JP2008190076A - Method for producing sheet-like article having pattern - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for producing a sheet-like article having a good skin touch and a pattern, without requiring special equipment, and capable of applying various patterns. <P>SOLUTION: This method for producing the sheet-like article having the pattern includes ejecting a fluid on the surface of a grinding material when napping the sheet-like article, and forming the pattern on the surface of the sheet-like article by changing the density of the surface of the grinding material. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for producing a sheet-like material having a good touch and having a pattern, and relates to a method for producing a variety of patterns.

  As a method for adding a pattern to a napped sheet-like material, conventionally, embossing for suppressing nap by heat or printing that hardens the napped with a paste material has been used. However, in these methods, the raised hairs are partially solidified, so that there is a problem that the surface is hard and the touch is generally inferior.

  In addition, as a method of imparting a pattern while maintaining a good touch, a method of partially imparting a concave pattern by partially overgrinding the surface of the sheet is used when raising the surface of the sheet-like material. It has been. Moreover, in patent document 1, an uneven | corrugated pattern is provided without solidifying a nap by drawing a pattern directly on the surface of an abrasive and rubbing the surface of a sheet-like material, or a pattern is drawn on the member pressed against an abrasive. As a method of rubbing the surface, Patent Document 2 discloses a method of applying a pattern using equipment capable of accurately controlling the unevenness of a member pressed against an abrasive by computer control.

  Furthermore, in Patent Document 3, there is also a method of imparting a pattern to the surface of a sheet-like object by rubbing the surface of the sheet using an abrasive having a partially changed particle size by laminating a coarse abrasive and a fine abrasive. It is used.

However, all of these methods require the preparation of a special member having a specific pattern, special equipment, abrasives, etc., and due to the limitations of the apparatus, only a certain periodic pattern can be formed. There was a problem that I could not.
Japanese Patent Laying-Open No. 2005-082916 JP-A-9-209260 JP-A-6-287861

  In view of the background of the prior art, the present invention can provide a wide variety of patterns without requiring a special abrasive in a method for producing a sheet-like material having a good texture and a pattern. It is intended to provide a manufacturing method.

  The present invention employs the following means in order to solve such problems. That is, in the method for producing a sheet-like material of the present invention, when raising the surface of the sheet-like material containing ultrafine fibers of 1 decitex or less, the surface-like material is rubbed with an abrasive whose surface clogging is partially changed. A pattern is formed on the surface.

  ADVANTAGE OF THE INVENTION According to this invention, the surface napping sheet-like thing which has a favorable touch and various patterns can be provided.

  The present invention has been intensively studied on the above-mentioned problem, a method for producing a surface raised sheet having a good touch and a variety of patterns, and when raising the surface of a sheet containing ultrafine fibers of 1 dtex or less, When the surface was rubbed with an abrasive whose surface clogging was changed, it was possible to successfully solve this problem.

  The sheet-like material in the present invention means, for example, a woven fabric, a nonwoven fabric, a knitted fabric, a film, a resin, etc., and the surface is covered with napping, but it is easy to become a good touch after grinding. Is preferably a non-woven fabric.

  The ultrafine fiber referred to in the present invention has a single fiber fineness of 1 dtex or less in order to obtain a good touch of the product. In order to obtain a better touch, the fineness is preferably thinner, preferably 0.3 dtex or less, more preferably 0.1 dtex or less, and still more preferably 0.01 dtex or less.

  The sheet-like material in the present invention preferably contains 50% or more of ultrafine fibers of 1 dtex or less, and more preferably 80% or more.

  In addition, the single fiber fineness of the ultrafine fiber which comprises a sheet-like material, and the number ratio of the ultrafine fiber whose single fiber fineness is 1 dtex or less are calculated | required as follows. That is, when the cross section of the ultrafine fiber is circular or an ellipse close to a circle, a scanning electron microscope (SEM) photograph of the surface of the sheet is taken at a magnification of 2000 times, 100 ultrafine fibers are randomly selected, and the fiber diameter Is converted into the fineness from the specific gravity of the material polymer, and the ratio of the number of ultrafine fibers of 1 dtex or less out of 100 is calculated as a percentage.

  On the other hand, in the case where the ultrafine fibers constituting the sheet-like material have an irregular cross section, the outer peripheral circular diameter of the irregular cross section is calculated as the fiber diameter in the same manner. In addition, when the circular cross section and the irregular cross section are mixed, or when the ones with greatly different fineness are mixed, 100 are selected so that each has the same number. Calculated by converting to the area of a perfect circle.

  Although the material is not limited, ultrafine fibers are made of polyester fibers such as polyethylene terephthalate, polybutylene terephthalate and polytrimethylene terephthalate, and polyamides such as nylon 6 and nylon 66 from the viewpoint of ease of processing and the texture of the product. It is desirable that the material is at least one material selected from natural fibers such as fibers, acrylic fibers, cotton, wool, and silk. In order to obtain a better texture, polyester fibers, polyamide fibers, and acrylic fibers are desirable.

  The sheet-like material referred to in the present invention may be in any form as long as the constituent fibers include the ultrafine fibers and the surface thereof is covered with nappings made of the constituent fibers including the ultrafine fibers, for example, spunbond or needle punch. Alternatively, those obtained by entanglement of fibers with a water jet punch or the like are preferably used. In addition, there is no particular limitation on the napped form on the surface, but from the viewpoint of the design effect, it has napped length and directional flexibility to the extent that a so-called finger mark that leaves a mark when the napped direction changes when traced with a finger. Preferably it is.

  The pattern referred to in the present invention refers to a pattern in which long hairs and short hairs are formed by different lengths of napped fibers, and the combination of the long and short hairs is a pattern. Although there is no restriction | limiting in particular in the napping length of this long part and a short part, in order to obtain a clear pattern, it is desirable that a napping length difference is 0.1 mm or more. The pattern is not particularly limited, and can be applied to, for example, a non-periodic or irregular pattern or a logo mark in addition to a regular pattern.

  As a method of obtaining the ultrafine fibers constituting such a sheet-like material, a method of directly obtaining ultrafine fibers and a method of once creating ultrafine fiber generating fibers and then expressing the ultrafine fibers can be adopted. In view of the point at which it is easy to obtain and the flexibility of the sheet-like material to be obtained, a method of once producing an ultrafine fiber-generating fiber and then expressing the ultrafine fiber is preferably used. For example, a method in which a plurality of polymers having different solubilities are spun together to obtain fibers capable of expressing ultrafine fibers, and then at least one kind of polymer is removed to form ultrafine fibers, or radial, For example, a method of separating and dividing a plurality of different polymers alternately arranged in layers can be used.

  As a composite form when spinning such fibers capable of expressing ultrafine fibers, it is preferable to use a side-by-side type in which polymers are bonded to each other or a sea-island type in which another polymer exists in an island shape in the polymer. it can. Examples of the polymer to be removed include polyolefins such as polyethylene and polystyrene, copolymer polyesters obtained by copolymerizing sodium sulfoisophthalic acid, polyethylene glycol, and the like to improve alkali solubility.

  Next, the method of developing ultrafine fibers varies depending on the type of component to be removed, but for polyolefins such as polyethylene and polystyrene, organic solvents such as toluene and trichlorethylene are used, and water is used for copolymerized polyesters with increased alkali solubility. A method of performing extraction by dipping in an aqueous alkali solution such as sodium oxide can be preferably used.

  Next, a method for forming the ultrafine fiber into a sheet will be described. Such a sheet may be a woven fabric, a knitted fabric, a short fiber nonwoven fabric, or a long fiber nonwoven fabric, but a short fiber nonwoven fabric is preferable when emphasis is placed on texture and quality. As a method for obtaining such a short fiber nonwoven fabric, a method using a card machine or a cross wrapper, or a papermaking method can be employed. Moreover, the nonwoven fabric obtained by these methods may be entangled with a needle punch or a water jet punch, or may be integrated with another woven fabric, knitted fabric, or nonwoven fabric.

  In producing the sheet-like material of the present invention, it is possible to adopt a method of forming ultrafine fibers first and then forming into a sheet, or after forming the above-described fibers capable of developing ultrafine fibers into a sheet, the above-mentioned treatment is performed to make ultrafine fibers. It is also possible to adopt a method for expressing fibers.

  The sheet-like material of the present invention may contain an elastic resin. For example, polyurethane-based, polyester-based, polyamide-based, polyolefin-based elastomer resins, acrylic resins, silicone resins, ethylene-vinyl acetate resins, etc. can be used as long as the performance and texture as a binder are not impaired. From the viewpoint, polyurethane is preferably used. As such a polyurethane application method, a method in which a polyurethane solution is impregnated with a sheet-like material and further immersed in water or an aqueous organic solvent solution to solidify the polyurethane is preferable. As the solvent used in such a polyurethane solution, N, N′-dimethylformamide, dimethylsulfoxide, or the like can be preferably used. Moreover, you may add a pigment, a ultraviolet absorber, antioxidant, etc. as needed.

  Next, a method for raising the surface of the sheet-like material obtained in this way (napping treatment) will be described. That is, as the napping treatment, a method of grinding the surface of the sheet-like object with a buffing machine is preferable. The abrasive of the buffing machine used here is not limited as long as it can cut the surface of the sheet-like material, and sand paper, sand cloth or metal file can be used, particularly from the viewpoint of workability. A sandpaper as shown in FIG. 1 is preferably used. When sandpaper is used for the abrasive, the paper roughness is preferably 50 to 500, more preferably 100 to 350, from the viewpoint of surface quality. Moreover, there is no restriction | limiting in the material of the member pressed against an abrasive, A roll shape is preferably used from a sheet | seat workability about a shape. That is, a roller sander device as described in Patent Document 3 (Japanese Patent Application Laid-Open No. 6-287861) is preferable, and FIGS. 1 and 2 show only a sandpaper portion including a roll.

  In order to develop a pattern simultaneously with the napping treatment on the surface of the sheet-like material, the following method is adopted. That is, the present invention does not require a special abrasive such as combining sandpapers having different particle sizes as in the prior art, or forming a part that does not have sandpaper partially. Abrasive material that is partially rubbed with an abrasive material whose surface clogging has changed partially to form a pattern on the napped surface.

  The method for partially changing the clogging of the surface is not particularly limited, but it is preferable to partially change the clogging of the surface by injecting a fluid onto the abrasive.

  When the fluid is sprayed onto the abrasive, the clogged state of the abrasive in the sprayed portion changes, so the surface state of the sheet-like material ground by the abrasive that is not sprayed and the grinding of the sprayed portion. Different surface states are formed in the surface state of the sheet-like material ground by the material. Although it is necessary to install the injection nozzle so that the fluid hits the abrasive, no special equipment other than the portion related to the injection nozzle is necessary. However, when applying a complicated pattern, a system for controlling the injection pressure, the injection time, and the like may be necessary.

  The clogged state of the abrasive surface can be changed by adjusting the type and amount of the fluid to be ejected and the nozzle diameter. The fluid sprayed onto the abrasive is composed of at least one selected from gas and liquid, and may be a mixed fluid of gas and liquid. The fluid can contain a solid. As a simple method, as the fluid, compressed air, a gas such as nitrogen, or a liquid such as water can be used, but compressed air is preferred from the viewpoint of cost and ease of handling. When the gas or liquid contains a solid such as a powder or particle, clogging is promoted by using a powder or the like of a material that easily adheres to the abrasive. In addition, clogging is reduced by using a material that is difficult to adhere, such as metal particles. Further, the speed of the fluid to be ejected is not particularly limited, and can be set to a speed suitable for the pattern to be created.

  The clogging of the abrasive tends to increase the length of the napped surface of the sheet-like material as it is clogged, but the length depends on the material of the sheet-like material, the fibers contained, and the type of elastic resin. The degree of change is different. Further, since the length of the hair changes depending on the degree of clogging, it can be adjusted depending on the type and amount of the fluid.

  Furthermore, by combining the number and shape of the spray nozzles, the position of the spray nozzles, and the timing of spraying, in addition to periodic patterns such as striped patterns and polka dots, irregular patterns and logo marks, etc. It is possible to form a wide variety of patterns. For example, by continuously injecting fluid as shown in FIG. 1, a change in clogging in a vertical stripe pattern can be caused in the abrasive, and as a result, a vertical stripe pattern can be formed on the sheet-like material. FIG. 2 uses the same equipment as FIG. 1, but by intermittently injecting the fluid, the abrasive can be clogged in a polka dot pattern, resulting in a sheet-like material. A polka dot pattern can be formed. More complicated patterns are possible by controlling the change in the position of the injection nozzle, the timing of injection, and the like by a computer.

  Hereinafter, the present invention will be described in more detail with reference to examples.

[Evaluation methods]
(1) Ratio of ultrafine fibers with a single fiber fineness of 1 dtex or less Take a scanning electron microscope (SEM) photograph of the surface of a sheet-like material at a magnification of 2000 times, and randomly select 100 circular or nearly elliptical fibers The fiber diameter was measured and converted from the specific gravity of the fiber polymer to the fineness, and the percentage of ultrafine fibers of 1 dtex or less out of 100 was calculated as a percentage.

[Example 1]
Raw material of sea-island type composite fiber of polyethylene terephthalate as island component, component ratio 55/45 consisting of polystyrene as sea component, number of islands 32, composite fineness 3.3 decitex, fiber length 51mm, number of lodge 5.6 mountain / cm The raw cotton is opened using a card machine to form a web, and then the laminated web is formed by superimposing the web with a cross wrapper. Then, 3000 needles / cm ² was punched on the laminated web with a needle punch machine having a needle board in which needles were randomly planted to prepare a nonwoven fabric having a width of 120 cm and a basis weight of 300 g / m ² .

  The nonwoven fabric was impregnated with a 12% aqueous solution of polyvinyl alcohol and dried to give polyvinyl alcohol as a shape stabilizer to the sheet, and then exposed to a liquid flow of trichlorethylene in the extraction process to extract polystyrene as a sea component. This is impregnated in a polyurethane-dimethylformamide solution in the impregnation step, then the polyurethane is coagulated in water, further exposed to a stream of water to extract dimethylformamide and polyvinyl alcohol, and then dried in a drier to produce 1 dtex ultra fine polyethylene terephthalate fiber And an elastic resin-containing sheet having a width of 120 cm and a thickness of 1 mm made of polyurethane.

  Of the fibers constituting the elastic resin-containing sheet, the proportion of ultrafine fibers having a single fiber fineness of 1 dtex or less was 98%.

Next, when the obtained sheet is napped with sandpaper by a buffing machine, the spray nozzles having a mouth diameter of 1 cm are arranged in a row of 10 cm so that the compressed air hits the surface of the sandpaper of No. 200 paper roughness. Ten sheets were arranged at equal intervals, placed at a position 5 cm from the sandpaper, and the sheets were rubbed while jetting compressed air with a pressure of 6 kg / cm ² from each nozzle. At this time, the rotational speed of the sandpaper was 10 m / second, and the sheet was rubbed while being conveyed at a speed of 0.1 m / second, but the sandpaper had a portion that was less clogged by the injection of compressed air, A width of about 2 cm was formed continuously in the direction of sandpaper rotation.

  It was confirmed visually that the obtained napped sheet had vertical stripes with a width of about 2 cm at regular intervals.

[Example 2]
When napping the elastic resin-containing sheet similar to that in Example 1, 0.1 second compressed air is supplied at intervals of 0.9 seconds from one of the central nozzles of the injection nozzle attached in the same manner as in Example 1. Scraping was carried out while spraying at a pressure of 6 kg / cm ² . In the central portion of the sandpaper in the width direction, a portion that is less clogged by the injection of compressed air was formed at an equal interval of about 2 cm in diameter in the sandpaper rotation direction.

  It was confirmed by visual observation that a ball pattern having a diameter of about 2 cm was formed at intervals of 10 cm in the length direction in the center portion in the width direction of the napped sheet obtained.

[Comparative Example 1]
When the elastic resin-containing sheet similar to that in Example 1 was napped, it was rubbed without spraying compressed air onto the sandpaper surface. At this time, the moving speed of the sandpaper was 0.1 m / second, and the sheet was rubbed while being conveyed at a speed of 0.1 m / second.

  It was visually confirmed that the obtained napped sheet had no pattern.

In the manufacturing method of this invention, it is drawing which showed an example (continuous injection) of the abrasives and the fluid injection equipment. (Example 1) It is drawing which showed the case where the fluid was intermittently injected in the same abrasive material and fluid injection equipment as FIG. (Example 2)

Explanation of symbols

1: Roll 2: Abrasive material 3: Injection nozzle 4: Location where abrasive material is not clogged 5: Location where abrasive material is clogged 6: Roll

Claims (7)

When raising the surface of a sheet-like material containing ultrafine fibers of 1 dtex or less, the clogging of the surface is partially changed to an abrasive material of uniform roughness, and then the sheet-like material is abraded with the abrasive material. A method for producing a patterned sheet-like material, wherein a pattern is formed on the napped surface of the sheet-like material. The method for producing a patterned sheet-like material according to claim 1, wherein the clogging of the surface of the abrasive is changed by jetting a fluid onto the surface of the abrasive. The method for producing a patterned sheet-like material according to claim 2, wherein the fluid is at least one selected from a gas and a liquid. The method for producing a patterned sheet-like material according to claim 2 or 3, wherein the fluid contains a solid. The said sheet-like material contains elastic resin, The manufacturing method of the sheet-like material with a pattern in any one of Claims 1-4 characterized by the above-mentioned. 6. The method for producing a patterned sheet-like material according to claim 5, wherein the elastic resin is polyurethane. The method for producing a patterned sheet material according to any one of claims 1 to 7, wherein the sheet material is composed of at least one fiber selected from polyester, nylon, and acrylic.

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