.

In addition, an adhesive is attached to the compressed non-woven fabric, and by using this adhesive, the outer material can be
In the case of lining or filter applications, it is possible to obtain adhesive strength that cannot be obtained by adhering to the lining material (hereinafter referred to as "sheet material"), so the sheet material during the A11 work or the filter unit formation work. Since the misalignment can be reduced, there is almost no loss of material, and the above-mentioned workability is improved, resulting in stable quality.

Since a compressed nonwoven fabric with a high apparent density is used, the contact area between the compressed nonwoven fabric and the sheet material is much larger than that of conventional bulky nonwoven fabrics and the sheet material. Therefore, a stronger bond than could previously be obtained can be obtained.

In addition, it uses a type of thermoplastic resin adhesive that melts when heated and solidifies after cooling, making it easy to handle.
If the adhesive is attached to the surface of the compressed nonwoven fabric, it will not interfere with the bulk increase of the compressed nonwoven fabric.

In this way, excellent effects can be achieved by attaching an adhesive to a compressed nonwoven fabric. Compressed nonwoven fabric actually needs to increase its bulk even when used as a compressed nonwoven fabric, so a nonwoven fabric that can increase its bulk is used as a compressed nonwoven fabric, and an adhesive is attached so as not to interfere with the increase in bulk. This is very important.

The compressed nonwoven fabric and adhesive will be described in detail below.

The compressed nonwoven fabric in the present invention refers to a nonwoven fabric that can be increased in bulk and has no cloth-like bulk.

This compressed non-woven fabric is made by fixing a non-woven fabric that maintains its bulky shape in a compressed state using heat-melting fibers, low-melting point resin powder, etc., so that it is thinner and easier to handle.
It is preferably used because of its morphological stability when the bulk is increased. A material is formed by attaching an adhesive to this compressed nonwoven fabric, and this material is used to form clothing, filters, etc., and then heated with dry heat or warm heat to make the heat-fusible fibers, low-temperature The fixing force of the melting point resin powder is loosened, and the bulk is restored by the restoring force of the fiber itself.
Clothes, filters, etc. similar to those obtained using conventional bulky nonwoven fabrics can be obtained.

This compressed nonwoven fabric has already been developed by the applicant in Japanese Patent Application No. 2-10
As disclosed in No. 9184, crimp rate, residual crimp rate,
Crimp modulus is 12 to 70%, 7 to 70%, and 3, respectively.
These II
! After fixing the shape of I in a bulky state using a binder, thermal adhesive fiber, or a low melting point component of a composite fiber, the melting point of the binder, thermal adhesive fiber, low melting point component of the composite fiber, or highly crimped fiber is It is a cloth-like nonwoven fabric that has a high apparent density by compressing and fixing heat-fusible fibers and low-melting point resin powder that have a melting point 10°C or more lower than that of the nonwoven fabric.

However, the compressed nonwoven fabric that can be used in the present invention is not limited to those mentioned above, and any fabric that can be increased in bulk by dry heat or wet heat treatment can be preferably used. For example, it is also possible to use a nonwoven fabric that is made of only fibers and a binder and has both the ability to fix when the binder is compressed and to fix after increasing its bulk. In this nonwoven fabric, the fibers are fixed to each other in a compressed state with no bulk by a binder, but when heated, the fixing force of the binder weakens, the restoring force of the fibers increases the bulk, and then the binder again binds the fibers. The gap is fixed and the shape is maintained.

An adhesive is applied to at least one side of such a compressed nonwoven fabric. For example, when manufacturing bulky clothing,
When the adhesive is attached to one side, the sheet material can be glued to one side of the compressed nonwoven fabric, so you can: ■ Spread the material → ■ Cut each part → ■ Sewing the sheet material on the other side and the parts together at the same time. The sewing process can be simplified by forming the garment → increasing the bulk, and by increasing the bulk, it is possible to obtain a garment with a soft feel and excellent bulk. Also, if adhesive is applied to both sides, the sewing process of sewing the parts together can be easily performed, but if texture and bulkiness are important, it is recommended to apply adhesive only to one side. It is more preferable.

The adhesive used in the present invention fuses in two steps: adhering to the compressed nonwoven fabric and bonding the compressed nonwoven fabric and sheet material by applying heat treatment, so a thermosetting resin was used as the adhesive. Although it can be attached to a compressed nonwoven fabric, it cannot be bonded to a sheet material, so it is necessary to use a thermoplastic resin as the adhesive.

Examples of adhesives that can be used in the present invention include polyethylene, ethylene-vinyl acetate copolymer, ethylene-acrylate copolymer, ethylene-isobutyl acrylate copolymer, polyamide-based, polyester-based,
Butyral type, polyvinyl acetate and copolymer type, cellulose derivative type, polymethyl methacrylate type, polyvinyl ether type, polyurethane type, polycarbonate type, etc. can be used.

In addition, in the present invention, if the adhesive prevents the bulk increase of the compressed nonwoven fabric, bulky clothing, filter units, etc. with sufficient physical properties cannot be obtained. The state in which adhesive is present is expressed as adhesion. In this way, it is preferable that the adhesive attached to the compressed nonwoven fabric be in solid form;
It is preferable to apply an adhesive in the form of a powder, film, web-like sheet, thread, fabric, non-woven fabric, etc. to a compressed non-woven fabric. It can be used because it does not hinder the increase in bulk of the nonwoven fabric.

In addition, when applying an adhesive to paste dots, paste coatings, etc., it is necessary to remove moisture and melt and solidify the adhesive, so heat-melting wAIl!, which fixes the compressed nonwoven fabric in a compressed state, is used. It is necessary to use a low melting point resin powder or an adhesive having a melting point 10° C. or more lower than the melting point of the binder.

This is because, in the process of removing moisture and melting and solidifying, if hot-melt fibers, low-melting resin powder, or adhesives with a melting point higher than the binder are used, during the heating process to melt and solidify, This is because the fixing force of the heat-melting fibers, low-melting point resin powder, or binder becomes weaker, the bulk increases, and the advantages of being cloth-like cannot be obtained.

As described above, methods for adhering the adhesive onto the surface of the compressed nonwoven fabric include coating methods using a roll coater method such as a kiss roll type, a direct roll type, a gravure roll type, a metal ring type, and a reverse roll type; Screen dot method, knife coating method, extrusion coater method, spunbond method,
A method using powder coating, a method using a slot orifice coater, a method using a curtain coater, etc. can be used.

In addition, film-like, spider web-like sheet, thread-like, woven-like,
When attaching a non-woven adhesive, the adhesive can be manufactured separately and then placed on the compressed non-woven fabric and fused. The above adhesive is used to bond the compressed non-woven fabric and sheet material. Since heating is involved during this process, it is necessary to select an adhesive that does not affect the constituent components of the compressed nonwoven fabric.

For example, the melting point of the adhesive is high wound wire #a fiber, which is a component of the compressed nonwoven fabric, a binder that maintains its shape in a bulky state, heat-sealing fiber,
If the melting point is higher than the melting point of the low melting point component of the composite fiber, the compressed non-woven fabric will become film-like at the stage of bonding the compressed non-woven fabric and the sheet material by melting and solidifying the adhesive, and the increaseability of the material will deteriorate. This is because the volume of the compressed nonwoven fabric cannot be increased at the stage of increasing the volume of the compressed nonwoven fabric, and the volume of the compressed nonwoven fabric is lost.

If this adhesive is applied to the entire surface of the compressible nonwoven fabric, the texture will become hard and the pressure loss of the filter will be high. Even if the amount is less, the adhesive strength will be significantly lowered, so it is necessary to select an appropriate application amount depending on the application. For example, 1. When manufacturing material for clothing using spider web adhesive, 1 to 5 g
By setting the amount of shedding to about 0++, sufficient adhesive strength and texture can be obtained.

The material thus obtained was used to make bulky clothing. When making clothes, taffeta, twill,
Fabric products such as satin, satin, and octopus, coated cloth, film laminated cloth, moisture-permeable waterproof fabric such as high-density fabric, outer materials such as natural leather and artificial leather, taffeta, satin,
It is bonded to the lining of woven products such as de Chine, knit products such as tricot, pile knitting, and fleece knitting.

On the other hand, in the case of filter applications, there are various types of net-shaped materials such as punched metal and expanded metal that can increase filter strength, as well as non-woven fabrics such as split cloth and spunbond, which increase the resistance of the processing fluid. It will not be glued to the coarse material.

Note that when adhering the sheet material and the material via an adhesive, it is desirable to heat and press them simultaneously to integrate them. This is because although the adhesive used in the present invention has a lower melting point than the binder, heat-adhesive fiber, highly crimped fiber, heat-fusible cotton fiber, low-melting point resin powder, etc. that make up the compressed nonwoven fabric, the sheet material When adhering to the adhesive, a temperature higher than the melting point of the adhesive is applied, which may increase the bulk. Therefore, it is preferable to apply pressure to prevent the bulk from increasing.

Note that if the pressure applied when bonding the material and the sheet material is not applied, the adhesive will enter the inside of the compressed nonwoven fabric and bond and fix the constituent fibers, increasing the bulk of the compressed nonwoven fabric. In this case, since it is not possible to increase the thickness sufficiently, it is preferable to heat the material at intervals such as the sum of the thicknesses of the material and the sheet material, and to apply pressure to an extent that suppresses the increase in bulk of the material.

The effects of using the material of the present invention will be explained below.
A case in which bulky clothing is manufactured will be described in detail as an example.

When using the material of the present invention, the method for manufacturing bulky clothing is as follows.

■Adhesion of sheet material and rope material→■Spreading→■Cutting→■Sewing the cut pieces together→■Storage and transportation→■Increasing the bulk of the accumulated material In this way,
When the material of the present invention is bonded to a sheet material, work efficiency is greatly improved because it has dimensional stability, is easy to handle as it is like a cloth without bulk, and there is no fear that the material and the fabric will shift. It will be possible to manufacture bulky clothing with less material loss.

Looking more closely at the process of manufacturing bulky clothing using the material of the present invention, the following effects occur in each process.

First, in the spreading process, it was necessary to align bulky nonwoven fabrics, prevent distortion in bulky nonwoven fabrics, and reduce folding errors of bulky nonwoven fabrics, but conventional bulky nonwoven fabrics do not meet these requirements. It was difficult to satisfy the conditions.

However, when the material of the present invention is adhered to a fabric, the above conditions can be easily satisfied because there is no need to know.

In addition, since the material of the present invention is less than one-fifth of the thickness of conventional bulky nonwoven fabrics, the number of times the fabric can be folded in one spreading can be increased several times compared to conventional methods, and the spreading process can be reduced. It can also be automated, dramatically improving work efficiency.

Next, in the cutting process, when cutting each part of the garment, conventionally the bulky non-woven fabric is cut to a larger size than the fabric to be sewn together, and the fabric and bulky non-woven fabric are sewn together for each part to remove excess fabric. Previously, it was necessary to cut off parts, but since the material and fabric are glued together, it is possible to streamline the work by omitting the work of cutting larger pieces and cutting off excess parts as described above. This eliminates the wasted material, saves material, and brings favorable results in terms of cost. In addition, since it is a thin cloth-like material, its cutting performance is improved, making it possible to manufacture clothes with greater precision.

Furthermore, as in the spreading process, by increasing the number of stacked sheets during cutting and automating cutting, cutting can be performed with higher efficiency.

Next, in the sewing process, the cut parts are sewn together to form clothes, but since the material of the present invention is already glued to the fabric, there is no worry that the material and fabric will shift during sewing. Moreover, since it is thin and stable in form, it is easy to handle and has excellent workability.

Clothes sewn with the materials of the present invention bonded together can be stored and transported without bulk, so they do not require a large storage space as in the past, and transportation costs are significantly reduced.

After transportation, bulky clothing is completed by applying dry or wet heat to increase the bulk of the material.

How the bulk of the material is increased depends on how the compressed nonwoven fabric constituting the material is compressed and fixed. For example, when a water-soluble polymer such as polyvinyl alcohol is used as a binder to be compressed and fixed, it is preferable to treat it with steam at about 100° C. because the bulk increases easily.

[Example] (Example 1) Highly crimped polyester fiber (3dx 51am, melting point 25
6℃) and 90% by weight of low melting point core-sheath type composite polyester m
H (3dx 51mm, core melting point 256℃, sheath melting point 8
By carding 10% by weight (7°C), a fibrous web with a basis weight of 55 g IC was obtained. Thereafter, the resulting fibrous web was fixed between m strings using a self-crosslinking acrylic acid emulsion binder to obtain a nonwoven fabric with a basis weight of 60 g/m'. The obtained nonwoven fabric was heated to fA degree of 100°C and gauge pressure of 2k.
Compression pressing was performed using a heat roll of g/cm' to obtain a cloth-like compressed nonwoven fabric.

A cobweb-like sheet of polyamide resin (melting point 100°C, basis weight 5g/■1) is used as an adhesive on one side of this compressed nonwoven fabric.
After laminating the layers, the materials were melted using a Nojito roll at a temperature of 100° C. and a gauge pressure of 2 kg/cm to obtain the material of the present invention.

Nylon taffeta was laminated on the web-like sheet side of this material, and the nylon taffeta and material were bonded together using a Nojito roll at a temperature of 100° C. and a gauge pressure of 2 kg.

When we measured the peel strength of this bonded material, we found that the adhesive force between the material and the nylon taffeta was strong enough to cause the base fabric to break, and it was found that the adhesive force between the material and the nylon taffeta was strong enough to cause the fabric to peel when manufacturing bulky clothing. It was extremely easy to work with.

Furthermore, when the bonded material was exposed to steam at 100°C, the thickness of the material increased by 12 times, resulting in a normal bulky padded cotton.

(Example 2) Instead of the low melting point core/sheath type composite polyester fiber of Example 1, fibers of low melting point core/sheath type composite polyester fiber (3dX 51, core melting point 256°C, sheath melting point 110°C) were used. A nonwoven fabric having a basis weight of 60 g/m' was obtained in the same manner as in Example 1 except that the following was used. This nonwoven fabric was heated at a temperature of 120°C and a gauge pressure of 2
Compression pressing was performed using a heat roll of 1.5 kg/cm" to obtain a cloth-like compressed nonwoven fabric.

A roll coater is applied to one side of this compressed nonwoven fabric as an adhesive.
A paste-like polyamide resin (melting point 86℃,
After imparting a basis weight of 3 g/g+''), the material was melted and dried using a dryer at a temperature of 100° C. to obtain the material of the present invention.

Nylon taffeta was laminated on the resin-treated surface of this material, and the nylon taffeta and material were bonded together using a heat roll of door 1 at a temperature of 100° C. and a gauge pressure of 2 kg/c.

When we measured the peel strength of this bonded material, we found that the adhesive force between the material and the nylon taffeta was strong enough to cause the base fabric to break, and it was found that the adhesive force between the material and the nylon taffeta was strong enough to cause the fabric to peel when manufacturing bulky clothing. It was extremely easy to work with.

When the bonded material was heated in a dryer at 150° C., the thickness of the material increased tenfold, resulting in a bulky padded cotton.

(Comparative example) A compressed nonwoven fabric obtained in the same manner as in Example 1 was laminated with nylon taffeta without adhering an adhesive, and the temperature was 100°C.
The low melting point core-sheath type composite polyester MA, which fixes the compressed nonwoven fabric in a compressed state by passing it between heat rolls with a gauge pressure of 3 kg/cm'', was also used as an adhesive with the nylon taffeta to bond it. .

When the peel strength was measured, it was found that there was almost no adhesive force and it was easy to peel off. Therefore, as a matter of course, it easily peels off during sewing work, resulting in extremely poor workability.

(Example of use) After laminating the web-like sheet of the material of Example 1 with nylon taffeta with the material in between, the material and nylon taffeta were laminated using a heat roll at a temperature of 100°C and a gauge pressure of 2 kg/am. Then, using twill as the other fabric, clothes were manufactured in the following order: ■ Spreading → ■ Cutting → ■ Sewing → ■ Storage and transportation → ■ Increasing the bulk of the material. In the spreading and cutting process,
12 times more sheets than conventional bulky non-woven fabrics,
#1 iWfI could be done all at once, resulting in significant streamlining.

In addition, the material is thin and has excellent shape stability, so the cut material can be used with twill and 1a! Not only was it easy to handle and excellent in workability in the 11 process, but it was also economically superior as it enabled large quantities to be stored and transported.

It should be noted that the bulk of clothes manufactured from this material also increased satisfactorily by treatment with steam at 100° C. for 30 seconds, making it possible to easily obtain bulky clothes.

The obtained clothes also had excellent dry cleaning resistance.

[Effects of the Invention] Since the bulk-increasable material of the present invention is based on a compressed nonwoven fabric whose bulk increases by heating, it is a material with excellent workability and cost during manufacturing, storage, and transportation.

Furthermore, since the adhesive is a thermoplastic resin, it can be bonded to the sheet material, and since the adhesive is attached to the surface of the compressed nonwoven fabric, it does not hinder the bulk of the compressed nonwoven fabric.

Specifically, the effects of creating bulky clothing by bonding the material of the present invention to fabric are as follows: (1) The material is easy to align during the spreading process, which does not cause distortion or folding errors. In addition, by increasing the number of stacked sheets, work efficiency is greatly improved.

(2) In the cutting process, the conventional process of cutting the fabric to be larger than the fabric to be sewn together, joining the fabric and non-woven fabric for each part, and cutting off the excess at the same time can be omitted; This eliminates losses and brings about favorable results in terms of cost. Further, since the number of sheets to be cut is large, the workability is greatly improved.

(3) In the sewing process, there is no misalignment between the fabric and the material during sewing, and the fabric is thin and easy to handle, so bulky clothing can be manufactured with greater precision.

In addition, the process of tightening, which was conventionally performed to prevent misalignment between the fabric and the material, can be omitted, making it possible to streamline the process.

(4) Since storage and transportation can be carried out before the bulk of the material increases, no space is required, and storage and transportation costs can be significantly reduced, which is a great cost advantage.

The above description is for the case of manufacturing clothes, but the material that can increase the bulk of the present invention is not limited to clothes, but can be used for filters, bra cups, shoulder pads, pillows, etc. .

Claims (1)

[Claims] (1) A material capable of increasing bulk, characterized in that a thermoplastic resin adhesive is attached to at least one side of a compressed nonwoven fabric whose thickness increases through heat treatment.