EP0404032B1 - Récupération de volume d'un non-tissé, procédé de production et méthode pour retrouver le volume initial de celui-ci - Google Patents

Récupération de volume d'un non-tissé, procédé de production et méthode pour retrouver le volume initial de celui-ci Download PDF

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Publication number
EP0404032B1
EP0404032B1 EP90111488A EP90111488A EP0404032B1 EP 0404032 B1 EP0404032 B1 EP 0404032B1 EP 90111488 A EP90111488 A EP 90111488A EP 90111488 A EP90111488 A EP 90111488A EP 0404032 B1 EP0404032 B1 EP 0404032B1
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EP
European Patent Office
Prior art keywords
nonwoven fabric
fiber
bulk
adhesive agent
recoverable
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.)
Expired - Lifetime
Application number
EP90111488A
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German (de)
English (en)
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EP0404032A1 (fr
Inventor
Kanji Hosokawa
Hisaya Okamura
Zenji Yoshida
Noboru Matsui
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Japan Vilene Co Ltd
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Japan Vilene Co Ltd
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Publication date
Priority claimed from JP10918490A external-priority patent/JP2865370B2/ja
Application filed by Japan Vilene Co Ltd filed Critical Japan Vilene Co Ltd
Publication of EP0404032A1 publication Critical patent/EP0404032A1/fr
Application granted granted Critical
Publication of EP0404032B1 publication Critical patent/EP0404032B1/fr
Anticipated expiration legal-status Critical
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Classifications

    • 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
    • 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
    • D04H1/558—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 in combination with mechanical or physical treatments other than embossing
    • 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
    • D04H1/58—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/60—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 applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently
    • 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
    • D04H1/74—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 orientated, e.g. in parallel (anisotropic fleeces)

Definitions

  • the present invention relates to a bulk-recoverable nonwoven fabric, a process for producing the same and a method for recovering the bulk thereof, and more particularly to a bulk-recoverable nonwoven fabric which can be preferably used as a wadding, a base material for a brassiere cup, a base material for a shoulder pad, a filter and the like, a process for producing the same and a method for recovering the bulk thereof.
  • a bulky nonwoven fabric containing a large amount of air is generally used as a wadding for a sportswear and the like, a filter, and the like. Because the bulky nonwoven fabric contains a large amuont of air, carrying or storing the bulky nonwoven fabric is such as carrying or storing air. Accordingly, there is a disadvantage for cost because a considerably wide space is necessitated when a large amount of the bulky nonwoven fabric is carried at a time or stored in a storehouse. There is also a defect that it is inconvenient to handle the bulky nonwoven fabric when producing a sportswear and the like because the nonwoven fabric is bulky and soft.
  • a method for recovering the bulk of a bulky nonwoven fabric comprising enwrapping the bulky nonwoven fabric with a film, removing air from the bulky nonwoven fabric to diminish the bulk of the bulky nonwoven fabric so that the nonwoven fabric can be easily carried or stored, and recovering the bulk of the nonwoven fabric by blowing hot air into the nonwoven fabric when the nonwoven fabric is used, is proposed in Japanese Examined Patent Publication No. 58086/1985.
  • the bulk-diminished nonwoven fabric is poor in recoverability to the original shape because the arrangement of the fibers of the bulky nonwoven fabric is influenced, and wrinkles or deformations generate when air is removed from the bulky nonwoven fabric.
  • the method is also extremely wrong in labour effectiveness because two processes of removing air from the nonwoven fabric and recovering the bulk of the nonwoven fabric by applying hot air are necessitated.
  • the above method also has not yet been improved in processability because the nonwoven fabric should be used in a bulky state when a sportswear and the like are actually produced.
  • the nonwoven fabric is fixed in a compressed state or a deformed state at the time of being subjected to a post processing of the wadding because the powder resin is melted when the wadding is heated.
  • the nonwoven fabric produced by the above method has a defect that the nonwoven fabric is poor in durability when the nonwoven fabric is subjected to dry-cleaning because the powder resin is poor in durability against a solvent as well as poor in thermal resistance, and the bonding of the fibers formed by the powder resin is destroyed.
  • the fibers of the nonwoven fabric are merely fixed to each other by the powder resin, the nonwoven fabric is wrong in shape stability when the powder resin is reheated to melt. Accordingly, it is not preferable for using the nonwoven fabric as a wadding. Further, since the bulk of the nonwoven fabric is recovered by heating to a temperature of about 150°C, the influence of the heat against the fibers of the nonwoven fabric cannot be neglected.
  • the object of the present invention is to provide a bulk-recoverable nonwoven fabric which is excellent in durability after the bulk of the nonwoven fabric is recovered, shape stability and processability when a sportswear and the like are produced and which can diminish the cost during storage, a process for producing the same, and a method for recovering the bulk thereof.
  • a bulk-recoverable nonwoven fabric comprising a nonwoven fabric of which consituting fiber is bonded to each other by an adhesive agent to bond fibers characterized in that the nonwoven fabric is compressed, and the compressed state is maintained by a temporary adhesive agent having a melting temperature at least 10°C lower than the melting temperatures of the constituting fiber and the adhesive agent to bond fibers, after being heated to a temperature of at most 100°C, the amount of said temporary adhesive agent being 5 to 40% by weight of said nonwoven fabric.
  • the present invention provides for a process for producing a bulk-recoverable nonwoven fabric comprising blending a constituting fiber and a thermally fusible fiber to form a web, bonding the web with an adhesive agent to bond fibers to form a nonwoven fabric, pressing and heating the nonwoven fabric to melt the thermally fusible fiber characterized in that a compressed state of the nonwoven fabric is maintained by the thermally fusible fiber having a melting temperature of at least 10°C lower than the melting temperatures of the constituting fibers and the adhesive agent to bend fibers, and a process for producing a bulk-recoverable nonwoven fabric comprising bonding a web with an adhesive agent to bond fibers to form a nonwoven fabric, adding a powder resin having a low melting point with the nonwoven fabric, and pressing the nonwoven fabric characterized in that the nonwoven fabric is heated to melt the powder resin having a low melting point, and fixed in a compressed state.
  • the present invention also provides for a method for recovering the bulk of the bulk-recoverable nonwoven fabric comprising heating the bulk-recoverable nonwoven fabric to a temperature of at least the melting temperature of the temporary adhesive agent but below the temperatures at which both the constituting fiber and the adhesive agent to bond fibers melt, to recover the bulk of the bulk-recoverable nonwoven fabric.
  • the bulk-recoverable nonwoven fabric of the present invention comprises
  • the constituting fiber used in the present invention is not particularly restricted. However, it is preferable that the constituting fiber recovers the bulk of a nonwoven fabric largely when the temporary adhesive agent is melted to release the nonwoven fabric from the compressed state.
  • Representative examples of the constituting fiber which can recover the bulk of the nonwoven fabric are, for instance, crimped fibers such as a highly crimped fiber, and the like.
  • crimped fibers such as a highly crimped fiber, and the like.
  • a latently crimped fiber is preferable because the latently crimped fiber reveals high crimping when being subjected to heating.
  • the crimped fiber shows resilience when the temporary adhesive agent, which has been temporary bonded to the constituting fiber, is melted so that the adhesive strength of the temporary adhesive agent is lowered because the distorted crimped fiber recovers to the original state.
  • the resilience acts as a power for recovering the bulk of the nonwoven fabric. Accordingly, it is preferable that a crimped fiber having a high percentage of crimp, high percentage of residual crimp and high percentage of crimp modulus is used.
  • the crimped fiber having a high percentage of crimp, high percentage of residual crimp and high percentage of crimp modulus is intended to mean a crimped fiber having a crimp percentage of 12 to 70 %, a residual crimp percentage of 7 to 70 % and a percentage of crimp modulus of 30 to 100 %.
  • the values of the crimp percentage, percentage of residual crimp and percentage of crimp modulus are intended to mean to values when crimp is revealed. In case that crimp is not revealed, values when crimp is revealed are shown.
  • Examples of the above cripmed fiber are, for instance, a hollow fiber, a thick fiber having a fineness of at least 6 denier, a fiber having a large crimp radius, a fiber showing a three-dimensional spiral structure when being subjected to heating or humidifying, which is generally called as a highly crimped fiber, and the like.
  • a fiber having a crimp of about 4 to about 30 per a length of 25 mm, which is produced by mechanically imparting the crimp can also be used other than the above-mentioned crimped fibers.
  • the percentage of crimp, percentage of residual crimp and percentege of crimp modulus are defined as follows.
  • a length (a) is measured when an initial tension of 2 mgf per 1 denier is loaded to a sample.
  • a length (b) is measured when a tension of 500 mgf per 1 denier is loaded to the sample. After the tension of 500 mgf is removed and the sample is allowed to stand for one minute, a length (c) is measured when an initial tension of 2 mgf per 1 denier is loaded to the sample.
  • the percentage of crimp (%) and percentage of residual crimp (%) are calculated in accordance with the following equations. The test was done 20 times, and each average of the percentage of crimp and percentage of residual crimp is calculated. The percentage of crimp modulus (%) is calculated in accordance with the following equation.
  • a fiber having a high percentage of crimp, high percentage of residual crimp and high percentage of crimp modulus can be preferably used other than a porous fiber, a fiber having a large fineness and a fiber having large crimp radius because the fiber is excellent in recoverability.
  • high crimped fiber is mainly intended to refer to a fiber having a high percentage of crimp, high percentage of residual crimp and high percentage of crimp modulus, and a fiber having a three-dimensional spiral structure in the instant specification.
  • any of fibers having revealed crimps and fibers having latent crimps can be used.
  • Examples of the fiber showing a three-dimensional spiral structure when the fiber is heated to shrink by means of dry heat or wet heat are, for instance, a conjugated fiber having revealed crimps, a conjugated fiber having latent crimps, a fiber consisting of one component showing crimp when being subjected to a specific heat history, and the like.
  • conjugated fiber examples include, for instance, a side-by-side type conjugated fiber, a core-sheath type conjugated fiber, an eccentric conjugated fiber, which are composed of two components of a polyester having a low melting point and a polyester having a high melting point, and the like.
  • the fiber consisting of one component showing crimp when being subjected to a specific heat history is intended to mean a fiber to which a heat history is imparted by scratching the fiber with a heated edge during tensing the fiber or by scratching a heated fiber with an edge so that the arrangement of molecules of the fiber is distorted by touching the fiber with the edge.
  • the fiber is shrunk to generate a three-dimensional spiral structure by applying heat in a state of dry heat or wet heat.
  • the crimp may be present or latent when a bulk-recoverable nonwoven fabric has been produced.
  • the fiber having latent crimps is desirable from the viewpoint of recovering the bulk largely because the fiber reveals crimp when the fiber is heated to recover the bulk.
  • the thickness of the nonwoven fabric in the direction of bulk becomes larger in accordance with increasing the number of crimp.
  • the area of the nonwoven fabric in the direction of width becomes smaller because shrinkage generates in the direction of width. Accordingly, when the nonwoven fabric is particularly required for dimensional stability, it is desirable that the crimp is revealed at the time the nonwoven fabric is produced.
  • the crimp can be revealed by heating the fiber to a temperature generating the crimp after a bulk-recoverable nonwoven fabric is produced.
  • an adhesive agent to bond fibers is used in order to bond the constituting fiber to each other.
  • the adhesive agent to bond fibers is classified into a thermosetting resin binder and a thermally adhesive fiber.
  • thermosetting resin binder and the thermally adhesive fiber act as an agent for retaining the original shape of the nonwoven fabric when the nonwoven fabric is reheated to recover the bulk of the nonwoven fabric.
  • an agent which is not affected by heating for melting the temporary adhesive agent and reheating for recovering the bulk of the nonwoven fabric, is used.
  • thermosetting resin binder examples include, for instance, self-crosslinking acrylic acid ester emulsion, a latex such as ethylene-vinyl acetate copolymer latex, polyvinyl acetate latex, polyvinyl chloride latex, synthetic rubber latex, polyurethane latex or polyester latex, into which a crosslinking agent is added, and the like.
  • a latex such as ethylene-vinyl acetate copolymer latex, polyvinyl acetate latex, polyvinyl chloride latex, synthetic rubber latex, polyurethane latex or polyester latex, into which a crosslinking agent is added, and the like.
  • acrylic acid ester emulsion can be particularly preferably used.
  • the reason why the acrylic acid ester emulsion can be preferably used is that the softness of a film of an adhesive agent prepared from the acrylic acid ester emulsion can be widely and easily adjusted.
  • the acrylic acid ester emulsion is excellent in adhesion property and water resistance against polyester fiber which is frequently used as one of the constituting fibers of the nonwoven fabric.
  • a resin binder having a melting temperature of at least 10°C higher than that of the temporary adhesive agent also can be used other than the thermosetting resin binder because the resin binder is little influenced by heating and reheating.
  • thermally adhesive fiber examples include, for instance, an all-fusible fiber composed of a resin such as non-stretched polyester, polyester having a low melting point or polyamide having a low melting point, a conjugated fiber of which one component is the above resin, and the like. It is desirable that the melting temperature of the thermally adhesive fiber is at least 10°C, preferably at least 20°C higher than that of the temporary adhesive agent. The melting temperature of the thermally adhesive fiber is preferably 100° to 230°C.
  • the component having a low melting point of the conjugated fiber can be used as an adhesive agent to bond fibers.
  • the thermosetting resin binder and the thermally adhesive fiber there is no necessity to use the thermosetting resin binder and the thermally adhesive fiber.
  • the melting temperature of the component having a low melting point should be higher than that of the temporary adhesive agent.
  • melting temperature is intended to mean a temperature where a solid is melted, and solid phase and liquid phase coexist at equilibrium, which is generally called as melting point when the solid is subjected to dry heating, or a temperature where a non-crystalline material is softened in the presence of water, and solid phase and liquid phase of the non-crystalline material which is to be liquid phase coexist at equilibrium in the presence of water when the non-crystalline material is subjected to wet heating.
  • the temporary adhesive agent mentioned later should satisfy the above relations when the temporary adhesive agent is subjected to dry heating or wet heating.
  • the example is a case where the temporary adhesive agent is, for instance, polyvinyl alcohol.
  • the polyvinyl alcohol shows a melting temperature of about 120° to about 150°C at dry heating.
  • the polyvinyl alcohol generates adhesive strength at heating with a steam having a temperature of about 100°C because the polyvinyl alcohol is swollen and softened and then melted.
  • the temperature can be adjusted to about 100°C.
  • the melting temperature of the temporary adhesive agent sometimes depends upon the conditions where the temporary adhesive agent is subjected to dry heating or wet heating.
  • the temporary adhesive agent used in the present invention acts as an agent to temporarily diminish the bulk of the nonwoven fabric, i.e., to form a nonwoven fabric having a high density so that the nonwoven fabric can be easily treated at first and an agent to lower its adhesive strength to recover the bulk of the nonwoven fabric with a resiliency of the crimped fiber when the bulk of the nonwoven fabric is finally recovered. Therefore, the temporary adhesive agent having a melting temperature, at which the constituting fiber of the nonwoven fabric and the adhesive agent for fibers are not affected, is necessitated. It is an essential condition that the melting temperature of the temporary adhesive agent is at least 10°C lower than the melting temperatures of the constutiting fiber of the nonwoven fabric and the adhesive agent for fibers. It is particularly preferable that the melting temperature of the temporary adhesive agent is at least 20°C lower than their melting temperatures.
  • the melting temperature of the temporary adhesive agent is at most 100°C.
  • the reason why the temperature being at most 100°C is preferable is because the constituting fiber of the nonwoven fabric is little affected and the bulk of the nonwoven fabric can be easily recovered by means of a conventional heating system when the nonwoven fabric is subjected to sewing.
  • Examples of the form of the temporary adhesive agent are, for instance, fibrous, powdered, and the like.
  • the fibrous temporary adhesive agent are, for instance, thermally fusible fiber, and the like.
  • a conjugated fiber and a single component fiber are exemplified.
  • the treatment can be easily carried out because only the component having a low melting point of the conjugated fiber is melted and the conjugated fiber is not excessively melted or adhered to the constituting fiber, therefore, the hand-feeling of the nonwoven fabric does not deteriorate.
  • conjugated fiber are, for instance, a conjugated fiber composed of polyester having a low melting point/polyester having a high melting point, polyamide having a low melting point/polyester having a high melting point, and the like.
  • Examples of the form of the conjugated fiber are, for instance, side-by-side type, core-sheath type, islands-in-sea type, and the like. Since the melting temperature of the component having a low melting point of the conjugated fibers is generally about 80° to about 100°C, heating and reheating for recovering the bulk of nonwoven fabric can be carried at a low temperature. Therefore, there are some advantages that energy can be reduced and operation efficiency is improved as well as no affection is imparted to the constituting fiber.
  • the ratio of the thermally fusible fiber to the other constituting fiber is so high because the nonwoven fabric is hardened and the constituting fiber is bonded in a deformed state when the nonwoven fabric is subjceted to dry-cleaning after the bulk of the nonwoven fabric is recovered.
  • the ratio of the thermally fusible fiber is so low, the adhesive strength of the temporary adhesive agent comes to be insufficient as well as the dispersion of the thermally fusible fiber comes to be uneven. Accordingly, it is desirable that the content of the thermally fusible fiber in the fibers of the nonwoven fabric is 5 to 40 % by weight, preferably 10 to 30 % by weight.
  • Representative examples of the temporary adhesive agent having a powder form are a powder resin having a low melting point and a water-soluble powder resin.
  • Exampels of the powder resin having a low melting point are, for instance, a powder resin having a melting temperature of at most 100°C, preferably 80° to 100°C or so such as polyamide, polyethylene or ethylene/vinyl acetate copolymer, and the like.
  • water-soluble powder resin examples include water-soluble powder resin having a melting temperature of 80° to 110°C or so in a state of wet heating such as polyvinyl alcohol, and the like.
  • the thickness of the nonwoven fabric of which constituting fiber is bonded to each other with the adhesive agent to bond fibers can be diminished to 1/5 to 1/30 or so of the original thickness of the nonwoven fabric because the compressed state of the nonwoven fabric is maintained by the temporary adhesive agent when the nonwoven fabric is cooled in a compressed state after the nonwoven fabric is heated to a temperature of at most 100°C and compressed.
  • the bulk of the nonwoven fabric can be recovered to 5 to 30 times of the bulk of the compressed nonwoven fabric by applying heat having the same temperature as mentioned above after the nonwoven fabric is subjected to transporting or carring, storing, sewing, and the like.
  • thickness is intended to mean a thickness when a load of 0.01 g per 100 mm2 of a sample is applied to the sample having a size of 250 mm x 250 mm in the instant specification.
  • the process for producing a bulk-recoverable nonwoven fabric differs depending upon whether a thermosetting resin binder or a thermally adhesive fiber is used as an adhesive agent to bond fibers, or whether a thermally fusible fiber or a powder resin having a low melting point is used as a temporary adhesive agent.
  • a thermally adhesive fiber is used as an adhesive agent to bond fibers and a thermally fusible fiber is used as a temporary adhesive agent
  • a web is produced by means of carding or the like after blending the constituting fiber, the thermally adhesive fiber and the thermally fusible fiber.
  • a bulk-recoverable nonwoven fabric is produced by heating the web and fusing the thermally adhesive fiber to bond the constituting fibers of the web to each other.
  • a thermally adhesive fiber is used as an adhesive agent to bond fibers and a resin powder having a low melting point is used as a temporary ahdesive agent
  • a web is produced by means of carding or the like after blending the constituting fiber and the thermally adhesive fiber.
  • a bulk-recoverable nonwoven fabric is produced by heating the web and fusing the thermally adhesive fiber to bond the constituting fiber of the web to each other and adding the resin powder having a low melting point to the web.
  • thermosetting resin binder When a thermosetting resin binder is used as an adhesive agent to bond fibers and a thermally fusible fiber is used as a temporary adhesive agent, a web is produced by means of carding or the like after blending the constituting fiber and the thermally fusible fiber.
  • a bulk-recoverable nonwoven fabric is produced by bonding the thermosetting resin binder to the web to bond the constituting fiber of the web to each other.
  • thermosetting resin binder When a thermosetting resin binder is used as an adhesive agent to bond fibers and a resin powder having a low melting point is used a temporary adhesive agent, a web is produced by carding the constituting fiber, or the like. A bulk-recoverable nonwoven fabric is produced by bonding a thermosetting resin binder to the web and adding the resin powder having a low melting point thereto.
  • the content of the highly crimped fiber in the constituting fiber can be properly adjusted in accordance with the uses or useage of the bulk-recoverable nonwoven fabric.
  • a resin powder having a low melting point when used as a temporary adhesive agent, it is difficult to produce a web by means of carding after blending the constituting fiber and the resin powder having a low melting point.
  • a resin powder having a low melting point when added to a web and the web is bonded with a thermosetting resin binder to give a nonwoven fabric, it sometimes occurs that the temporary adhesive agent does not act as an adhesive agent sufficiently because the binder envelops and bonds with the resin powder having a low melting point. Accordingly, the resin powder is added to a nonwoven fabric after the nonwoven fabric is produced in the present invention.
  • the amount of the adhesive agent added to the constituting fiber differs depending upon the kind thereof.
  • the amount (solids content) of the thermosetting resin binder is usually adjusted to 3 to 50 % by weight, preferably 5 to 30 % by weight of the nonwoven fabric.
  • the amount of the thermosetting resin binder is less than the above-mentioned range, there is a tendency that durability or strength of the nonwoven fabric becomes insufficient after the bulk of the nonwoven fabric is recovered.
  • thermosetting resin binder When the amount of the thermosetting resin binder is more than the above-mentioned range, there are tendencies that it is difficult to produce a bulky nonwoven fabric and only a nonwoven fabric having a small percentage of bulk recovery is produced, and that the hand-feeling of the nonwoven fabric comes to be hard after the bulk of the nonwoven fabric is recovered.
  • the used amount of the thermally adhesive fiber differs depending upon the kind of the thermally adhesive fiber.
  • the amount of the all-fusible fiber is adjusted so that the all-fusible fiber is contained in a nonwoven fabric in a content of 30 to 55% by weight, preferably 35 to 50 % by weight.
  • the amount of the all-fusible fiber is less than the above-mentioned range, there is a tendency that durability for dry-cleaning and washing deteriorates after the bulk of the nonwoven fabric is recovered.
  • the amount of the all-fusible fiber exceeds the above-mentioned range, there is a tendency that producing a bulky nonwoven fabric comes to be difficult.
  • the amount of the conjugated fiber is adjusted so that the conjugated fiber is contained in a nonwoven fabric in a content of 30 to 95 % by weight, preferably 40 to 90 % by weight.
  • the amount is less than the above-mentioned range, there is a tendency that durability for dry-cleaning and washing deteriorates after the bulk of the nonwoven fabric is recovered.
  • the amount of the conjugated fiber exceeds the above-mentioned range, there are tendencies that a sufficient amount of a temporary adhesive agent cannot be blended into a nonwoven fabric and that the thickness of a nonwoven fabric comes to be so thin after the nonwoven fabric is subjected to pressing.
  • the temporary adhesive agent when the amount of the temporary adhesive agent is so large, there is a tendency that the temporary adhesive agent disturbs the bulk recovery of the nonwoven fabric, and when the amount of the temporary adhesive agent is so small, there is a tendency that a sufficient effect generated by adding the temporary adhesive agent is not exhibited. Accordingly, when the temporary adhesive agent is a thermally fusible fiber, it is preferable that the amount of the thermally fusible fiber is 5 to 40 % by weight, desirably 10 to 30 % by weight of a nonwoven fabric.
  • the amount of the resin powder having a low melting point is 5 to 40 % by weight, desirably 10 to 30 % by weight of a nonwoven fabric. Since the weight of the bulk-recoverable nonwoven fabric of the present invention depends upon the uses of the bulk-recoverable nonwoven fabric, and the like, the weight cannot be absolutely determined. For instance, when the bulk-recoverable nonwoven fabric is used as a wadding for sportswear, it is preferable that the weight is about 30 to about 200 g/m2. When the bulk-recoverable nonwowen fabric is used as a filter, it is preferable that the weight is about 50 to about 400 g/m2.
  • the nonwoven fabric is heated to a temperature of at least 10°C lower than the melting temperatures of the constituting fiber and the adhesive agent to bond fibers, and pressed to give a nonwoven fabric having a thickness of 1/5 to 1/30 or so of the original nonwoven fabric.
  • a part of the thermally fusible fiber is melted and the nonwoven fabric is fixed in a compressed state.
  • Examples of a heating and pressing method are, for instance, roller pressing method, flat pressing method, and the like.
  • the roller pressing method is preferable from the viewpoint of productivity because a nonwoven fabric can be continuously heated and pressed.
  • the nonwoven fabric When the nonwoven fabric is derived from a roller pressing device, flat pressing device or belt pressing device for heating and pressing a nonwoven fabric, the nonwoven fabric is fixed in a compressed state because the temporary adhesive agent is cooled to solidify and fixed at that time. It is desirable that the nonwoven fabric is allowed to cool or compulsively cooled after the heating while the nonwoven fabric is continuously kept in a compressed state in order to fix the nonwoven fabric more firmly in a compressed state. If the above heating and pressing process can be conducted during the temperature of the heated nonwoven fabric is not lowered, a step for pressing can be conducted after heating.
  • the nonwoven fabric can be pressed on the whole surface or some spots of the surface. It is preferable that the nonwoven fabric is pressed on some spots of the surface because the nonwoven fabric is temporarily bonded at the spots, and as the result, the bulk of the nonwoven fabric can be easily recovered by reheating the nonwoven fabric.
  • the thus produced bulk-recoverable nonwoven fabric recovers the bulk when the nonwoven fabric is subjected to a heat treatment at a temperature of lower than the melting temperatures of the constituting fiber and the adhesive agent to bond fibers. It is preferable that the bulk of the nonwoven fabric is recovered by imparting steam in actuality because the bulk can be easily recovered.
  • the recovery percentage and expansion ratio of the nonwoven fabric which are defined as follows, are at least 70 % and at least 5 times, respectively.
  • the bulk-recoverable nonwoven fabric of the present invention is excellent in various physical properties such as durability of washing and dry-cleaning before pressing the nonwoven fabric and after recovering the bulk of the nonwoven fabric in comparison with conventional nonwoven fabrics.
  • the bulk-recoverable nonwoven fabric is used in for instance wears and the like, it is preferable that the bulk of the nonwoven fabric is recovered after sewing is completed from the viewpoint of processability.
  • the bulk cannot be recovered after sewing because a heat treatment for recovering the bulk affects outer fabric or lining cloth of the wears and the like, the bulk of the nonwoven fabric can be recovered after the nonwoven fabric is transported, stored or cut.
  • the nonwoven fabric of the presnet invention can be diminished in the bulk before the nonwoven fabric is used, the nonwoven fabric has some advantages that the nonwoven fabric is convenient to handle when the nonwoven fabric is transported or stored and that costs for transporting or storing the nonwoven fabric can be diminished.
  • Fibers comprising 90% by weight of a highly crimped polyester fiber (melting point: 256°C, fineness: 3 denier, fiber length: 51mm) as a constituting fiber and 10 % by weight of a core-sheath type conjugated polyester fiber having a low melting point (core: polyester (melting point: 256°C), sheath: polyester having a low melting point (melting point: 87°C), fineness: 3 denier, fiber length: 51 mm) as a temporary adhesive agent were carded to form a web having a weight of 55 g/m2.
  • core polyester (melting point: 256°C)
  • sheath polyester having a low melting point (melting point: 87°C)
  • fineness 3 denier, fiber length: 51 mm
  • a self-crosslinking acrylic acid ester emulsion as a binder was impregnated into the web to bond the constituting fiber of the web to each other and a nonwoven fabric having a weight of 60 g/m2 was obtained.
  • Some spots of the nonwoven fabric were compressed by means of a heating roller having a temperature of 100°C under the condition of a guage pressure of 2 kg/cm2.
  • a steam having a temperature of 100°C was applied to the nonwoven fabric to recover the bulk. At that time, the recovery percentage was 85 % and the expansion ratio was 11 times.
  • the mixing ratio of the core-sheath type conjugated polyester fiber having a low melting point to a highly crimped polyester fiber was changed into 3, 5, 15, 20, 30, 35, 40 or 45 % by weight to give a web having a weight of 55 g/m2.
  • a self-crosslinking acrylic acid ester emulsion was impregnated into each of the webs to bond the constituting fiber of the web to each other and nonwoven fabrics having a weight of 60 g/m2 were obtained.
  • Some spots of each of the nonwoven fabrics were compressed and heated in the same manner as in Example 1.
  • a steam having a temperature of 100°C was imparted to each of the nonwoven fabrics to recover the bulk thereof, and recovery percentage and expansion ratio were investigated in the same manner as in Example 1.
  • Table 1 As is clear from Table 1, it can be seen that when the content of the core-sheath type conjugated polyester fiber is 5 to 40 % by weight, preferable physical properties can be given to the nonwoven fabric.
  • Example 2 After the nonwoven fabric containing 15 % by weight of a core-sheath type conjugated polyester fiber obtained in Example 1 was allowed to stand for 30 days, the bulk of the nonwoven fabric was recovered with a steam having a temperature of 100°C.
  • washing resistance and dry-cleaning resistance were exmamined.
  • the washing resistance and dry-cleaning resistance of each of the above two nonwoven fabrics were Class 3 and Class 5, respectively. No change after pressing to bond was observed.
  • the durability of the nonwoven fabric of the present invention was superior to that of the conventional nonwoven fabric.
  • the testing methods for examining washing resistance and dry-cleaning resistance are as follows.
  • a sample having a size of 250 mm x 250 mm was prepared from the obtained nonwoven fabric.
  • the sample was enveloped in a nylon taffeta and it was washed in a high stream of water by means of an automatic contrarotating washing machine for 90 minutes under the conditions that the temperature of water was 40° ⁇ 3°C, the used amount of 0.2 % synthetic detergent aqueous solution containing no phosphorous compounds was 32 l and loaded cloth was added to the washing machine so that the weight ratio of water to the sample and loaded cloth was 50 to 1.
  • a sample having a size of 250 mm x 250 mm was prepared from the obtained nonwoven fabric and enveloped in a nylon taffeta.
  • a detergent a commercially available perchlene dry cleaner was used. Loaded cloth was used so that total amount of washing was 500 g.
  • a process comprising washing for 8 minutes at a temperature of 25°C, wasting solvent for one minute, taking off solvent for 4 minutes, drying for 5 minutes at 60°C and deodorizing for 2 minutes was repeated 3 times. After that, the surface of the sample was observed. The evaluation was the same as in the above-mentioned washing resistance.
  • a highly crimped polyester fiber (melting point: 256°C, fineness: 3 denier, fiber length: 51 mm) as a constituting fiber was carded to form a web having a weight of 55 g/m2.
  • a self-crosslinking acrylic acid ester emulsion as a binder was impregnated into the web to bond the constutiting fiber of the web to each other.
  • polyvinyl alcohol powder resin was dispersed onto the surface of the web in an amount of 10 g/m2 to give a nonwoven fabric having a weight of 70 g/m2.
  • Some spots of the nonwoven fabric were compressed by means of a heating roller having a temperature of 120°C under the condition of a guage pressure of 3 kg/cm2.
  • a steam having a temperature of 100°C was applied to the nonwoven fabric to recover the bulk. At that time, the recovery percentage was 80 % and the expansion ratio was 7 times.
  • the washing resistance and dry-cleaning resistance of the nonwoven fabric were Class 3 and Class 5, respectively.
  • the nonwoven fabric exhibited excellent durability, which was the same as that of a nonwoven fabric which was neither compressed nor fixed.
  • Fibers comprising 80 % by weight of a highly crimped polyester fiber (melting point: 256°C, fineness: 3 denier, fiber length: 51 mm) and 20 % by weight of a core-sheath type conjugated polyester fiber having a low melting point (core: polyester (melting point: 256°C), sheath: polyester having a low melting point (melting point: 87°C), fineness: 4 denier, fiber length: 51 mm) as a constituting fiber were carded to form a nonwoven fabric having a weight of 60 g/m2. Some spots of the nonwoven fabric were compressed by means of a heating roller having a temperature of 100°C under the condition of a guage pressure of 2 kg/cm2. After 30 days, a steam having a temperature of 100°C was applied to the nonwoven fabric to recover the bulk. At that time, the recovery percentage was 40 % and the expansion ratio was 6.5 times.
  • the washing resistance and dry-cleaning resistance were Class 1 and Class 2, respectively. Accordingly, the nonwoven fabric had a problem in durability.
  • a highly crimped polyester fiber (melting point: 256°C, fineness: 3 denier, fiber length: 51 mm) as a constituting fiber was carded to form a web having a weight of 49.5 g/m2.
  • a polyamide powder resin having a low melting point was applied onto the web in a ratio of 10.5 g per 1 m2 of the web to give a nonwoven fabric having a weight of 60 g/m2. After that, some spots of the nonwoven fabric were compressed by means of a heating roller having a temperature of 100°C under the condition of a gauge pressure of 2 kg/cm2. After 30 days, a steam having a temperature of 100°C was applied to the nonwoven fabric to recover the bulk. At that time, the recovery percentage was 40 % and the expansion ratio was 4.5 times.
  • Fibers comprising 60 % by weight of a highly crimped polyester fiber (melting point: 256°C, fineness: 3 denier, fiber length: 51 mm), 30 % by weight of a core-sheath type conjugated polyester fiber having a low melting point (core: polyester (melting point: 256°C), sheath: polyester having a low melting point (melting point: 110°C), fineness: 4 denier, fiber length: 51 mm) and 10 % by weight of a core-sheath type conjugated polyester fiber having a bow melting point (core: polyester (melting point: 256°C), sheath: polyester having a low melting point (melting point: 87°C), fineness: 3 denier, fiber length: 51 mm) were carded to give a web having a weight of 60 g/m2. After that, a heat having a temperature of 150°C was applied to the web so that the constituting fiber was bonded to each other, and a nonwoven fabric was obtained.
  • core
  • Some spots of the nonwoven fabric were compressed by means of a heating roller having a temperature of 100°C under the condition of a gauge pressure of 2 kg/cm2. After 30 days, a steam having a temperature of 100°C was applied to the nonwoven fabric to recover the bulk. At that time, the recovery percentage was 45 % and the expansion ratio was 8 times.
  • the washing resistance and dry-cleaning resistance were Class 3 and Class 3, respectively.
  • the nonwoven fabric exhibited preferable durability which was the same as the nonwoven fabric which was not compressed to fix the constituting fiber.
  • Fibers comprising 90 % by weight of a core-sheath type conjugated fiber having a low melting point (core: polypropylene, sheath: polyethylene (melting point: 130°C), fineness: 14 denier, fiber length: 76 mm) as a constituting fiber and 10 % by weight of a core-sheath type conjugated polyester fiber having a low melting point (core: polyester (melting point: 256°C), sheath: polyester having a low melting point (melting point: 87°C), fineness: 3 denier, fiber length: 51 mm) as a temporary adhesive agent were carded to give a web having a weight of 300 g/m2. After that, a heat having a temperature of 150°C was applied to the web to bond the constituting fiber of the web, and the thickness of the web was adjusted by means of a heating roller to give a nonwoven fabric having a thickness of 20 mm.
  • core polypropylene, sheath: polyethylene (melting point: 130°
  • Some spots of the nonwoven fabric were compressed by means of a heating roller having a temperature of 110°C under the condition of a guage pressure of 4 kg/cm2. After 3 days, a steam having a temperature of 100°C was applied to the nonwoven fabric to recover the bulk. At that time, the recovery percentage was 105 %, and the expansion ratio was 11 times.
  • the nonwoven fabric As to the nonwoven fabric, initial pressure loss and collection efficiency of dust as an air filter were examined. Under the conditions of a wind speed of 2.5 m/sec. and a dust concentration of 22.3 mg/m3, the initial pressure loss and collection efficiency were examined. As the result, the initial pressure loss was 10 mm Aq, and the average collection efficiency of dust was 80 % until the pressure loss attained to 20 mm Aq. As is clear from the above results, the nonwoven fabric satisfies the physical properties required for an air filter.
  • Fibers comprising 10 % by weight of a core-sheath type conjugated polyester fiber (core: polyester (melting point: 256°C), sheath: polyester having a low melting point (melting point: 87°C), fineness: 3 denier, fiber length: 51 mm) as a temporary adhesive agent and 90 % by weight of a core-sheath type conjugated polyester having a low melting point (core: polyester (melting point: 130°C), sheath: polyester having a low melting point (melting point: 125°C), fineness: 2 denier, fiber length: 51 mm) as a constituting fiber were carded to give a web having a weight of 50 g/m2.
  • core polyester (melting point: 256°C)
  • sheath polyester having a low melting point (melting point: 87°C), fineness: 3 denier, fiber length: 51 mm
  • core-sheath type conjugated polyester having a low melting point core: polyester (melting point: 130°
  • a heat having a temperature of 150°C was applied to the web to bond the constituting fiber of the web, and some spots of the web was compressed by means of a heating roller having a temperature of 100°C under the condition of a guage pressure of 2 kg/cm2 to give a nonwoven fabric.
  • washing resistance was Class 4
  • dry-cleaning resistance was Class 4, respectively.
  • the nonwoven fabric of the present invention no change caused by compressing to bond was observed.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Treatment Of Fiber Materials (AREA)

Claims (9)

  1. Non-tissé capable de retrouver son volume initial, comportant un non-tissé dont les fibres qui le constituent sont liées entr'elles par un agent adhésif permettant de lier les fibres, caractérisé en ce que le non-tissé est comprimé et l'état comprimé est maintenu, après chauffage à une température d'au plus 100 °C, par un agent adhésif temporaire ayant une température de fusion inférieure d'au moins 10 °C aux températures de fusion des fibres constituant le non tissé et de l'agent adhésif servant à lier les fibres, la quantité dudit agent adhésif temporaire étant de 5 à 40 % en poids dudit non-tissé.
  2. Non-tissé capable de retrouver son volume initial selon la revendication 1, tel que ledit agent adhésif servant à lier les fibres est un liant en résine thermodurcissable.
  3. Non-tissé capable de retrouver son volume initial selon la revendication 1, tel que l'agent adhésif servant à lier les fibres est une fibre thermiquement adhésive.
  4. Non-tissé capable de retrouver son volume initial selon la revendication 1, tel que lesdites fibres constitutives comportent une libre conjuguée, et l'agent adhésif servant à lier les fibres est un composant à faible point de fusion de ladite fibre conjuguée.
  5. Non-tissé capable de retrouver son volume initial selon la revendication 1, 2, 3 ou 4, tel que ledit agent adhésif temporaire est une fibre thermofusible.
  6. Non-tissé capable de retrouver son volume initial selon la revendication 1, 2, 3 ou 4, tel que ledit agent adhésif temporaire est une résine en poudre ayant un point de fusion bas.
  7. Procédé pour produire un non-tissé capable de retrouver son volume initial, dans lequel on mélange des fibres constitutives et une fibre thermofusible pour former un tissu, on lie le tissu avec un agent adhésif permettant de lier les fibres de façon à former un non-tissé, on presse et on chauffe le non-tissé pour faire fondre la fibre thermofusible, ce procédé étant caractérisé en ce que l'on maintient un état comprimé du non-tissé au moyen de la fibre thermofusible qui a une température de fusion inférieure d'au moins 10 °C aux températures de fusion des fibres constitutives et de l'agent adhésif servant à lier les fibres.
  8. Procédé pour produire un non-tissé capable de retrouver son volume initial, dans lequel on lie un tissu avec un agent adhésif pour lier les fibres de façon à former un non-tissé, on ajoute une résine en poudre au non-tissé, on presse et on chauffe le non-tissé pour fondre la poudre de résine, le procédé étant caractérisé en ce que l'on maintient un état comprimé du non-tissé à l'aide de la poudre de résine ayant une température de fusion inférieure d'au moins 10 °C à la température de fusion des fibres constitutives du tissu et de l'agent adhésif servant à lier les fibres.
  9. Procédé pour produire un non-tissé capable de retrouver son volume initial, caractérisé en ce que le non-tissé capable de retrouver son volume initial de la revendication 1 est chauffé à une température au moins égale à la température de fusion de l'agent adhésif temporaire mais inférieure aux températures auxquelles fondent les fibres constitutives et l'agent adhésif servant à lier les fibres, de façon à retrouver le volume initial du non-tissé.
EP90111488A 1989-06-20 1990-06-19 Récupération de volume d'un non-tissé, procédé de production et méthode pour retrouver le volume initial de celui-ci Expired - Lifetime EP0404032B1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JP15929489 1989-06-20
JP159294/89 1989-06-20
JP109184/90 1990-04-25
JP10918490A JP2865370B2 (ja) 1989-06-20 1990-04-25 嵩回復可能な不織布、その製造法およびその嵩回復方法

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EP0404032A1 EP0404032A1 (fr) 1990-12-27
EP0404032B1 true EP0404032B1 (fr) 1995-03-15

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DE (1) DE69017762T2 (fr)
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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5405682A (en) 1992-08-26 1995-04-11 Kimberly Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and elastomeric thermoplastic material
US5643662A (en) 1992-11-12 1997-07-01 Kimberly-Clark Corporation Hydrophilic, multicomponent polymeric strands and nonwoven fabrics made therewith
US6500538B1 (en) 1992-12-28 2002-12-31 Kimberly-Clark Worldwide, Inc. Polymeric strands including a propylene polymer composition and nonwoven fabric and articles made therewith

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2080453C (fr) * 1991-10-17 1999-02-09 Randall E. Kozulla Non-tisse a haute elasticite fabrique selon la methode d'incorporation de fibres adhesives
US5382400A (en) 1992-08-21 1995-01-17 Kimberly-Clark Corporation Nonwoven multicomponent polymeric fabric and method for making same
US7131171B2 (en) 2002-09-25 2006-11-07 Kao Corporation Method for restoring bulkiness of nonwoven fabric

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3607500A (en) * 1969-06-04 1971-09-21 Du Pont A molding fibrous webs
US3816226A (en) * 1972-03-31 1974-06-11 Avco Corp Fire protection material

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5405682A (en) 1992-08-26 1995-04-11 Kimberly Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and elastomeric thermoplastic material
US5643662A (en) 1992-11-12 1997-07-01 Kimberly-Clark Corporation Hydrophilic, multicomponent polymeric strands and nonwoven fabrics made therewith
US6500538B1 (en) 1992-12-28 2002-12-31 Kimberly-Clark Worldwide, Inc. Polymeric strands including a propylene polymer composition and nonwoven fabric and articles made therewith

Also Published As

Publication number Publication date
EP0404032A1 (fr) 1990-12-27
ES2073477T3 (es) 1995-08-16
DE69017762T2 (de) 1995-08-24
DE69017762D1 (de) 1995-04-20

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