EP0277234A1 - Verfahren zur herstellung von nicht-gewobenem gewebe - Google Patents
Verfahren zur herstellung von nicht-gewobenem gewebe Download PDFInfo
- Publication number
- EP0277234A1 EP0277234A1 EP87903431A EP87903431A EP0277234A1 EP 0277234 A1 EP0277234 A1 EP 0277234A1 EP 87903431 A EP87903431 A EP 87903431A EP 87903431 A EP87903431 A EP 87903431A EP 0277234 A1 EP0277234 A1 EP 0277234A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- web
- woven fabric
- manufacturing
- treatment
- set forth
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000004745 nonwoven fabric Substances 0.000 title claims abstract description 51
- 238000000034 method Methods 0.000 title claims abstract description 50
- 230000008569 process Effects 0.000 title claims abstract description 22
- 239000000835 fiber Substances 0.000 claims abstract description 98
- 239000004744 fabric Substances 0.000 claims abstract description 37
- 239000012530 fluid Substances 0.000 claims abstract description 27
- 238000009826 distribution Methods 0.000 claims abstract description 9
- 238000011282 treatment Methods 0.000 claims description 38
- 238000004519 manufacturing process Methods 0.000 claims description 33
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 26
- 238000003825 pressing Methods 0.000 claims description 9
- 238000005314 correlation function Methods 0.000 claims description 5
- 230000007423 decrease Effects 0.000 claims description 4
- 229920001474 Flashspun fabric Polymers 0.000 claims description 2
- 239000004751 flashspun nonwoven Substances 0.000 claims description 2
- 238000007664 blowing Methods 0.000 claims 1
- 150000002500 ions Chemical class 0.000 claims 1
- 230000001678 irradiating effect Effects 0.000 claims 1
- 238000009987 spinning Methods 0.000 abstract description 19
- 230000002829 reductive effect Effects 0.000 abstract description 6
- 239000000306 component Substances 0.000 description 23
- 238000004080 punching Methods 0.000 description 21
- -1 poly(butylene terephthalate) Polymers 0.000 description 10
- 238000003475 lamination Methods 0.000 description 8
- 229920002292 Nylon 6 Polymers 0.000 description 5
- 150000001450 anions Chemical class 0.000 description 4
- 150000001768 cations Chemical class 0.000 description 4
- 230000008859 change Effects 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 229920002678 cellulose Polymers 0.000 description 3
- 235000010980 cellulose Nutrition 0.000 description 3
- 229920001577 copolymer Polymers 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 230000004927 fusion Effects 0.000 description 3
- 239000010985 leather Substances 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 230000002441 reversible effect Effects 0.000 description 3
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 description 2
- 239000001913 cellulose Substances 0.000 description 2
- 239000008358 core component Substances 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 150000002148 esters Chemical class 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 2
- 238000002074 melt spinning Methods 0.000 description 2
- 239000008041 oiling agent Substances 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 229920000139 polyethylene terephthalate Polymers 0.000 description 2
- 239000005020 polyethylene terephthalate Substances 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- QMMJWQMCMRUYTG-UHFFFAOYSA-N 1,2,4,5-tetrachloro-3-(trifluoromethyl)benzene Chemical compound FC(F)(F)C1=C(Cl)C(Cl)=CC(Cl)=C1Cl QMMJWQMCMRUYTG-UHFFFAOYSA-N 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 description 1
- 208000034888 Needle issue Diseases 0.000 description 1
- 229920000305 Nylon 6,10 Polymers 0.000 description 1
- 229920002302 Nylon 6,6 Polymers 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000002202 Polyethylene glycol Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 229920000297 Rayon Polymers 0.000 description 1
- 235000010724 Wisteria floribunda Nutrition 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 150000001408 amides Chemical class 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 230000006378 damage Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- LQZZUXJYWNFBMV-UHFFFAOYSA-N dodecan-1-ol Chemical compound CCCCCCCCCCCCO LQZZUXJYWNFBMV-UHFFFAOYSA-N 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000004299 exfoliation Methods 0.000 description 1
- 230000003619 fibrillary effect Effects 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 239000012510 hollow fiber Substances 0.000 description 1
- 239000012770 industrial material Substances 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000003595 mist Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 230000036961 partial effect Effects 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 229920002959 polymer blend Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 239000002964 rayon Substances 0.000 description 1
- 238000007790 scraping Methods 0.000 description 1
- 238000003892 spreading Methods 0.000 description 1
- 230000007480 spreading Effects 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 238000009864 tensile test Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
Classifications
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
- D04H3/03—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments at random
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
Definitions
- This invention relates to a novel method of manufacturing non-woven fabric. Particularly, it relates to a method of directly manufacturing fabric enabling to extend the width with a spinning machine of a small number of spindles.
- the present invention is intended to resolve the foregoing problems. Specifically, it aims at distinguished homogeneity, high isotropy, simple width setting, weight setting, production of broad products with a small investment and less selvage loss.
- the present invention is essentially as follows.
- non-woven fabric which is characterized in that filaments carried on a high speed fluid are collected in the form of a web and that such webs are introduced in a cloth lapper into a lapped web, or more preferably, characterized in that the web in the foregoing method has a cross section in which the weight near each selvage gradually decreases toward the selvage and terminates in the selvage.
- the first point of the invention exists in the following. That is, while the prior art found the reasonableness directly in the high productivity of fabric, the method of the present invention has its merit found in the combination with a cloth lapper of low productivity against said high productivity.
- the cloth lapper produces "lines" incidental to lapping, resulting in defective non-woven fabric with lines.
- the webs were usually made as thinner as practicable as they came out of a short staple card or web making machine before lapping and were lapped in 50 to 60 sheets at a high speed (from the standpoint of productivity) to prevent non-uniformity accompanying the cloth lapping.
- a preferable method of the invention that is, when the spun fiber filaments are drawn on a high speed air flow to form on the collecting surface a continuous web having the selvages in the form of the skirt of Mt.
- a particularly preferable method of the invention is to apply the filaments withdrawn by a high speed fluid flow onto a reflecting plate or surface which has its direction changed repeatedly to scatter the filaments and thus very effectively form a web of a smooth and even mountainous distribution.
- the web of the mountainous distribution has a selvage expressed by the formula where Y is weight in unit of g/m 2 , and X is the distance from the selvage edge of the web in unit of cm.
- the web is cut into squares of a side of 5 cm successively from the selvage edge, and the weight of each square is measured. This procedure is repeated five times for a web, and the mean values are obtained to provide a weight distribution curve in the direction of width of the web.
- the distance to a point of 20 cm from the selvage edge of the web and a primary regression curve of weight are obtained.
- five values are, of course, to be used for the distance and weight respectively in obtaining the primary regression curve.
- each selvage of the web is within the range of the foregoing formula.
- a particularly preferable form of the web selvage is that expressed by the formula or, more preferably, by the formula
- a web a correlation function of said primary regression curve of 0.55 or higher is preferable.
- a web of a correlation function of 0.65 or higher is preferable.
- the selvages are very smooth, and so a good web laminate is provided with a small number of webs.
- the width of the selvage (where weight changes) is subject to vary with the overall breadth of the web and is not determinable generally, but in many cases, a width of about 20 cm will suffice. It is also possible to electrostatistically repulse the fibers with one another by forced or frictional charging to provide a web having a more homogeneous central part and smoothly decreasing selvages.
- the fluid used for withdrawing the fibers may be air, steam, water or a combination thereof, but a preferable fluid is a gas comprised mainly of air or steam.
- Air is easy to handle, and steam is advantageous in that it allows collection of fibers and, at the same time, heat treatment or stretching and orientation.
- a liquid such as water, it allows a high speed for drawing and is, therefore, effective when a high degree of orientation is aimed at.
- Such fluid is normally used at room temperature, but by using, for example, high temperature air, the filament quality can be modified.
- the fibers collected by such fluid is not particularly limited.
- the fibers may be in the form of filaments or those obtainable by melt blow or flash spinning. That the fibers are collected in a mountainous distribution enhances the advantages of the method of the invention.
- the mountainous distribution is readily obtainable of the fibers in the form of filaments or staples if they are carried on a fluid for collecting.
- the filament, very fine fiber, melt-blow fiber and flash spun fiber could hardly transformed into a web, and so that the method of the invention is applicable to them is very significant.
- any material that can be provided in the form of a fiber is usable.
- esters such as poly(butylene terephthalate) and Poly(ethylene terephthalate), nylons such as nylon 6, 66 and 610, polyolefins such as polyethylene and polypropylene, flexible polyurethanes, copolymers of poly(tetramethylene glycol) and an amide, ester or urethane, and regenerated celluloses such as rayon.
- the fiber used according to the method of the invention may be comprised of one component or be a multi-component fiber.
- fibers that can be subdivided by chemical treatment, mechanical treatment or heat treatment or a combination thereof are preferable.
- those having a plurality of fibers generated from a fiber are preferable.
- the sea-island fiber, radially subdividable fiber and radially subdividable hollow fiber are representative.
- Such fibers are collected by a fluid flowing at a high speed into a web.
- any well known method is usable, and thus the collecting method is not limited in any way.
- the velocity of the high speed fluid is subject to vary with the kind of the fiber or fluid and is not generally determinable, and it must be determined appropriately through testing.
- the speed at which the fiber is spouted or drawn that is, 2000 m/m or more or, more particularly, 3000 m/m is preferable.
- the web obtained by such method may be directly introduced to a cloth lapper into a laminate.
- preliminary bonding is desirable.
- the non-woven web is very unstable in the form with the fibers merely overlaid upon one another, and in the process of introducing to the cloth lapper for lamination, it may have a web disturbance such as scraping, cramping or stretching generated by a turbulence or trap, resulting in uneven folding at the time of lamination to make it difficult to obtain a satisfactory non-woven fabric.
- the high speed fluid treatment, needle punching, adhesion, fusion and pressing are suitable for such preliminary bonding.
- Such treatment is chosen appropriately depending on the purpose, use and the kind of the fibrous material. Bonding by means of high speed fluid or needle punch has a great degree of freedom of bond between the fibers and is thus advantageous in that various processings are allowed latter. It also provides a flexible product.
- the fluid or, more particularly, water jet or air jet is suitable for treating a web of very find fibers.
- the needle punch may have the needle broken when it is applied to the very fine fibers. But, the high speed fluid flow is free from such problem. It also facilitates interwining.
- the heat pressing with a calendar roll or belt nip used is fast in the processing speed and has thus a great advantage that the productivity is high.
- this method used it is also enabled to suppress the hardening of the texture by using a composite fiber having the core component of a higher melting point than the sheath component.
- the web is charged to preclude smooth movement from the cloth lapper or from the preceding collecting device to the subsequent process. This was particularly noticeable when a web comprised of a less conductive thermoplastic fiber was carried at a high speed, producing a problem that the transfer of the non-woven web from the carrier to the laminate support would become irregular, resulting in uneven folds.
- the charge of the web is quickly neutralized to allow the web to drop stationarily from the carrier. That is, a non-woven fabric having the folds evenly arranged is obtainable with less selvage cut loss and improvement of the process yield.
- the apparatus used for the method of the invention is preferably made of materials which are scarcely charged.
- Apparatus having a coat of conductive substance over the surface or comprised of conductive materials is preferable.
- apparatus having the surface comprised mainly of cellulose and/or cellulose derivative of a small electric resistance is particularly preferable.
- the type of the cloth lapper is not specifically limited. But, a cloth lapper having the carrier comprised of a pair of belts and carrying the non-woven web between them is preferable as the non-woven web is scarcely disturbed. Particularly, a cloth lapper of the type pressing the web constantly while lapping is preferable. As a cloth lapper of this type repeatedly lapping while pressing the lapped web to the conveyor, the product of Asran, France, is well known. Moreover, the cloth lapper of this type features in that the lapping speed is high and that the web is not disturbed by the wind incidentally generated by the reciprocal movement.
- the web When the web is too thin, it is entwined over the lattice on the cloth lapper and is hardly laminated. In such case, the web should be lapped continuously on a carrier which is comprised of a gas permeable member and has its back side adapted to slide over the suction port of a gas suction device.
- a non-woven web of lower weight had a problem of being so much more disturbed by the turbulent flow or mechanical vibration when placed on the carrier, resulting in uneven folds at the edges or creaps generated, and a satisfactory process yield was hardly attained. But, by holding the web on the carrier surface through suction, very exact, stable and efficient laminating is enabled.
- the number of layers to be laminated by the cloth lapper is preferably 3-60, or more preferably 5-50, from the uniformity of weight and productivity of the equipment.
- the web thus laminated is directly usable effectively. But, it is preferable to bond the layers further for improvement of the ease of handling, physical property and homogeneity.
- the high speed fluid treatment, needle punching, adhesion, fusion and pressing are applied depending on the use.
- the high speed fluid treatment is suitable for production of a flexible non-woven fabric of a weight of 300 g/m 2 or less or treatment of very fine fibers or partially fibrillary fibers.
- the needle punching is used for production of a non-woven fabric of 100 g/m 2 or more, and the adhesion, fusion and pressing are used for production of a non-woven fabric of which a hardness or repulsiveness is required and for production of a sheet used in the field where omission of fibers from the sheet is shored.
- these treatments are usable in combination.
- needle punching is taken for example, when a foundation for artificial suede leather is to be provided, needle punching of 100 needles/cm 2 or more, particularly 1000 needles/cm or more, is preferable. When the foundation is for silvering leather, needle punching less than 2000 needles/cm is generally effective. For development to the sanitary field such as diaper, needle punching of about 200 needles/cm 2 will suffice. Of course, these values are subject to change with the type of the needle.
- the fibers constituting the web laminated by the cloth lapper are generally oriented in a lateral direction, and so stretching the laminated web is effective for controlling the direction of orientation of the fibers. By taking such measure, it is enabled to improve the anisotropy in physical property of the sheet obtained. Stretching of the laminated web is preferably made before the bonding treatment of the laminated web. It is, of course, preferable to give a bonding treatment, then stretching and again give a bonding treatment. Stretching may also be made simultaneously with the bonding treatment.
- the multi-core fibers subdividable into a number of core components such as a polymer oriented fiber, the so-called exfoliating type fibers and the polymer blend fibers.
- the fibers may, of course, be subdivided in the preliminary bonding or any other treatment. Subdivision does not always mean that the fiber is subdivided over the whole length and includes partial subdivision.
- Needle punching has less movement or sliding of fibers with finer fiber to produce needle breaking. As the result, the fibers are not entwined together, but the non-woven fabric has the apparent density increased, that is, takes the so-called corrugated board structure and has thus the quality degraded.
- the fluid jet or, more specifically, water jet punching works more effectively as the fiber becomes finer and is, therefore, preferable for 0.2 denier or less or, more particularly, 0.07 denier or less.
- the water jet punching it is also possible to exfoliate the multi-core fibers or remove the bond component, and in this case, it is possible to directly produce a non-woven fabric having very fine fibers highly entwined.
- the multi-core fibers or relatively thick fibers needle punching is suitable and that water jet punching is suitable for the fibers which are adapted to become thin or have become thin.
- the method of the invention satisfies both successfully.
- those sea-island type fibers which have the sea component dissolve in water or hot water.
- the sea-island fibers having the island component further transformed into a sea-island structure may have the very find fibers obtained readily or the island component removed readily.
- the number of islands is preferably 50 or more or, more preferably, 100 or more.
- the upper limit may be as large as 10,000, but for increasing the proportion of the island component to the sea component, 1000 or less is preferable, 500 or less being more preferable.
- the proportion of the island component is preferably 75 percent or higher or, more preferably, 85 percent or higher, and the sea component is preferably watersoluble.
- the needle punching it- is desirable to apply a slippery oiling agent to the fibers. It is also desirable to perform the needle punching with the web heated at a temperature of from 40°C to 100°C.
- a columnar jet flow rather than a mist flow is preferable.
- a preferable water pressure is 70-150 kg per square centimeter.
- the water temperature should be 30-60°C, more preferably 45-60°C.
- Multi-core fibers using for one component a hot water soluble sea component of a copolymer of terephthalic acid, isophthalic acid or 5-sodium-sulfoisophthalic acid with ethylene glycol or a copolymer having polyethylene glycol further copolymerized are particularly suitable.
- a polyalkylether or its compound is added to the sea component, destruction of the sea component by the water jet is accelerated to enhance the entwining effect.
- water of a former stage covers the surface of the web to reduce the effect of the subsequent water jet, and so draining water quickly by suction becomes an effective method for entwining.
- Rectangular samples of 5 cm x 20 cm were taken for the lateral and longitudinal directions respectively, and using a constant speed tensile testing machine of a tensile speed of 10 cm/min, the values of maximum strength and the elongation at the maximum strength were measured and taken as the lateral and longitudinal tensile strength (kg/5 cm) and lateral and longitudinal tensile elongation (%).
- the correlation function of X and Y was 0.88. This web was lapped in a width of 58 inches while it was held by a high speed cloth lapper, product of Asran, France, in 20 laps (pitch 12 cm). In the ordinary card webbing, this was in shortage in the number of lappings, but a very clean cloth lap web was formed with selvages neatly arranged. Weight was about 120 g/m 2 . It was subjected to needle punching at a needle density of 50 needles/m 2 then to water jet punching. The water jet was of oscillating type, and an impact treatment was given at a water pressure of 100 kg/cm 2 through a nozzle having a number of small holes of 0.23 mm diameter arranged at a pitch of 6 mm.
- Nylon 6 was spun through a spinning device having two spinning nozzles disposed in a longitudinal direction at a spacing of 32 cm, each nozzle having 156 nozzle holes of a diameter of 0.15 mm, at a spinning temperature of 265°C, then drawn through air ejectors respectively at 5000 m/min, and the filaments thus obtained were guided to hit a metal surface for opening by frictional charging then deposited on a moving wire gauge, and there was obtained a web of a single fineness of 0.5 denier, mean weight of 4.8 g/m 2 and width of 110 cm. Observing the weight distribution of the web by an optical weight gauge incorporated on line, it presented a form of mountain foot having a flat central part and gradually decreasing side parts. The web had a nearly uniform weight for about 70 cm at the central part and was a good one with the web weight (Y) and the distance from the web selvage end (X) expressed by the formula
- the correlation function of X and Y was 0.83.
- the web had a pressing treatment rendered as a preliminary bonding treatment by a pair of 50 cm diameter calendar rollers heated at a surface temperature of 160°C, then it was guided to the carrier of a cloth lapper and had air containing anions and cations irradiated and was continuously dropped on a moving support comprised of a gas permeable unit the back of which slides in contact with the suction port of a gas suction device, with the atmosphere in the vicinity of the surface of said gas permeable unit sucked in the backward direction, into a laminate of 10 layers in the mean number of lamination and a width of 5.9 cm.
- the top and reverse surfaces were alternately treated twice repeatedly by a high pressure, high speed columnar flow of 25 kg/cm 2 from a rectangular nozzle having a number of 0.2 mm diameter nozzle holes arranged at a spacing of 1.2 mm which moves reciprocally at an amplitude of 1.2 mm and 20 cycles on the support, then the laminate was dried by hot air of 120°C, and there was obtained a long fiber non-woven fabric of a mean weight of 52 g/m 2 and a width of 5.7 m.
- this long fiber non-woven fabric was, when compared with the reference, of a broader width, very small in the weight variation as well as anisotropy, high in the process yield, with the trace of lamination by the cloth lapper scarcely observed and the folds at both ends well arranged, and was thus of a high grade in appearance and was very suitable for clothing such as operating gown or dust-free clothing or as an industrial material for leather or filter foundation.
- Example 2 A web was obtained similarly to Example 2. It was guided to the carrier of a cloth lapper and had air containing anions and cations irradiated then had the lamination, bond treatment and bonding made similarly to Example 2, and there was obtained a long fiber non-woven fabric the mean weight and width of which were nearly the same to those in Example 2. With respect to the weight variation and anisotropy, this long fiber non-woven fabric was a distinguished one similar to that of Example 2, as shown in Tables 1 and 2. The process yield was far distinguished over the reference.
- Example 2 Similarly to Example 2, a web was obtained. It was guided to the carrier of a cloth lapper with no preliminary bonding treatment rendered, then had a voltage of 30 k V applied by a high voltage generator, product of Kasuga Denki, and air containing anions and cations irradiated. Thereafter, it was successively dropped on a moving wooden lattice into a laminate of 10 layers in the mean number of layers and a width of 5.9 m. Further, under the same conditions with Example 2, a bonding treatment and drying were made, and there was obtained a long fiber non-woven fabric which was nearly the same with Example 1 in the mean weight and width. As shown in Tables 1 and 2, this long fiber non-woven fabric was a distinguished long fiber non-woven fabric similar to Example 2 so long as the weight variation and anisotropy were concerned. The process yield was considerably distinguished over the reference.
- the direction and angle of the metal surface were carefully adjusted so that the filaments would be deposited as evenly as practicable, while a side plate having a high voltage of 50 kV loaded in order to prevent the web from spreading excessively was provided at each end of the wire gauge conveyor.
- the web had the top and reverse surfaces alternately treated twice repeatedly by a high pressure, high speed columnar flow of 25 kg/cm 2 from a reactangular nozzle having a number of 0.2 mm nozzle holes arranged at a spacing of 1.2 mm which makes a reciprocal movement at an amplitude of 1.2 mm and (a frequency of) 20 cycles in the direction of the width on a support comprised of a 100 mesh wire gauge conveyor.
- the web was dried by hot air of 120°C and had the selvages cut, and there was obtained a long fiber non-woven fabric of a mean weight of 52 g/m 2 and a width of 1.0 m.
- This long fiber non-woven fabric was inferior in the weight variation and anisotropy to Examples 2, 3 and 4 and involved a great selvage cut loss, resulting in a low yield, degraded appearance and smaller width.
- each spinning unit comprised of a melt spinning machine, an air ejector and a reflecting plate
- a web consisting of nylon 6 filaments of a mean single size of 0.9 denier and having a mean weight of 14 g/m 2 , a width of 50 cm and selvages similar to those of Example 2.
- the web had an oiling agent (butylstearate, 6%; ethylene oxide additive of lauryl alcohol, 4%; phosphate static eliminator, 1%; and water, 89%) applied in an amount of 4.5% to the web weight.
- the stretched laminate was guided to a needle punch for a bonding treatment from both top and reverse surfaces at a needle density of 300 needles/cm 2 , then after drying, had each selvage cut by 2 cm, and there was obtained a long fiber non-woven fabric of a mean weight of 180 g/m 2 and a width of 4.46 m at a speed of 0.5 m/min.
- the tearing strength of the non-woven fabric thus obtained was 3.9 kg/4.1 kg in longitudinal/lateral direction. With a non-woven fabric obtained similarly except stretching, the tear strength was 4.8 kg/3.0 kg.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP134403/86 | 1986-06-10 | ||
JP61134403A JPS62299557A (ja) | 1986-06-10 | 1986-06-10 | 不織布の製造方法 |
Publications (3)
Publication Number | Publication Date |
---|---|
EP0277234A1 true EP0277234A1 (de) | 1988-08-10 |
EP0277234A4 EP0277234A4 (de) | 1988-10-24 |
EP0277234B1 EP0277234B1 (de) | 1991-11-13 |
Family
ID=15127571
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP87903431A Expired - Lifetime EP0277234B1 (de) | 1986-06-10 | 1987-05-28 | Verfahren zur herstellung von nicht-gewobenem gewebe |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP0277234B1 (de) |
JP (1) | JPS62299557A (de) |
KR (1) | KR880701301A (de) |
DE (1) | DE3774561D1 (de) |
WO (1) | WO1987007658A1 (de) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH03269151A (ja) * | 1990-03-16 | 1991-11-29 | Kanebo Ltd | 不織布の製造方法 |
JP5159139B2 (ja) * | 2007-03-29 | 2013-03-06 | 株式会社クラレ | 長繊維不織布の製造方法および人工皮革用基材の製造方法 |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3798100A (en) * | 1971-04-26 | 1974-03-19 | Rhone Poulenc Textile | Apparatus for making spunbonded fabrics |
US3903568A (en) * | 1966-07-29 | 1975-09-09 | Celanese Corp | Production of batting |
DE3501897A1 (de) * | 1985-01-22 | 1986-07-24 | Bayer Ag, 5090 Leverkusen | Verfahren zur herstellung einer mehrlagigen fasermatte |
Family Cites Families (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1495564A (en) * | 1974-05-03 | 1977-12-21 | Ici Ltd | Non-woven fabric |
JPS58169557A (ja) * | 1982-03-31 | 1983-10-06 | 東レ株式会社 | 交絡不織布およびその製造方法 |
JPH0834748B2 (ja) * | 1984-04-25 | 1996-03-29 | 旭化成工業株式会社 | 不織ウェブの製造方法 |
JPS6216206A (ja) * | 1985-07-15 | 1987-01-24 | Sanyo Electric Co Ltd | 垂直磁気ヘツド |
JPS62162064A (ja) * | 1986-01-10 | 1987-07-17 | 日本不織布株式会社 | 不織布の製造方法 |
CA2076127A1 (en) * | 1991-09-26 | 1993-03-27 | Louis R. Nerone | Electronic ballast arrangement for a compact fluorescent lamp |
-
1986
- 1986-06-10 JP JP61134403A patent/JPS62299557A/ja active Granted
-
1987
- 1987-05-28 EP EP87903431A patent/EP0277234B1/de not_active Expired - Lifetime
- 1987-05-28 KR KR1019880700144A patent/KR880701301A/ko not_active Application Discontinuation
- 1987-05-28 WO PCT/JP1987/000341 patent/WO1987007658A1/ja active IP Right Grant
- 1987-05-28 DE DE8787903431T patent/DE3774561D1/de not_active Expired - Fee Related
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3903568A (en) * | 1966-07-29 | 1975-09-09 | Celanese Corp | Production of batting |
US3798100A (en) * | 1971-04-26 | 1974-03-19 | Rhone Poulenc Textile | Apparatus for making spunbonded fabrics |
DE3501897A1 (de) * | 1985-01-22 | 1986-07-24 | Bayer Ag, 5090 Leverkusen | Verfahren zur herstellung einer mehrlagigen fasermatte |
Non-Patent Citations (1)
Title |
---|
See also references of WO8707658A1 * |
Also Published As
Publication number | Publication date |
---|---|
EP0277234B1 (de) | 1991-11-13 |
JPS62299557A (ja) | 1987-12-26 |
DE3774561D1 (de) | 1991-12-19 |
EP0277234A4 (de) | 1988-10-24 |
JPH0361788B2 (de) | 1991-09-20 |
WO1987007658A1 (en) | 1987-12-17 |
KR880701301A (ko) | 1988-07-26 |
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