JP2009084751A - Production method of napped sheet-like product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production method of a sheet-like product having good touch and uniform surface conditions. <P>SOLUTION: The production method of the sheet-like product includes, setting an abrasive for napping to be positioned at an angle other than 90°, wherein the longitudinal direction of the sheet-like products is 0°, against the sheet-like product and to be horizontal against the sheet-like product surface, and napping, when napping the surface of the sheet-like products. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for producing a sheet-like product having a good touch and a uniform surface state.

  As a method for raising a sheet-like material, conventionally, a method for raising a sheet using a grinding material such as sand paper, sand cloth, sand net, or sand roll, a brush, a needle cloth, or the like has been used. In the method using an abrasive, a sheet is put in a specific direction and brought into contact with the above-mentioned abrasive or the like to raise the surface. When the surface is raised with sandpaper or sand cloth while the sheet-like material is continuously run as in Patent Literature 1 and Patent Literature 2, it corresponds to a long sheet-like material or is convenient for processing. Then, the rotating body having the abrasive material on the surface is disposed at 90 degrees with respect to the length direction of the sheet material, and the rotating material is rotated so that the surface of the abrasive material continuously contacts the sheet material. A method of raising napping while conveying an object is common.

However, since these methods arrange the abrasives at 90 degrees with respect to the length direction of the sheet-like material, the sheet is caused by differences in the fine surface state of the abrasives and the members that support the abrasives, deterioration during processing, etc. There was a problem that a portion having different lengths of napped portions was continuously formed in the length direction at a specific position in the width direction of the object, and a pattern like a vertical stripe might be seen.
JP-A-6-287861 JP-A-6-123060

  In view of the background of the prior art, the present invention is intended to provide a method for producing a sheet-like product having no vertical stripes due to napping treatment and having the surface raised uniformly.

  The present invention employs the following means in order to solve such problems. That is, in the method for producing a sheet-like material according to the present invention, the angle θ between the rotation axis of the abrasive material and the conveying direction of the sheet-like material is an angle other than 90 degrees, and the abrasive material is in horizontal contact with the sheet-like material plane. It arrange | positions so that it may raise and it may be raised.

  According to the present invention, it is possible to provide a sheet-like material having a good touch and a uniform surface raised state.

  The present invention has intensively studied the above-mentioned problem, a method for producing a surface raised sheet-like material having a good touch and a variety of patterns, and an angle θ formed by the rotating shaft of the abrasive and the conveying direction of the sheet-like material is other than 90 degrees. At this angle, the abrasive was placed so as to be in contact with the sheet-like object plane in a horizontal manner and raised, and this problem was successfully solved.

  The sheet-like material in the present invention is, for example, a woven fabric, a nonwoven fabric, a knitted fabric, a film, a resin or the like, and the napped sheet-like material means a sheet-like material whose surface is covered with napped hairs.

  In the present invention, a sheet-like material containing ultrafine fibers is preferable because it is likely to have a good touch after the napping treatment, and the sheet-like material is preferably a nonwoven fabric.

  The ultrafine fiber in the present invention preferably 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. For the purpose of obtaining a good touch of the product, the ultrafine fibers are preferably present on the surface of the sheet.

  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 napped sheet-like material preferably used in the present invention may have any form as long as the ultrafine fibers are included in the constituent fibers and the surface thereof is covered with the napped fibers made of the constituent fibers including the ultrafine fibers. Those obtained by entanglement of fibers by a needle punch or a water jet punch 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 state in which the surface raised state in the present invention is uniform means that the length of the raised fiber is different so that a long part and a short part of the hair are not formed, and the combination of the long part and the short part is a pattern. It means things that are not. Although there is no restriction | limiting in particular in the napping length of this napped surface, In order to obtain a favorable texture, napping length of the grade which the said finger mark emits is preferable.

  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 in which a plurality of different polymers alternately arranged in layers are separated by separation 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. The sheet-like material 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 the texture and quality. As a method for obtaining such a short fiber nonwoven fabric, a usual method such as a method using a card machine or a cross wrapper or a paper making 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. Further, when a woven fabric, a knitted fabric, or a long-fiber nonwoven fabric is used, a normal manufacturing method can be used.

  In producing the sheet-like material in the present invention, it is possible to employ a method of first forming an ultrafine fiber and then forming it into a sheet. It is also possible to adopt a method for expressing fibers.

  The sheet-like material in 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 buffing machine abrasive used here is not limited as long as it can cut the surface of the sheet-like material, and conventionally used for napping of sheet-like materials such as sandpaper, sand cloth and metal files. Although a material can be used, sandpaper is preferably used particularly from the viewpoint of workability. 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 shown in FIGS. 1 and 2 is preferable.

  In a general napping method, since the sheet-like material is long, it is ground by being pressed against the sheet-like material while moving the abrasive while being conveyed in the length direction. As for how to move the abrasive, as shown in FIG. 4, in the case of a roller sander device, the pressed portion is in exactly the same direction (0 degrees) as the sheet material conveyance direction, or completely reverse (180 degrees). It is usually rotated so that That is, the conveying direction of the sheet and the axis of movement of the abrasive coincide. That is, in the case of a roller sander device, the angle θ formed by the rotating shaft of the abrasive and the conveying direction of the sheet-like material is 90 degrees.

  On the other hand, in the present invention, the following method is adopted when napping the surface of the sheet-like material. That is, the present invention is not arranged so that the angle θ formed by the rotation axis of the abrasive and the conveying direction of the sheet-like material is 90 degrees as in the prior art, but is arranged so as to contact at an angle other than 90 degrees. By grinding and grinding, a uniform surface state having no pattern such as vertical stripes due to the napped length difference or density difference is formed on the napped surface.

  The angle θ between the rotational axis of the abrasive and the sheet conveying direction is not particularly limited as long as it is an angle other than 90 degrees, but it is 45 degrees or more and 135 degrees or less excluding 90 degrees for ease of processing. Angle is preferred. Further, when grinding is performed by continuously conveying the sheet-like material in contact with the abrasive, if the angle θ is too far from 90 degrees, the conveyance of the sheet-like material is hindered. An angle of not less than 120 degrees and not more than 120 degrees is more preferable. When the friction between the abrasive and the sheet-like material is large, an angle of 75 degrees or more and 105 degrees or less excluding 90 degrees is more preferable. Further, even if it is not 90 degrees, the effect is reduced if the angle is too close to 90 degrees, so it is preferable to set the angle within the range of 45 to 85 degrees or 95 to 135 degrees.

  In the present invention, when using a roller sander device using a grinding material such as roll sandpaper, the rotational direction of the grinding material can be set as needed, and the rotational speed is particularly limited. It is possible to set appropriately.

  According to the manufacturing method of the present invention, the napping on the surface of the sheet-like material is formed at an angle different from the length direction of the sheet-like material, so that it is continuous in the length direction at a specific position in the width direction of the sheet-like material. A vertical stripe pattern is not formed on the surface, and a uniform raised surface is formed with a good touch. Further, no special device is required except that the angle θ formed between the rotating shaft of the abrasive and the conveying direction of the sheet-like material is set horizontally with respect to the plane of the sheet-like material at an angle other than 90 degrees.

  Furthermore, the napping process can be performed a plurality of times on the sheet-like material. When raising the surface of the sheet-like material by performing the napping treatment a plurality of times, for example, as shown in FIG. 3, the angle θ formed by the rotation axis of the abrasive and the conveying direction of the sheet-like material may be changed every time. Is possible.

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

[Evaluation methods]
(1) Ratio of the number of ultrafine fibers having a single fiber fineness of 1 dtex or less A scanning electron microscope (SEM) photograph of the surface of a sheet-like material was taken at a magnification of 2000 times, and 100 circular or nearly elliptical fibers were randomly selected. The fiber diameter was selected and converted from the specific gravity of the fiber polymer to the fineness, and the ratio of the number 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. Next, 3000 needles / cm ² of needle punching was performed 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 An elastic resin-containing sheet-like material having a width of 120 cm and a thickness of 1 mm made of polyurethane was prepared.

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

  Next, when the obtained sheet-like material is napped with sandpaper by a buffing machine (roller sander device shown in FIG. 1), sandpaper having a paper roughness of No. 200 is used. As shown in FIG. It arranged so that it may contact | connect at (theta) = 60 degree | times and the napping process was performed.

  At this time, the sandpaper was rotated at a speed of 10 m / second in the direction opposite to the sheet conveyance direction, and the sheet was rubbed while being conveyed at a speed of 0.1 m / second.

  It was confirmed visually that the obtained napped sheet-like product had no vertical stripe pattern and had a uniform napped surface.

[Example 2]
When napping the elastic resin-containing sheet-like material similar to that in Example 1, the nap paper was disposed so that the sandpaper was in contact at θ = 120 degrees as in Example 1, and napping was performed.

  At this time, the sandpaper was rotated at a speed of 10 m / second in the direction opposite to the sheet conveyance direction, and the sheet was rubbed while being conveyed at a speed of 0.1 m / second.

  It was confirmed visually that the obtained napped sheet-like product had no vertical stripe pattern and had a uniform napped surface.

[Example 3]
When an elastic resin-containing sheet-like material similar to that in Example 1 was napped, napping was performed by a buffing machine in which two sheets of the sheet-like material were continuous. The buffing machine is the same as the buffing machine used in the first embodiment.

  At this time, the first buffing machine is arranged so that the sandpaper contacts the sheet at θ = 60 degrees, and the second buffing machine is arranged so that the sandpaper contacts the sheet at θ = 120 degrees. Arranged. The sandpaper rotates at a speed of 10 m / second in the direction opposite to the sheet conveyance direction, and the sheet-like material is conveyed at a speed of 0.1 m / second so that the napping processing is continuously performed on two sandpapers. While rubbing.

  It was confirmed by visual observation that the obtained napped sheet-like product had no vertical stripe pattern and had a uniform napped surface, and confirmed that it had a good hand feeling.

[Comparative Example 1]
When an elastic resin-containing sheet-like material similar to that in Example 1 was napped, the sandpaper was placed so that it contacted at θ = 90 degrees, and napped. At this time, the moving speed of the sandpaper was 10 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-like material had a vertical stripe pattern.

It is drawing which showed an example of the manufacturing method of this invention. (Θ = 60 degrees) (a) is a perspective view, and (b) is a view from the side (perpendicular to the conveying direction). It is drawing which showed another example of the manufacturing method of this invention ((theta) = 60 degree | times), and is the figure seen from right side (direction perpendicular to a conveyance direction). It is drawing which showed another example of the manufacturing method of this invention ((theta) 1 <> theta2), and is the figure seen from right above (direction perpendicular | vertical to a conveyance direction). It is drawing which showed the napping method of the prior art. (Θ = 90 degrees) (a) is a perspective view, and (b) is a view from the side (perpendicular to the conveying direction).

Explanation of symbols

1: Sheet-like material 2: Grinding material 3: Sheet-like material conveyance direction 4: Axis of rotation of the grinding material θ: Angle between the sheet-like material and the grinding material

Claims (5)

  The angle θ between the rotation axis of the abrasive and the conveying direction of the sheet-like material is an angle other than 90 degrees, and the abrasive is arranged so as to be in horizontal contact with the plane of the sheet-like material, and is raised. The manufacturing method of napped sheet-like material   2. The method for producing a napped sheet-like material according to claim 1, wherein an angle θ formed by the rotating shaft of the abrasive and the conveying direction of the sheet-like material is an angle of 45 ° to 135 ° excluding 90 °. .   3. The method for producing a napped sheet-like product according to claim 1, wherein the napping is performed a plurality of times.   4. The method for producing a napped sheet-like material according to claim 3, wherein when the napping is performed a plurality of times, the angles θ formed by the rotating shaft of the abrasive and the conveying direction of the sheet-like material are set to different angles, respectively. .   The said sheet-like material contains elastic resin, The manufacturing method of the napping sheet-like material in any one of Claims 1-4 characterized by the above-mentioned.

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