JP2008223216A - Method for continuously producing nonwoven fabric for reinforcing back face, and the nonwoven fabric product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To produce a nonwoven fabric formed product and a plane nonwoven fabric product by continuously producing the nonwoven fabric of a fiber made of a thermoplastic resin material, to which a reinforcing sheet material, reinforcing powder, or particles is pasted on the back face. <P>SOLUTION: A press mold product and a flat product of the nonwoven fabric of product portions are produced by needle punching each commercial product portion of a thermoplastic resin fiber laminate and a laminate portion connecting the same by an NC apparatus to produce the nonwoven fabric product and its connection portion, and continuously reinforcing the back of the same with a molten resin sheet, resin particles or powder which are the same kinds as the nonwoven fabric to be thermally bonded. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a continuously reinforced non-woven fabric product.

  In the production of a conventional nonwoven fabric, a plurality of pile fibers stacked in multiple layers are driven into a predetermined width with a needle, and the fibers are entangled with each other to form a cloth. (Reference Japanese Patent Application No. 2005-71867 [Background Art] [0003] [0004] [0005] and [FIG. 5]) However, the needle is operated to form a shape necessary for final productization, Product efficiency is improved by not operating parts that are not necessary for commercialization.

  Therefore, for commercialization, it is necessary to thermally weld a backing material or a molten sheet that is thermally welded to the pile fiber on the back surface of the nonwoven fabric in order to provide three-dimensional molding or necessary product rigidity. For this purpose, it is necessary to use a nonwoven fabric fiber as a thermoplastic resin and spray a molten powdery or granular material of the same material that is thermally welded to the back surface, or paste a molten sheet on the back surface of the nonwoven fabric.

  In order to do so, it is necessary to reinforce the back surface. Conventionally, the work has been performed for each product, which is an inefficient operation.

  It is necessary to attach a back surface reinforcing material to make a three-dimensional thermoformed product using a nonwoven fabric or to give rigidity to a planar nonwoven fabric product.

  In terms of production technology, it is necessary to continuously perform the back surface reinforcement work for the parts required for the commercialization of the products.

  The NC device or the like is driven so that the needle is driven only into the productized shape, and the NC device is also set to be driven to the shape portion that connects the productized portions in a connected form. The connecting shape needs to have a size and strength sufficient to continuously move the fiber weight of the commercialized part.

After forming the nonwoven fabric of the connecting portion, it is solid to continuously introduce it into the back surface reinforcing step, but when it is not possible, the nonwoven fabric may be wound up and sent to the back surface reinforcing step.
In that case, a connecting portion having a size and a weight capable of continuously winding the product portion is required.

  In the back surface reinforcing step, the nonwoven fabric is reinforced by welding it to a portion necessary for commercialization of the back surface of the nonwoven fabric fiber with a melted powder, particles, or sheets that are thermally welded to the thermoplastic nonwoven fabric fiber. It is also necessary for three-dimensional heating.

  Cut to the required shape in the next process, or three-dimensionally molded with a press mold and cut to the required shape, and attach the mounting parts.

  Unused scrap after cutting is sent to the recycling process.

  Since the fibers are used only in the portions where the nonwoven fabric is necessary for commercialization, the fiber saving and the working time are greatly reduced as compared with the case of forming the nonwoven fabric with a constant width.

  The back reinforcement work for each product in the back face reinforcing process of the nonwoven fabric is eliminated, and automatic continuous work is possible, improving production technical efficiency.

  Material costs and manufacturing costs for interior parts such as automobiles, vehicles, ships, airplanes and buildings can be reduced.

  Material to be discarded can be reduced, and industrial waste can be eliminated.

As shown in FIG. 1, since the nonwoven fabric products 1 are continuously heat-bonded by the back surface reinforcing sheet 3 that is heat-sealed to each other, the nonwoven fabric products 1 are formed by connecting the nonwoven fabric production connecting portions 2.
As the sheet material to be reinforced on the back surface, a thermoplastic resin such as polypropylene, polyethylene, soft vinyl chloride, or the like, which is heat-welded with the nonwoven fiber material, is used.

  An automatic device such as an NC device is programmed so that the needle is inserted into only the non-woven fabric product portion and its connection portion.

  Although the embodiment is a sheet-shaped back surface reinforcement, a granular or powdered resin material of the same material as the nonwoven material may be heated and softened and sprayed onto the back surface of the nonwoven fabric.

  The product is not limited to a flat product as shown in the figure, but it is also possible to heat-soften the nonwoven fabric reinforced on the back surface and perform press solid molding with a mold made of hard resin or the like.

  After the product has been commercialized, the parts other than the commercialization of the backside reinforcement are cut off and sent to the recycling process.

  When the manufacturing process for reinforcing the back surface is not continuous, the nonwoven fabric may be formed into a roll shape.

It is the nonwoven fabric product part in the nonwoven fabric manufacturing process of this invention, its nonwoven fabric manufacture connection part, and a back surface reinforcement sheet | seat.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 Nonwoven fabric product 2 Nonwoven fabric manufacturing connection part 3 Back surface reinforcement sheet

Claims (2)

  In a manufacturing apparatus for manufacturing a nonwoven fabric by inserting a needle into a laminated web-like thermoplastic material fiber, the needle is in a shape necessary for the final productized portion of the laminated web-like fiber. Set to be controlled and driven using a shape control device such as an NC device so as to be inserted into the shape portion to which it is connected, and the productized portion fiber and heating on the back of the productized portion of the nonwoven fabric produced by the drive A method for producing a continuous nonwoven fabric product by applying a sheet made of a thermoplastic resin to be melted or by adhering molten particles or powder.   A non-woven fabric product obtained by press-solid forming the non-woven fabric according to claim 1 excluding a continuous portion, which is reinforced on the back surface, and removing unnecessary portions or cutting into a predetermined planar shape.

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