JP2001171028A - Nonwoven fabric material excellent in abrasion resistance and elasticity, and secondary processed product thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a nonwoven fabric material excellent in abrasion resistance and elasticity and suitably used for being finished into a chair cover, a car seat, bags, porches or shoes. SOLUTION: A nonwoven fabric material excellent in abrasion resistance and elasticity is constituted by bonding a thermoplastic sheet with a melting point of 150 deg.C or lower to the single surface of a nonwoven fabric comprising fine synthetic fibers with 1.1 decitex or less under heating and pressure while holding a sheetlike state.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a nonwoven material having excellent abrasion resistance and elasticity, and more particularly to a nonwoven material made of a nonwoven material having improved abrasion strength and a nonwoven material having such a nonwoven material. The present invention relates to a nonwoven fabric material having improved wear strength.

[0002]

2. Description of the Related Art Conventionally, for example, a nonwoven fabric made of fine synthetic fibers of 1.1 decitex or less is formed as a nonwoven fabric structure in a state of a thick composite fiber before being made into a fine synthetic fiber, and thereafter, the composite fiber is formed. It has been produced by chemically removing one of the components or by dividing each component by physical or chemical action.

[0003] In the nonwoven fabric made of fine synthetic fibers produced in this manner, one component of the conjugate fiber is removed,
Alternatively, since it is manufactured by dividing each component by a physical or chemical action, there is a phenomenon that the force for restraining the fiber becomes weak.

That is, in order to manufacture a fine synthetic fiber nonwoven fabric, a nonwoven fabric structure is formed in the state of a thick composite fiber before being made into a fine synthetic fiber, and then one component in the composite fiber is chemically removed. By doing so, or by dividing each component by physical or chemical action, there is a phenomenon that the force for restraining the fiber becomes weak.

[0005] For example, as an application example of such a nonwoven fabric, an adhesive (a commonly used adhesive is a urethane resin) is impregnated in a portion where the fibers of the nonwoven fabric intersect, and then sliced. There is a technique in which the surface of the nonwoven fabric is raised by buffing into a nonwoven product having a suede-like appearance, either as two sheets or as one sheet as it is. In the production of a nonwoven product having such a suede-like appearance, The nonwoven fabric is manufactured by removing one component of the composite fiber, or by dividing each component by physical or chemical action, etc., and further undergoes buffing, etc. The binding force was weak, and the nonwoven fabric had low strength and high elongation, and was weak against abrasion.

[0006] The term "weak to abrasion" as used herein means a phenomenon in which fine fibers on the surface of the nonwoven fabric are liable to fall off when the surface of the nonwoven fabric is rubbed.

[0007]

When such a nonwoven fabric is made into, for example, chair upholstery, automobile seats, luggage, pouches, shoes, etc., the surface of the nonwoven fabric is repeatedly rubbed. In other words, there is a problem that the fine fibers on the surface fall off as the object is put into the device and used, resulting in low abrasion resistance.

In particular, when these are tailored for their use, the water absorption is high due to the capillary action between fibers, which is a characteristic of the fine fiber nonwoven fabric. There was also a problem that water could easily enter the inside of shoes, pouches and shoes, and permeate easily.

An object of the present invention is to provide a nonwoven fabric material having high abrasion resistance and excellent in abrasion resistance and elasticity which is convenient for tailoring to the above-mentioned various applications in view of the above-mentioned points. Another object of the present invention is to provide a secondary processed product such as an upholstery, an automobile seat, a bag, a pouch, and shoes using the nonwoven fabric.

[0010]

Means for Solving the Problems The nonwoven fabric material of the present invention which achieves the above-mentioned objects is as described in the following (1) to (5). (1) A thermoplastic sheet having a melting point of 150 ° C. or less is thermocompression-bonded to one surface of a nonwoven fabric made of fine synthetic fibers of 1.1 decitex or less while maintaining the sheet shape. Excellent nonwoven material. (2) When the thermoplastic sheet is thermocompression-bonded to one surface of the nonwoven fabric, the thermoplastic sheet is superimposed on the back surface of the nonwoven fabric and thermocompression-bonded. Excellent nonwoven material. (3) The nonwoven fabric material having excellent wear resistance and elasticity according to the above (1), wherein a fiber fabric is further thermocompression-bonded to the thermoplastic sheet side. (4) The non-woven fabric made of fine synthetic fibers of 1.1 decitex or less, at least one surface of which is subjected to a water-repellent treatment, wherein the non-woven fabric described in (1), (2) or (3) above Non-woven material with excellent abrasion and elasticity. (5) The above-mentioned (1), wherein the nonwoven fabric made of fine synthetic fibers of 1.1 decitex or less is impregnated with a polyurethane resin and the surface of the nonwoven fabric is buffed to give a suede tone. And (3) or (4).

Further, the chair upholstery of the present invention, an automobile seat,
Secondary processed products such as bags, pouches, shoes, and the like include chair coverings, car seats, and bags using the nonwoven fabric described in (1), (2), (3), (4), or (5) above. Types, pouches or shoes.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A preferred embodiment of a nonwoven fabric material having excellent wear resistance and elasticity according to the present invention will be described below with reference to the drawings. Of course, the following is an example, and other various forms are included in the present invention.

FIG. 1 is a schematic cross-sectional view schematically showing a cross section of a nonwoven fabric 1 which is a basic element of a nonwoven fabric material according to the present invention. FIG. FIG. 3 is a schematic cross-sectional view schematically showing a state in which a thermoplastic sheet is pressure-bonded to one surface of a nonwoven fabric, and a fiber cloth is further laminated and thermo-pressed.

In FIG. 1, reference numeral 1 denotes a nonwoven fabric which is the basis for obtaining the nonwoven fabric materials 5 and 9 of the present invention. The nonwoven fabric 2 has a suede-like appearance by a nap body 2 of fine synthetic fibers. The polyurethane adhesive 3 maintains the strength of the nonwoven fabric, and is formed of a portion of the cavity 4 formed by removing one component of the composite fiber.

It is important that the fine synthetic fibers have a density of 1.1 decitex or less for obtaining a suede-like texture. Preferably, it is in the range of 0.0001 to 1.1 dtex, more preferably 0.01 to 0.5 dtex.

The nonwoven fabric material of the present invention is
Although the thermoplastic sheet is formed by thermocompression bonding, it is important that the sheet is thermocompression bonded while substantially maintaining the sheet shape.

The thermoplastic sheet may be, for example, a synthetic resin film made of polyester, polyamide, or the like, a knitted fabric, or the like, and is not limited thereto. In addition, a nonwoven fabric or the like may be used. . It is important that the thermoplastic sheet has a melting point of 150 ° C. or less. This is because using a material having a melting point exceeding 150 ° C. is inconvenient in that the nonwoven fabric material is deteriorated or discolored by heat when subjected to heat and pressure processing. According to various findings of the present inventors, the preferred range of the melting point of the thermoplastic sheet,
It is in the range of 60 to 150 ° C.

Also, as an application example of the nonwoven fabric, an adhesive (a commonly used adhesive is a urethane resin) is impregnated in a portion where the fibers of the nonwoven fabric intersect, and then sliced into two sheets. There is a technique in which the surface of the nonwoven fabric is raised by buffing to produce a nonwoven product having a suede-like appearance. By attaching a plastic sheet, the value of the nonwoven material for various uses described above is high, and a more effective nonwoven material product can be obtained.

In the present invention, as shown in FIGS. 2 and 3, the thermoplastic sheets 6 and 11 are laminated on the back surface of the nonwoven fabric 1 and thermocompression-bonded to adhere to the back surface of the nonwoven fabric 1 by fusion. It is. In these figures, 8, 10,
14 is a thermocompression bonding surface, and 13 is a fiber cloth body. Reference numerals 7 and 12 are monofilaments constituting the nonwoven fabric buried in the thermoplastic sheets 6 and 11.

At the time of the fusing, the bonding strength between the two is determined by the melting point temperature of the sheet and the magnitude of the thermocompression bonding force.

According to various findings of the present inventors, thermoplastic sheets 6 and 11 are commercially available sheets such as polyester and polyamide (for example, a sheet made of polyamide manufactured by Toray Synthetic Film Co., Ltd., registered trademark “Reifan”). , A melting point of 102 ° C.) and the like.
° C, thermocompression force 5-30 kg / cm, processing speed 0.5-1
It is preferable to perform thermocompression bonding under conditions such as 0 m / min.

However, the range shown here is an example,
The combination of temperature, thermocompression force, and time requires a nonwoven material having excellent abrasion resistance and elasticity, which can be set according to the characteristics required for each application.

For example, when pressing, the temperature of only one surface of the thermoplastic sheet side is increased and thermocompression bonding is performed, so that the thermoplastic sheet dissolves and penetrates into the back surface of the nonwoven fabric 1 and the change in the temperature of the nap body on the surface is given. Can be reduced.

According to the knowledge of the present inventors, the abrasion resistance on the front surface of the nonwoven fabric on the opposite surface is improved by overlapping and thermocompression bonding on the back surface of the nonwoven fabric as described above.

Further, a fiber cloth 13 can be appropriately bonded to the thermoplastic sheet side. With such at least three-layer configuration, even if it is made into a chair upholstery, an automobile seat, a bag or a porch, water can hardly permeate into the interior.

Further, in order to obtain a feeling necessary for a chair upholstery, an automobile seat, a bag, a porch, shoes, etc., that is, a waisted feeling, the thickness of the thermoplastic sheet is appropriately changed. be able to.

According to various findings of the present inventors, the thickness of the thermoplastic sheet is preferably from 10 to 250 μm.

Further, when it is necessary to adjust the waist, strength, and elongation, the type of knitted fabric to be bonded to the back, or a thin material such as a tricot knitted fabric, is rich in softness.
It is more suitable for pouches, and if it is laminated with a thick material such as jersey, it will be more suitable for luggage, shoes, upholstery, automobile seats and the like.

[0029]

Embodiments Hereinafter, the configuration and effects of the present invention will be specifically described based on embodiments.

In the examples, the wear amount was measured by
The following method was used. (1) Amount of wear Using a uniform type abrasion tester manufactured by San-ei Measuring Instruments Co., Ltd., the sample was rotated 200 times with a nylon brush under a load of 8 kg according to JIS L1018-8.
It was measured according to the -181A method. The measurement averaged the number of n as 5.

A sample having an abrasion amount of 50 × 10 ⁻⁴ g or less was evaluated as “Excellent” and an abrasion amount of 150 × 10 ^-4 g
^-4 to 250 × 10 ⁻⁴ g were evaluated as good, and evaluated as “○”, and those with an abrasion amount exceeding 250 × 10 ⁻⁴ g were evaluated as “Δ” as slightly poor.

Example 1, Comparative Example 1 A sheet made of a copolymer polyamide having a melting point of 102 ° C. and a thickness of 50 μm (manufactured by Toray Synthetic Film Co., Ltd., registered trademark “Rayfan”) and a fine synthetic fiber of 0.2 decitex or less. And an artificial suede-like nonwoven fabric having a weight of 350 g /
m ² ), placed on the back side, passed between two calender rolls (combination of steel and paper), and thermocompressed to form a nonwoven fabric material of the present invention. 1 is shown.

Examples 1-1 and 1-2 shown in Table 1
Comparative Example 1-1 is a non-woven material as it is, and Comparative Example 1-2 is resistant to heat and pressure only by using a hot press roller without using a polyamide sheet. This is an attempt to improve the wear properties.

The evaluation results are shown in Table 1.

As is evident from Table 1, the wear resistance of the material according to the present invention was remarkably improved as compared with Comparative Examples 1-1 and 1-2.

Using the thus obtained nonwoven fabric material of the present invention, various secondary products such as chair upholstery, car seat, bag, pouch and shoes were produced.

As a result, it was confirmed that all the secondary products can be used more favorably for a long period of time than those made by using the non-woven fabric as it is because the non-woven fabric surface has high wear resistance. .

[0038]

[Table 1]

Example 2 Using the same copolyamide sheet as used in Example 1 and an artificial suede-like nonwoven fabric, the opposite side of the artificial suede-like nonwoven fabric was used to make the copolyamide sheet a middle layer. Polyester fiber yarn knitted fabric (200g basis weight)
/ M ² ) and passed between two calender rolls (combination of steel and paper) and thermocompression bonded to form a nonwoven fabric material of the present invention. The test results are shown in Table 2. Was.

Example 2 shown in Table 2 relates to the present invention, and Comparative Example 2 is a nonwoven fabric as it is.
As is apparent from Table 2, the present invention relates to:
The abrasion resistance was improved as compared with the non-woven material as it was, and the non-woven material had high strength and excellent elasticity.

[0041]

[Table 2]

[0042]

According to the present invention, a non-woven fabric having high abrasion resistance and excellent in abrasion resistance and elasticity which is suitable for applications such as upholstery, car seats, luggage, pouches, shoes and the like. Materials are provided.

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view schematically showing a cross section of a nonwoven fabric 1 which is a basic element of a nonwoven fabric material for handicrafts or a nonwoven fabric material having excellent wear resistance according to the present invention.

FIG. 2 is a schematic cross-sectional view schematically showing a state in which a thermoplastic sheet is thermocompression-bonded to one surface of the nonwoven fabric 1;

FIG. 3 is a schematic cross-sectional view schematically showing a state in which a thermoplastic sheet is pressure-bonded to one surface of a nonwoven fabric, and a fiber fabric is further laminated and thermocompression-bonded.

[Explanation of symbols]

 1: Non-woven fabric 2: Napped body 3: Adhesive 4: Cavity 5, 9: Non-woven fabric material 6, 11: Thermoplastic sheet 7, 12: Single fiber 8, 10, 14: Thermo-compression surface 13: Fabric body

Continued on the front page (72) Inventor Koichi Kagawa 1-1-1, Sonoyama, Otsu, Shiga Prefecture Inside Shiga Shokusan Co., Ltd. (72) Inventor Hirotaka Nakajima 1-6-20, Dojima, Kita-ku, Osaka-shi, Osaka Toray F-term in Osaka Works Co., Ltd. (Reference) 4F055 AA02 AA18 AA21 AA27 BA12 BA16 CA15 DA07 EA03 EA11 EA24 EA30 EA31 FA13 GA34 HA03 4F100 AK01B AK01C AK46 AK51A BA02 BA03 BA04 BA08 BA10A BA10C BA10D DG11E03 EC03 DG11 ECG GB81 JA20A JB16B JB16C JK07 JK09 YY00A 4L033 AA04 AB04 AB07 AC03 AC08 CA50 CA69 4L047 AA23 AB08 CA04 CA06 CB01 CC09 DA00

Claims (10)

[Claims] An abrasion resistance characterized in that a thermoplastic sheet having a melting point of 150 ° C. or less is thermocompression-bonded to one surface of a nonwoven fabric made of fine synthetic fibers of 1.1 decitex or less while maintaining the sheet shape. Non-woven material with excellent elasticity. 2. The abrasion resistance and elasticity according to claim 1, wherein when the thermoplastic sheet is thermocompression-bonded to one surface of the nonwoven fabric, the thermoplastic sheet is superposed on the back surface of the nonwoven fabric and thermocompression-bonded. Excellent nonwoven material. 3. The nonwoven fabric material having excellent wear resistance and elasticity according to claim 1, wherein a fiber fabric is further thermocompression bonded to the thermoplastic sheet side. 4. A non-woven fabric comprising fine synthetic fibers of 1.1 decitex or less, wherein at least one surface of the non-woven fabric is subjected to a water-repellent treatment. Non-woven material with excellent elasticity. 5. A non-woven fabric made of fine synthetic fibers of 1.1 decitex or less impregnated with a polyurethane resin, and the non-woven fabric has a suede-like surface obtained by buffing the surface of the non-woven fabric. 3. A nonwoven fabric material excellent in wear resistance and elasticity according to 3 or 4. 6. An upholstery made of the nonwoven fabric material having excellent abrasion resistance and elasticity according to claim 1, 2, 3, 4, or 5. 7. An automobile seat formed by using the nonwoven fabric material having excellent wear resistance and elasticity according to claim 1, 2, 3, 4, or 5. 8. A luggage characterized by being formed using the nonwoven fabric material having excellent abrasion resistance and elasticity according to claim 1, 2, 3, 4 or 5. 9. A pouch characterized by being formed using the nonwoven fabric material having excellent abrasion resistance and elasticity according to claim 1, 2, 3, 4 or 5. 10. A shoe formed by using the nonwoven fabric material having excellent wear resistance and elasticity according to claim 1, 2, 3, 4, or 5.