JP2009235638A - Nonwoven fabric with pattern and method for producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a nonwoven fabric with a pattern in a stable state of pattern, which forms a clear pattern, comprises fibers sufficiently fixed on surface and inside and a method for producing the same. <P>SOLUTION: The method for producing a nonwoven fabric with a pattern comprises continuously jetting steam on a fiber web placed on an open substrate that has a large number of openings and can be transported while transporting the fiber web by the open substrate in which the open substrate has at least a pair of adjacent openings having the mutual shortest distance of ≥2 mm in the projected figure of the open substrate, the fiber web contains a latently crimpable fiber and the temperature of the steam is the crimping temperature of the latently crimpable fiber or more. The nonwoven fabric with a pattern is obtained by the production method. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for producing a patterned nonwoven fabric suitable for producing a patterned nonwoven fabric by spraying steam onto a fiber web, and a patterned nonwoven fabric produced by the production method.

  2. Description of the Related Art Conventionally, a method for manufacturing a nonwoven fabric by spraying steam onto a fiber web is known. For example, Patent Document 1 discloses a method for carrying and transporting a porous fiber web that travels in one direction using a pressurized steam jet nozzle. There is described a method for producing a nonwoven fabric in which constituent fibers are entangled by continuously injecting pressurized steam from a number of nozzle holes along the width direction of the fiber web placed on the means. According to this method, the superheated steam ejected from the steam ejection nozzle is steam that has been heated to a temperature equal to or higher than the saturation temperature under the saturated steam pressure, and is unlikely to condense and liquefy between the saturation temperature and the superheat temperature. . For this reason, the superheated steam ejected from the steam ejection nozzle does not condense even when it hits the fiber web, penetrates into the inside and penetrates it, and entangles the surrounding fibers while heating them. As a result, it is described that the entanglement of the fibers and the heat setting are simultaneously performed by the passage of the heating steam.

  Further, as the above-mentioned porous fiber web carrying and transferring means, for example, a wire net or punching metal can be used, and it is described that the mesh degree of each transferring means is preferably 20 to 40 (pieces / 2.54 cm). Has been. In addition, a pressurized high-temperature air ejection device is provided in front of the pressurized steam ejection nozzle, and a low melting point fiber is mixed in a part of the constituent fibers of the fiber web, prior to the application of the pressurized steam. It is possible to stabilize the surface form of the fiber web by applying pressurized air to melt the low melting point fibers contained in the constituent fibers near the surface of the fiber web and fusing them together. It is described that.

  Unlike the method of injecting steam onto the fiber web as described above, a method of entangling fibers by injecting a columnar high-pressure water stream onto a fiber web placed on a porous fiber web carrying and transferring means is known. . In the case of the latter method, it is considered that the fiber is pushed into the opening of the fiber web carrying and transferring means by the water flow and the fiber is highly entangled. On the other hand, in the case of the former method, the steam collides with the non-opening portion of the fiber web carrying and transferring means, and the fibers gather in the opening portion of the fiber web carrying and transferring means due to the force that spreads in the lateral direction. It is considered to be slightly entangled compared with the case of.

  However, as described above, Patent Document 1 is a technique for simultaneously performing fiber entanglement and heat setting, and it has not been possible to manufacture a nonwoven fabric with a clear pattern by the technique described in Patent Document 1. That is, Patent Document 1 describes that the meshing degree of the transfer means is preferably 20 to 40 (pieces / 2.54 cm). In this case, with reference to FIG. 17 showing a 20 mesh wire mesh, when the meshing degree of the transfer means is 20 per 2.54 cm, 2.54 cm is divided into 20 equal parts, and as a result, the transfer means Even if the thickness of the woven mesh constituting the mesh is a value close to 0, the length of one side l (or m) of the opening is 0.127 cm (2.54 cm ÷ 20 = 0.127 cm). Never exceed. Further, the distance c between one opening and the adjacent opening in the oblique direction of this opening does not exceed 0.18 cm (0.127 cm × 1.41 = 0.18 cm). Therefore, many fibers cannot be collected in such a small opening, and even if some fibers are collected, the pattern due to some of the fibers is too fine and cannot be recognized as a clear pattern by visual observation. Further, the thickness b1 (or b2) of the woven mesh forming the non-opening does not exceed 0.127 cm (2.54 cm ÷ 20 = 0.127 cm). Therefore, the force that the vapor collides with this non-opening and spreads in the lateral direction is extremely weak, and the fiber of the fiber web is not moved or the amount of the fiber moved is very small. It cannot be recognized as a special pattern.

  Furthermore, when the problem in the case of manufacturing a patterned nonwoven fabric is examined, in the case of manufacturing a patterned nonwoven fabric, it is necessary for the fibers in the fiber web to move, and the fibers can be easily moved in this respect. It would be advantageous to utilize a technique for injecting steam. That is, it is preferable to apply a method of injecting steam onto a fiber web placed on a transferable opening support provided with openings corresponding to a required pattern. However, even if a pattern is formed on the nonwoven fabric by this method, there is a problem that the entanglement of the fiber is light and the shape stability is lacking, and it is necessary to fix the pattern by fixing the fiber. Therefore, it is conceivable that a low melting point fiber is mixed in the fiber web in advance, and the formation of the pattern by the movement of the fiber and the bonding of the fiber intersection are performed simultaneously by applying pressurized steam. However, there is a problem that when the fiber intersection is bonded by the low melting point fiber, the fiber is fixed and the movement of the fiber is hindered. As a result, the target pattern is not formed. Alternatively, when the low melting point fiber melts, there is a problem that the fiber surface slips and the movement of the fiber is hindered. As a result, there is a problem that a target pattern is not formed.

JP 2004-238785 A

  The present invention solves the above-mentioned problems, and provides a patterned nonwoven fabric in which a clear pattern is formed, the fibers are sufficiently fixed both on the inside and inside, and the pattern is stable, and a method for producing the same. Is an issue.

  In order to solve the above-mentioned problem, the invention according to claim 1 is directed to the fiber web while transferring the fiber web placed on the transferable opening support having a plurality of openings by the opening support. A method for producing a patterned nonwoven fabric by continuously injecting steam, wherein the opening support has at least a pair of adjacent openings whose minimum distance is 2 mm or more in the projected view. A method for producing a patterned nonwoven fabric characterized by containing latent crimpable fibers in the fiber web and setting the temperature of the steam to be equal to or higher than the crimp expression temperature of the latent crimpable fibers. It is possible to provide a non-woven fabric with a pattern in which a pattern is formed and the fibers are sufficiently fixed both on the surface and inside, and the pattern is stable.

  In the invention according to claim 2, the opening support includes a plurality of pairs of adjacent openings whose shortest distance is 2 mm or more, and the shortest distance between the pair of adjacent openings is another pair of adjacent openings. It is different from the shortest distance of an opening, It is a manufacturing method of the patterned nonwoven fabric of Claim 1, There exists an advantage that the patterned nonwoven fabric with the design property in which the complicated pattern was formed can be obtained.

  The invention according to claim 3 provides an area in which one pattern is formed by disposing a plurality of openings including a pair of adjacent openings having a shortest distance of 2 mm or more on the opening support, and further, 3. The method for producing a patterned nonwoven fabric according to claim 1 or 2, wherein a plurality of areas having the same pattern as the area are repeatedly provided on the opening support, and the pattern having a design pattern is repeatedly formed. There is an advantage that a nonwoven fabric can be obtained.

  The invention according to claim 4 is characterized in that steam is continuously jetted onto the fiber web while the fiber web is nipped and transported between the opening support and the transferable opening pressing body. It is a manufacturing method of the nonwoven fabric with a pattern in any one of Claims 1-3, and there exists an advantage that the nonwoven fabric with a pattern in which the surface state was especially excellent and the clearer pattern was formed can be obtained.

  The invention according to claim 5 is a patterned nonwoven fabric formed by the method for producing a patterned nonwoven fabric according to any one of claims 1 to 4.

  According to the present invention, it is possible to provide a patterned nonwoven fabric in which a clear pattern is formed, the fibers are sufficiently fixed both on the surface and inside, and the pattern is stable, and a method for producing the same.

  The method for producing a patterned nonwoven fabric according to the present invention will be described using the patterned nonwoven fabric production apparatus 10 of FIG. 1 which is an example of an apparatus suitable for producing the patterned nonwoven fabric according to the present invention. While the fiber web 12 placed on the transportable opening support 11 is transported in the direction of arrow A by the opening support 11, the patterned nonwoven fabric 18 is sprayed on the fiber web continuously. It is a method of manufacturing.

  The patterned nonwoven fabric manufacturing apparatus 10 includes an opening support 11 made of an endless belt that has a large number of openings and can be transferred, a drive roll 16 or 17 that drives and rotates the opening support 11, and the opening support 11. Steam is ejected through the opening pressing body 15 to the opening pressing body 15 composed of an endless belt that rotates in synchronization with each other, and the fiber web 12 held between the opening support 11 and the opening pressing body 15. And a suction means 14 for sucking the steam ejected from the steam ejection nozzle 13 through the opening support 11, and is mounted on the opening support 11 rotated by the drive roll 16 or 17. The placed fiber web 12 is sandwiched between the opening support 11 and the opening pressing body 15 with rotation, and while the fiber web 12 is sandwiched, Vapor from the gas jet nozzle 13 towards the fiber web is ejected, the steam that has passed through the fibrous web 12 is adapted to be sucked by the suction means 14. In the patterned nonwoven fabric manufacturing apparatus 10 of FIG. 1, the opening support 11 is composed of an endless belt that has a large number of openings and can be transported. It can also consist of a rotating drum that has and can be transported.

  In the patterned nonwoven fabric manufacturing apparatus 10, the steam can be continuously sprayed onto the fiber web while the fiber web is nipped and transported between the opening support and the transferable opening pressing body. Although it is possible, since it is possible to prevent the surface of the fiber web from being disturbed by the jet of steam by such a method, it is possible to obtain a patterned nonwoven fabric in which the surface state is particularly excellent and a more clear pattern is formed. There is an advantage that you can.

  The steam jet nozzle 13 preferably has a steam jet inner diameter of 0.05 to 1 mm, and a pitch between the steam jet nozzles is preferably 0.5 to 3 mm. In addition, it is also possible for a vapor | steam ejection port to be a slit-shaped ejection port. Further, when steam is ejected from the steam ejection nozzle 13, the steam pressure introduced into the steam ejection nozzle 13 is preferably 0.1 to 2 MPa, and this steam is preferably superheated steam. With such a vapor pressure, there is an effect that the vapor can surely penetrate the front and back of the fiber web. In addition, it is practically preferable that a vapor | steam is water vapor | steam, and it is preferable that the temperature of a vapor | steam is about 105-240 degreeC if it is water vapor | steam.

  Further, the height of the steam ejection nozzle 13, which is the distance from the opening support 11, approximates the distance between the opening support 11 and the opening pressing body 15, but the height of the steam ejection nozzle 13 is Depending on the thickness of the fiber web, about 0.5 to 40 mm is preferable.

  The opening support 11 is provided with a number of openings so that a pattern is formed on the fiber web 12. As an aspect of this opening, for example, a vapor-impervious portion thicker than the thickness of the woven yarn is provided by closing the opening of a woven mesh made of a plastic net or a wire net, or the original woven net has There is a form in which the pattern can be clearly formed by making the area of the vapor impermeable portion larger than the area of the vapor impermeable portion, that is, the woven yarn portion of the woven mesh. The mesh of the woven mesh is preferably 8 to 40 (pieces / 2.54 cm) so that the fiber web 12 can be easily placed and steam can easily pass therethrough.

  As a method for the above-described sealing, there is a form in which a specific pattern is formed by embedding resin or a resin film by adhering and solidifying a molten resin or liquid resin to an opening portion of a woven mesh. As the liquid resin, for example, a thermosetting resin or an ultraviolet curable resin can be used. Further, for example, there is a form obtained by bonding and fixing a woven fabric or knitted fabric with a pattern formed according to the arrangement of yarns or the thickness of the yarn, or an embroidered woven fabric or knitted fabric to a woven net. In addition, by attaching a molten resin or liquid resin to the opening of the woven fabric or knitted fabric and solidifying it, a specific pattern is formed on the woven fabric or knitted fabric by embedding the resin or a resin film, and then the woven fabric or knitted fabric is applied to the woven net. There is a form obtained by bonding and fixing. Further, there is a form obtained by forming a large number of openings by cutting out a resin film or a resin sheet and then bonding and fixing the resin film or resin sheet provided with the openings to a woven net. In the case of hydroentanglement, if such a woven mesh is used, there is a problem that the woven or knitted fabric is damaged by the force of the water flow or the fiber web is entangled with the woven or knitted fabric. There is very little risk that the knitted fabric is damaged or the fiber web is entangled with the woven knitted fabric.

  Further, when the opening support is constituted by a rotating drum, the opening support may be formed by providing an opening in a metal drum or the like according to a desired pattern and providing a vapor impermeable portion. it can.

In the present invention, the opening support has a large number of openings. The size of the opening is such that the opening support is made of a woven mesh so that the fiber web 12 can be easily placed and the steam can easily pass therethrough. In this case, the mesh degree is preferably 8 to 40 (pieces / 2.54 cm). Further, it is preferable that as the area of the opening is 10mm ² ~0.1mm ^2. When the opening support is a metal drum, it is preferable to provide the opening so that the opening is 8 to 40 (pieces / 2.54 cm). Further, it is preferable that as the area of the opening is 10mm ² ~0.1mm ^2.

  In the present invention, as illustrated in FIG. 2, the opening support has at least a pair of adjacent openings whose shortest distance is 2 mm or more in the projection view. Here, the “adjacent opening” means an opening located around a specific opening. The term “periphery” refers to eight or less openings located in the front-rear, left-right, and diagonal directions with respect to the transfer direction. When the number exceeds eight, the openings located nearby are selected. Moreover, even if there are less than eight, the openings that are between the two openings around the specific opening and that are behind the two openings and are hidden by one of the two openings are adjacent to each other. Exclude from opening. The “shortest distance” is a straight line connecting each side of a pair of adjacent openings, a straight line connecting vertices, a straight line connecting arcs, a straight line connecting sides and vertices, a straight line connecting sides and arcs, or a vertex It can be represented by the length of the shortest straight line among the straight lines connecting the arcs.

  In this invention, since it has at least a pair of adjacent opening whose mutual shortest distance is 2 mm or more, the width | variety or area of the vapor | steam impermeable part which is a non-opening part becomes large. For this reason, when steam is sprayed on the fiber placed on the steam-impermeable portion, the force of the steam colliding with the non-opening and spreading in the lateral direction increases, and the fiber to the opening As a result, a large number of fibers gather at the opening, and a clear pattern is formed. In this way, it is possible to produce a patterned nonwoven fabric in which a clear pattern is formed. In the present invention, it has at least a pair of adjacent openings whose mutual shortest distance is 2 mm or more, but preferably has at least a pair of adjacent openings whose mutual shortest distance is 3 mm or more, It is more preferable to have at least a pair of adjacent openings whose mutual shortest distance is 4 mm or more, and even more preferable to have at least a pair of adjacent openings whose mutual shortest distance is 5 mm or more. In addition, when it does not have a pair of adjacent opening whose mutual shortest distance is 2 mm or more, it becomes impossible to manufacture the nonwoven fabric with a pattern in which a clear pattern is formed.

  Further, in the present invention, the opening support includes a plurality of pairs of adjacent openings whose shortest distance is 2 mm or more, and the shortest distance between the pair of adjacent openings is the other pair of adjacent openings. It is preferable to be different from the shortest distance, and there is an advantage that a patterned nonwoven fabric having a design pattern in which a complicated pattern is formed can be obtained. More preferably, the opening support includes three or more pairs of adjacent openings having a shortest distance of 2 mm or more, and in such a form, a design with a more complicated pattern formed. There is an advantage that a patterned non-woven fabric can be obtained.

The present invention will be described with reference to a specific example. FIG. 2 shows an example of an opening support composed of one type of opening, and one opening A forms a pair of openings in the transfer direction. Are B ₁ , B ₂ , B ₃ , B ₄ , C ₁ , C ₂ , C _3, and C ₄ located in the front-rear, left-right, and diagonal directions, and the shortest of these eight openings and opening A The distances are b ₁ , b ₂ , b ₃ , b ₄ , c ₁ , c ₂ , c ₃ and c ₄ , respectively. In FIG. 2, the lengths of c ₁ , c ₂ , c ₃ and c ₄ are the longest, and the lengths of b ₃ and b ₄ are shorter than those, and the lengths of b ₁ and b ₂ Is even shorter. In the present invention, one or more of b ₁ , b ₂ , b ₃ , b ₄ , c ₁ , c ₂ , c ₃ and c ₄ has a length of 2 mm or more. 2 is preferably provided on an endless belt-type opening support or a rotary drum-type opening support.

In addition, FIG. 3 shows an example of an opening support composed of two types of openings, and for one opening A, a pair of openings forms front and rear, right and left, and oblique directions with respect to the transfer direction. B ₁ , B ₂ , B ₃ , B ₄ , C ₁ , C ₂ , C ₃ and C ₄ , and the shortest distances between these eight openings and the opening A are b ₁ , b ₂ , b, respectively. ₃ , b ₄ , c ₁ , c ₂ , c ₃ and c ₄ . In FIG. 3, the lengths of c ₁ , c ₂ , c ₃ and c ₄ are the longest, and the lengths of b ₁ and b ₂ are shorter than those, and b ₃ and b ₄ The length is even shorter. In the present invention, at _{least one} of b ₁ , b ₂ , b ₃ , b ₄ , c ₁ , c ₂ , c ₃ and c ₄ has a length of 2 mm or more. 3 is preferably provided on an endless belt type opening support or a rotary drum type opening support.

FIG. 4 shows an example of an opening support made up of three or more types of openings, which is suitable for forming a complicated pattern. In this figure, with respect to one opening A, the openings forming a pair are B ₁ , B ₂ , B ₃ , B ₄ , C ₁ , C ₂ positioned in the front-rear, left-right, and diagonal directions with respect to the transfer direction. , C ₃ and C ₄ , and the shortest distances between these eight openings and the opening A are b ₁ , b ₂ , b ₃ , b ₄ , c ₁ , c ₂ , c ₃ and c ₄ , respectively. . In FIG. 4, the length of b ₁ is the longest, and the lengths of b ₄ and c ₃ are shortened in this order as compared with those lengths, and c ₁ , c ₂ , c ₄ , b ₂ and b The length of ₃ is even shorter. In the present invention, at _{least one} of b ₁ , b ₂ , b ₃ , b ₄ , c ₁ , c ₂ , c ₃ and c ₄ has a length of 2 mm or more. 4 is preferably provided in an endless belt type opening support or a rotary drum type opening support.

FIG. 5 shows an example of an opening support composed of two types of openings. For one opening A, the openings forming a pair are positioned in the front-rear direction and the left-right direction with respect to the transfer direction. B ₁ , B ₂ , B ₃ , B ₄ , B ₅ and B ₆ , and the shortest distances between these six openings and the opening A are b ₁ , b ₂ , b ₃ , b ₄ , b ₅ , and it has become a _{b 6.} In FIG. 5, the lengths b ₁ , b ₂ , b ₃ and b ₄ are the longest, and the lengths b ₅ and b ₆ are shorter than those. In the present invention, one or more of b ₁ , b ₂ , b ₃ , b ₄ , b ₅ , and b ₆ has a length of 2 mm or more. 5 is preferably provided on a rotary drum type opening support.

In addition, FIG. 6 shows an example of an opening support composed of one type of opening, and for one opening A, the openings forming a pair are positioned in the left-right and diagonal directions with respect to the transfer direction. B ₁ , B ₂ , C ₁ , C ₂ , C ₃ and C ₄ , and the shortest distance between these six openings and the opening A is b ₁ , b ₂ , c ₁ , c ₂ , c ₃ , respectively. and it has become a _{c 4.} In FIG. 6, the lengths of b ₁ , b ₂ , c ₁ , c ₂ , c ₃ , and c ₄ are the same, and b ₁ , b ₂ , c ₁ , c ₂ , c ₃ , and c ₄ are the same. One or more of the lengths are 2 mm or more. 6 is preferably provided on a rotary drum-type opening support.

  In the present invention, a plurality of openings including a pair of adjacent openings having a shortest distance of 2 mm or more are disposed on the opening support, thereby providing an area in which one pattern is formed, and the same pattern as the area It is possible to repeatedly provide the above-mentioned area on the opening support, and there is an advantage that a patterned nonwoven fabric in which a designable pattern is repeatedly formed can be obtained by such a method.

A specific example in which a plurality of the above-mentioned areas having the same pattern as the above-described areas are repeatedly provided on the opening support will be described with reference to FIG. 7. In FIG. 7, the opening support having a plurality of three or more types of openings. This example is suitable for forming a complicated pattern. In this figure, with respect to one opening A, there are B ₁ , B ₂ , B ₃ , B ₄ , C _1, and C ₂ that form a pair of openings that are located in the front-back direction and the oblique direction with respect to the transfer direction. The shortest distances between the six openings and the opening A are b ₁ , b ₂ , b ₃ , b ₄ , c ₁ , and c ₂ , respectively. In FIG. 7, the length of b ₃ is the longest, and the lengths of b ₁ , b ₂ , b ₄ , c ₁ , and c ₂ are shorter than those. In the present invention, one or more of b ₁ , b ₂ , b ₃ , b ₄ , c ₁ and c ₂ has a length of 2 mm or more. Then, in FIG. 7, the opening _{A, B 1, B 2,} B 3, B 4, C 1 , and one pattern to form areas composed of _{C 2} is provided on the opening support, the same as the zone Six pattern areas are repeatedly provided on the opening support at front, rear, left, and right positions. 7 is preferably provided on an endless belt type opening support or a rotary drum type opening support.

In FIG. 7, it has been described that the configuration of the present invention is realized by the combination of the openings B ₁ , B ₂ , B ₃ , B ₄ , C _1, and C ₂ that form a pair with the opening A. opening C ₁ and also by a combination of the surrounding opening, the configuration of the present invention is satisfied. An example thereof will be described with reference to FIG. 8. In FIG. 8, with respect to one opening A, B ₁ , B ₂ , B ₃ , There are B ₄ , C ₁ , C ₂ , C ₃ and C ₄ , and the shortest distance between these six openings and the opening A is b ₁ , b ₂ , b ₃ , b ₄ , c ₁ , c ₂ , c, respectively. and it has a ₃ and _{c 4.} In FIG. 8, the length of c ₃ is the longest, and the lengths are shorter in the order of b ₄ , c ₄ , c ₁ , b ₁ compared to these lengths, and b ₂ , b _3, and c _2. Is even shorter. In the present invention, at _{least one} of b ₁ , b ₂ , b ₃ , b ₄ , c ₁ , c ₂ , c ₃ and c ₄ has a length of 2 mm or more.

  In the present invention, a pattern is formed by continuously injecting steam onto the fiber web while the fiber web placed on the transportable opening support having a large number of openings is transported by the opening support. A latent crimpable fiber is contained in the fiber web, and the temperature of the steam is set to be equal to or higher than the crimp expression temperature of the latent crimpable fiber.

  The fiber web is not particularly limited as long as it contains latent crimpable fibers, and the fiber web is usually used as a method for producing a nonwoven fabric obtained by a dry method or a wet method known as a method for producing a nonwoven fabric. A fiber web can be applied. Among these, in the case of the dry method, for example, using a card machine or an air lay apparatus, the fiber raw cotton containing the latent crimpable fibers in the form of staple fibers that have been crimped in advance is opened to obtain fibers. After forming the fleece, the fiber fleece is laminated in one direction or with a cross lay to form a fiber web containing the latent crimpable fiber, and then steam is continuously sprayed onto the fiber web. Thus, a method for producing a patterned nonwoven fabric can be employed.

  If the dry method is used, staple fibers having a fiber length of about 15 to 100 mm and a number of crimps of about 5 to 30 pieces / inch are used, and the fiber length is relatively short. Since the fiber is easy to move, there is an advantage that a clear pattern is easily formed, and since the latent crimpable fiber can be mixed uniformly, there is less unevenness in bonding and the pattern is more stable There is an advantage that a patterned nonwoven fabric can be obtained. In addition, it is easy to mix other functional fibers, and it is possible to select a wide range of thickness, surface density, physical properties, etc., and it is possible to obtain a patterned non-woven fabric that is finely adapted to the intended use. There is.

  Further, in the case of a wet method, the latent crimpable fiber in a cut form using a paper machine of a horizontal long net method, an inclined wire type short net method, a circular net method, or a long net / circular net combination method. A pattern is obtained by making a raw material fiber containing a slurry, rolling up a fiber sheet from the slurry, forming a fiber web containing the latent crimpable fiber, and then continuously injecting steam onto the fiber web A method for producing a non-woven fabric with a mark can be employed.

  If the wet method is used, cut fibers having a fiber length of about 15 mm or less are used, and since the fiber length is short, the fibers are more easily moved by spraying steam, so that a clear pattern is easily formed. In addition, since the latent crimpable fibers can be mixed uniformly, there is an advantage that a patterned nonwoven fabric with less unevenness in bonding and a more stable pattern can be obtained. Further, it is easy to mix other functional fibers, and there is an advantage that a patterned nonwoven fabric corresponding to the intended use can be obtained.

  In the present invention, by containing the latent crimpable fiber in the fiber web, the crimp of the latent crimpable fiber is expressed with the jet of steam, and the fiber is entangled both on the surface and inside of the fiber web. It is possible to form a patterned nonwoven fabric in a stable state. As such a latent crimpable fiber, a composite fiber in which a plurality of resins having different melting points are combined, or a fiber having a specific heat history applied to a part of the fiber is used. For example, an eccentric core-sheath structure or a side-by-side composite fiber is preferably used as the composite fiber. As a combination of resins having different melting points, a combination of various synthetic resins such as polyester-low melting point polyester, polyamide-low melting point polyamide, polyester-polyamide, polyester-polypropylene, polypropylene-low melting point polypropylene, polypropylene-polyethylene can be used.

  When the latent crimped fiber is freely shrunk at a crimping expression temperature of about 105 to 240 ° C. where the crimping can be efficiently performed by jetting steam, the latent crimped fiber is more than twice the initial number of crimps. Those that reach the number of crimps are desirable. Specifically, it is desirable to express a relatively high number of crimps of, for example, 50 pieces / inch or more by heat treatment.

  In the present invention, it is necessary to contain latent crimpable fibers in the fiber web. By adding latent crimpable fibers to the fiber web, the pattern of the pattern due to movement of the fibers can be obtained by applying pressurized steam. Formation and fiber entanglement can be performed smoothly at the same time. That is, since many fiber intersections are not bonded by the heat-bonding fibers and the fibers are not fixed, the movement of the fibers is facilitated. As a result, a desired clear pattern is formed. Alternatively, even if the heat-adhesive fibers are melted, there is no problem that the fiber surface slips badly, so that the fibers can be moved easily. As a result, a desired clear pattern is formed. In addition, since the crimp of the latent crimpable fiber appears simultaneously with the formation of a clear pattern and the fibers are entangled, the fibers on the surface and inside are sufficiently fixed, and there is no fear that the pattern will be deformed and the clear pattern is formed. A stable patterned nonwoven fabric can be produced. When the latent crimpable fiber is not contained, there is a problem that the surface and internal fibers are not sufficiently fixed, the pattern is not stable, and is easily deformed. In addition, it is preferable that the mass ratio of the latent crimped fiber contained in a fiber web is 40-100 mass%, It is more preferable that it is 60-100 mass%, It is further that it is 75-100 mass%. preferable. When the mass ratio of the latent crimped fibers is less than 40% by mass, the entanglement of the fibers becomes weak and a stable pattern may not be formed.

  In the present invention, the fiber web can contain fibers other than latent crimpable fibers. Examples of the fibers that can be contained include polyester fibers such as polyethylene terephthalate and polybutylene terephthalate, nylon 6, nylon 66, and the like. Polyamide fiber, polyolefin fiber such as polypropylene and polyethylene, acrylic fiber such as polyacrylonitrile and synthetic fiber such as polyvinyl alcohol fiber, semi-synthetic fiber such as rayon, or natural fiber such as cotton and cellulose fiber Can be mentioned.

  Moreover, it is also possible to contain a small amount of heat-adhesive fiber as a fiber other than the latent crimpable fiber. By containing the heat-adhesive fiber, the surface and internal fibers are securely fixed, and the pattern is deformed. It is possible to produce a patterned non-woven fabric without fear and having a more stable clear pattern. Such a heat-adhesive fiber is not particularly limited as long as the heat-adhesive property is generated by jetting steam. For example, only one type of resin component having a melting point lower than that of other fibers contained in the fiber web is used. It can be a thermally adhesive fiber formed. Moreover, it is possible to be a heat-adhesive fiber composed of a composite fiber composed of a low-melting-point component and a high-melting-point component, and the low-melting-point component is exposed on at least a part of the fiber surface. Examples of such a composite fiber include a core-sheath type, a side-by-side type, an orange type whose cross section is divided by a resin having two or more components, and a sea-island type composite fiber.

  Also, the material of the heat-adhesive fiber is not particularly limited, and examples thereof include polyester resins such as polyethylene terephthalate and polybutylene terephthalate, polyamide resins such as nylon 6 and nylon 66, and polyolefin resins such as polypropylene and polyethylene. And acrylic resins such as polyacrylonitrile, polyvinyl alcohol resins, vinyl chloride resins, vinylidene chloride resins, and ethylene-vinyl alcohol copolymer resins. In the case of a composite fiber, the same kind of resin component can be selected from these resins, and different resin components can be selected and configured.

  In addition, when the said thermoadhesive fiber consists of one type of resin component, melting | fusing point needs to be lower than melting | fusing point of the fiber which has the lowest melting | fusing point among the other fibers contained in a fiber web. Such a heat-adhesive fiber or a heat-adhesive fiber comprising a low-melting-point component and a high-melting-point component, and a composite fiber in which the low-melting-point component is exposed on at least a part of the fiber surface is a latent crimpable fiber. In addition to forming a more distinct pattern by continuously injecting steam to the fiber web, the steam having a temperature equal to or higher than the crimping expression temperature and the melting point of the heat-adhesive fiber. Both the surface and the inside of the fiber web can be entangled and fixed to form a patterned nonwoven fabric with a more stable pattern. The thermal adhesive fiber is preferably 5 ° C. or more lower than the melting point of other fibers, more preferably 10 ° C. or more, and further preferably 15 ° C. or more. If it is lower than 5 ° C., the effect of the adhesive fiber may not appear.

  The content of the heat-adhesive fiber in the fiber web should be limited to a small amount, preferably 5 to 25% by mass of the heat-adhesive fiber is contained in the fiber web, and contains 5 to 20% by mass of the heat-adhesive fiber. It is more preferable to contain 5 to 15% by mass of the heat-adhesive fiber. When the content of the heat-adhesive fiber exceeds 25% by mass, the formation of the pattern by the movement of the fiber and the adhesion of the fiber intersection may not be performed smoothly by applying pressurized steam. That is, when a large number of fiber intersections are bonded by the heat-bonding fiber, the fiber is fixed, which may cause a problem that the movement of the fiber is hindered. As a result, there is a case where a target pattern is not formed. Alternatively, when a large number of heat-adhesive fibers are melted, there is a problem that the fiber surface slips and the movement of the fibers is hindered, and as a result, the target pattern may not be formed. .

  In the present invention, the fiber web placed on the transportable opening support having a large number of openings is transported by the opening support while the steam is continuously jetted onto the fiber web. While forming a simple pattern, the constituent fibers are entangled and bonded by the latent crimpable fibers contained in the fiber web. Depending on the process, heat treatment can be performed to further stabilize the pattern. As a heat treatment method, there are a method of passing between a pair of heating rolls, a method of passing through a dryer, a method of tenter processing, and the like.

  The patterned nonwoven fabric of the present invention is a patterned nonwoven fabric characterized by being formed by the above-described method for producing a patterned nonwoven fabric, has a clear pattern, and the surface and the interior are sufficiently entangled with fibers. It is a nonwoven fabric with a pattern in which the pattern is fixed and stabilized. As a specific example of the patterned nonwoven fabric of the present invention, as illustrated in FIGS. 9 to 12, the patterned nonwoven fabric of FIG. 10 obtained using the opening support of FIG. 9 and the opening support of FIG. There are the patterned nonwoven fabrics of FIG. 12 obtained by using these, and in these patterned nonwoven fabrics, the density of the fiber web in the portion corresponding to the opening portion of the opening support is high, and the portion corresponding to the vapor-impermeable portion of the opening support The fiber density is low, and a clear pattern is formed by the density of the fiber density. In addition, the fiber spans a portion where the fiber density is high and another portion where the fiber density is high. In other words, the portion where the fiber density is high and the portion where the other fiber density is high are connected by the fiber. And the part connected with this fiber is a part with low fiber density.

  As described above, according to the present invention, it is possible to provide a patterned nonwoven fabric in which a clear pattern is formed, the fibers are sufficiently fixed both on the surface and inside, and the pattern is stable, and a method for producing the same. It has become possible.

  Examples of the present invention will be described below, but these are only suitable examples for facilitating understanding of the invention, and the present invention is not limited to the contents of these examples.

Example 1
Latent composed of 2.2 dtex composite fiber (fiber length 51 mm, side-by-side type, first resin component is polyethylene terephthalate resin, second resin component is modified polyester resin, crimp expression temperature is about 175 ° C.) as latent crimpable fiber A crimpable fiber A was prepared. Next, a raw material fiber composed of 100% by mass of latent crimpable fiber A was used to produce a cross lay fiber web using a card machine and a cross layer apparatus.
Further, on the endless belt of the patterned nonwoven fabric manufacturing apparatus 10 shown in FIG. 1 provided with an endless belt made of a wire mesh having a mesh degree of 10 mesh in which a wire having a diameter of about 0.6 mm is knitted into a plain weave, FIG. As shown in the figure, an opening support member A was formed by placing an opening support member formed by cutting a square of 12 × 17 mm into a lattice shape with respect to the resin film.
Next, the fiber web is placed on the opening support A11, transferred at a speed of 3 m / min, and held between the opening support 11 and the opening pressing body 15 (set to 1.2 mm). Then, steam at 185 ° C. set at a vapor pressure of 1 MPa is jetted from the steam jet nozzle 13 toward the fiber web, and the steam passing through the fiber web 12 is sucked by the suction means 14. A patterned nonwoven fabric having a surface density of 120 g / m ² on which the pattern shown in FIG. 10 was formed was obtained.
A clear pattern was formed on the non-woven fabric with this pattern, and the fiber was sufficiently fixed both on the surface and inside, and the pattern was stable.

(Example 2)
A latent crimpable fiber A similar to that of Example 1 was prepared. Further, as a heat-adhesive fiber, a heat-adhesive fiber B made of 2.2 decitex composite fiber (fiber length 51 mm, core-sheath type, sheath is a modified polyester resin having a melting point of 135 ° C., and the core is a polyethylene terephthalate resin) Got ready. Subsequently, 85 mass% latent crimpable fiber A and 15 mass% heat-bondable fiber were mixed, and a cross lay fiber web was produced using a card machine and a cross layer apparatus.
Further, on the endless belt of the patterned nonwoven fabric manufacturing apparatus 10 shown in FIG. 1 provided with an endless belt made of wire mesh having a mesh degree of 10 mesh in which a wire having a diameter of about 0.6 mm is knitted into a plain weave, FIG. As shown in the figure, an opening support member B was formed by placing an opening support member formed by cutting a rhombus with a side of 22 mm in a zigzag pattern on the resin film.
Next, the fiber web is placed on the opening support B11, transferred at a speed of 3 m / min, and held between the opening support 11 and the opening pressing body 15 (set to 1.2 mm). Then, steam at 185 ° C. set at a vapor pressure of 1 MPa is jetted from the steam jet nozzle 13 toward the fiber web, and the steam passing through the fiber web 12 is sucked by the suction means 14. A patterned nonwoven fabric having a surface density of 112 g / m ² on which the pattern shown in FIG. 12 was formed was obtained.
A clear pattern was formed on the non-woven fabric with this pattern, and the fiber was sufficiently fixed both on the surface and inside, and the pattern was stable.

(Example 3)
As shown in FIG. 13 on the endless belt of the patterned nonwoven fabric manufacturing apparatus 10 shown in FIG. A surface density of 118 g / m ² on which the pattern shown in FIG. 14 was formed was the same as in Example 1 except that an opening support member made of knitted fabric with embroidery was placed to form an opening support C. A patterned nonwoven fabric was obtained. The knitted fabric had many portions where the embroidery yarns overlapped or bundled to become a thickness of 2 mm or more.
A clear pattern was formed on the non-woven fabric with this pattern, and the fiber was sufficiently fixed both on the surface and inside, and the pattern was stable.

Example 4
As shown in FIG. 15, on the endless belt of the patterned nonwoven fabric manufacturing apparatus 10 shown in FIG. 1 provided with an endless belt made of wire mesh having a mesh degree of 10 mesh in which a wire having a diameter of about 0.6 mm is knitted into a plain weave. A surface density of 121 g / m ² on which the pattern shown in FIG. 15 was formed in the same manner as in Example 1 except that an opening support member made of knitted fabric subjected to embroidery was placed to form an opening support D. A patterned nonwoven fabric was obtained. The knitted fabric had many portions where the embroidery yarns overlapped or bundled to become a thickness of 2 mm or more.
A clear pattern was formed on the non-woven fabric with this pattern, and the fiber was sufficiently fixed both on the surface and inside, and the pattern was stable.

(Comparative Example 1)
100% by mass of 1.7 dtex polyethylene terephthalate fiber (fiber length: 38 mm) was prepared, and a cross lay fiber web was prepared using a card machine and a cross layer device, in the same manner as in Example 1. A patterned nonwoven fabric with an areal density of 120 g / m ² was obtained.
The patterned nonwoven fabric had a clear pattern, but the surface and internal fibers were not sufficiently fixed, and the pattern was easily deformed and the pattern was not stable.

(Comparative Example 2)
30% by mass of heat-adhesive fiber A and 70% by mass of 1.7 dtex polyethylene terephthalate fiber (fiber length: 38 mm) were mixed, and a cross lay fiber web was prepared using a card machine and a cross layer device. Except for this, a patterned nonwoven fabric with a surface density of 105 g / m ² was obtained in the same manner as in Example 1.
In this patterned nonwoven fabric, the fibers were sufficiently fixed both on the surface and inside, but no clear pattern was formed.

It is a schematic diagram which shows an example of the manufacturing apparatus suitable for manufacturing the nonwoven fabric with a pattern of this invention. It is a schematic diagram which shows another example of the opening support body suitable for manufacturing the nonwoven fabric with a pattern of this invention. It is a schematic diagram which shows another example of the opening support body suitable for manufacturing the nonwoven fabric with a pattern of this invention. It is a schematic diagram which shows another example of the opening support body suitable for manufacturing the nonwoven fabric with a pattern of this invention. It is a schematic diagram which shows another example of the opening support body suitable for manufacturing the nonwoven fabric with a pattern of this invention. It is a schematic diagram which shows another example of the opening support body suitable for manufacturing the nonwoven fabric with a pattern of this invention. It is a schematic diagram which shows another example of the opening support body suitable for manufacturing the nonwoven fabric with a pattern of this invention. It is a schematic diagram which shows another example of the opening support body suitable for manufacturing the nonwoven fabric with a pattern of this invention. It is a schematic diagram which shows an example of an opening support member suitable for manufacturing the nonwoven fabric with a pattern of this invention. It is a schematic diagram which shows an example of the nonwoven fabric with a pattern of this invention manufactured using the opening support member shown in FIG. It is a schematic diagram which shows another example of the opening support member suitable for manufacturing the nonwoven fabric with a pattern of this invention. It is a schematic diagram which shows an example of the nonwoven fabric with a pattern of this invention manufactured using the opening support member shown in FIG. It is a schematic diagram which shows another example of the opening support member suitable for manufacturing the nonwoven fabric with a pattern of this invention. It is a schematic diagram which shows an example of the nonwoven fabric with a pattern of this invention manufactured using the opening support member shown in FIG. It is a schematic diagram which shows another example of the opening support member suitable for manufacturing the nonwoven fabric with a pattern of this invention. It is a schematic diagram which shows an example of the nonwoven fabric with a pattern of this invention manufactured using the opening support member shown in FIG. It is a schematic diagram explaining the mesh degree of the fiber web transfer means used for the conventional nonwoven fabric manufacturing apparatus.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Patterned nonwoven fabric manufacturing apparatus 11 Opening support 12 Fiber web 13 Steam jet nozzle 14 Suction means 15 Opening pressing body 16 Drive roll 17 Drive roll 18 Patterned nonwoven fabric

Claims (5)

  A nonwoven fabric with a pattern is produced by continuously injecting steam onto the fiber web while the fiber web placed on the transportable aperture support having a large number of openings is transported by the aperture support. The opening support has at least a pair of adjacent openings whose minimum distance is 2 mm or more in the projected view, the fiber web contains latent crimpable fibers, and A method for producing a patterned nonwoven fabric, characterized in that a temperature of the steam is equal to or higher than a crimp expression temperature of the latent crimpable fiber.   The opening support includes a plurality of pairs of adjacent openings whose shortest distance is 2 mm or more, and the shortest distance of a pair of adjacent openings is different from the shortest distance of another pair of adjacent openings. The manufacturing method of the patterned nonwoven fabric of Claim 1 characterized by the above-mentioned.   By disposing a plurality of openings including a pair of adjacent openings having a shortest distance of 2 mm or more on the opening support, an area in which one pattern is formed is provided, and an area having the same pattern as the area is provided. The method for producing a patterned nonwoven fabric according to claim 1, wherein a plurality of the openings are repeatedly provided on the opening support.   The steam is continuously sprayed onto the fiber web while the fiber web is nipped and transferred between the opening support and a transferable opening pressing body. The manufacturing method of the nonwoven fabric with a pattern as described in 2.   A patterned nonwoven fabric formed by the method for producing a patterned nonwoven fabric according to any one of claims 1 to 4.

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