JP2012149371A5 - - Google Patents

Description

The plurality of protrusions 12 have a first surface 12SA and a second surface 12SB that face each other. The first surface 12SA and the second surface 12SB may be flat surfaces or curved surfaces.
When viewed from above, each of the first surface 12 S A of the respective projections oriented in the same direction, each of the second surface 12SB facing in the same direction in the opposite direction to the first surface 12SA. Further, the projection 12 is long in a plan view, in the first and second surfaces 12SA and 12SB directions, and has a rectangular shape with rounded corners, for example. Thus, the shape of the cross section of the protrusion 12 is preferably a rectangle having rounded corners except for the top. Furthermore, between the 1st surface 12SA and 2nd surface 12SB of the protrusion 12, it has the 3rd surface (side surface) 12SC connected to the periphery of each surface, The outer periphery of the 3rd surface 12SC is the 1st surface. It is preferable that it exists in the inside of a cycloid curve seeing from the normal line direction (MD direction) of 12SA or 2nd surface 12SB.

Moreover, it is preferable that the said hole 13 has the center of the hole 13 in the center between the processus | protrusions 12 adjacent to each direction in both MD direction and CD direction. And when the said hole 13 is projected from MD direction, it is preferable to arrange | position so that the projection image of the hole 13 distribute | arranged to MD direction may overlap. That is, when the holes 13 are arranged in a rhombus pattern and the pitch of the holes 13 on the same line in the CD direction is Pcd, [pitch Pcd / 2] <[diameter φ c of the hole 13 (not shown) or CD direction Width Wcd ]. [The diameter φc of the hole 13 (not shown) or the width Wcd in the CD direction] − [pitch Pcd / 2] is preferably as large as possible. However, due to processing restrictions and other dimensions, [pitch Pcd / 2] +0.2 <[diameter φc of hole 13 (not shown) or CD-direction width Wcd ]] is preferably used. The rhombus pattern arrangement means that the shape connecting the centers of the four holes 13 arranged around the projection 12 (four sides) is a rhombus.
In addition, the hole area ratio (area ratio) occupied by the holes 13 is preferably as large as possible so that the gas to be blown out is good, but the hole area ratio is determined in consideration of the strength of the support 10. The open porosity is preferably 50% or less than 10%, more preferably 15% to 40% or less, more preferably 20% or more than 35%, particularly preferably 35% or more 30% or less.

In addition, when the fiber web is shaped into a concavo-convex shape using the support 10, the protrusion 12 is configured to be long in the direction of the first and second surfaces 12SB and 12SA in plan view. The fibers can be easily selected by orienting the fibers along the first and second surfaces 12SB and 12SA. In addition, there is an advantage that an enormous wind speed is not required at the time of shaping .
In addition , it is advantageous that the width of the protrusion in the CD direction is narrow in that the selection is easy and a huge wind speed is not required at the time of shaping.
Considering this point, the base width Wpc of the projection 12 in the CD direction , which will be described later, is preferably as small as possible . Since the unevenness to be shaped becomes too small, the base width Wpc is preferably 0.5 to 10 mm, more preferably 1 to 5 mm, and still more preferably 1 to 2 mm as a preferable projection size. If the base width of the protrusion 12 in the MD direction is Wpm, Wpm / Wpc is preferably 1.1 to 10, more preferably 2 to 4.

First, the dimensions of each part of the support 10 will be described below.
As shown in FIG. 7, the thickness of the rod-like body 11 and T b. For the protrusion 12, the MD direction pitch is Ppm, the CD direction pitch is Ppc, the height of the protrusion 12 is H, the base width of the MD direction protrusion 12 is Wpm, and the base width of the CD direction protrusion 12 is Wpc. . The round radius of the top of the side surface of the projection 12 projected from the CD direction is Rts, and the round radius of the top of the projection 12 projected from the MD direction is Rt. Furthermore, the shape of the side surface of the projection 12 projected from the MD direction is a curve.

[Example 1-10]
The support body 10 of Example 1 is integrally molded. The thickness of the rod-shaped body 11 is T b = 3 mm. The protrusions 12 and the holes 13 are alternately arranged in the MD direction and the CD direction, the protrusions 12 are arranged at equal intervals, and the holes 13 are arranged at equal intervals.
The pitch of the protrusion 12 in the MD direction is Ppm = 10.0 mm, the pitch in the CD direction is Ppc = 5.0 mm, the height of the protrusion 12 is H = 7.5 mm, and the base width of the protrusion 12 in the MD direction is Wpm = 5. The base width of the protrusion 12 in the CD direction is 0 mm and Wpc = 1.5 mm. Further, the shape of the protrusion 12 viewed from the CD direction is generally triangular (Δ) having roundness (R) at the tip, and the shape of the protrusion 12 viewed from the MD direction is generally rectangular having roundness (R) at the corners. (□) . Further, the radius of roundness at the top of the side surface of the projection 12 projected from the CD direction is Rts = 0.6 mm, and the radius of roundness at the top of the projection 12 projected from the MD direction is Rt = 0.5 mm. Further, the outer shape excluding the top of the projection 12 projected from the CD direction is also a shape having a curvature.
The cross-sectional shape of the rod-shaped body 11 is a circular shape having a diameter of 3 mm. Therefore, the thickness of the rod-shaped body 11 is Tb = 3.0 mm, and the width is Wb = 3.0 mm.
The holes 13 have a pitch in the MD direction of Phm = 10.0 mm, a pitch in the CD direction of Phc = 5.0 mm, a length in the MD direction of φm = 2.0 mm, and a length in the CD direction of φc = 3.5 mm. is there.
The overlapping length of the projected images of the holes 13 arranged in the MD direction projected from the MD direction is Lm = 1 mm, and the projected images of the holes 13 arranged in the MD direction projected from the MD direction are overlapped. Furthermore, the hole area ratio is R = 28%.
The distance between the bases of the protrusions is 1. 4 mm.

Example 2 is the same as Example 1 except that H = 2.0 mm.
Example 3 is Example 1 except that Ppc = 7.5 mm, Phc = 7.5 mm, φc = 6.0 mm, Lm = 2.25 mm, R = 32% , and the distance between the bases of the protrusions is 2.1 mm. It is the same.
In Example 4, Ppc = 7.5 mm, Wpc = 3.0 mm, Phc = 7.5 mm, φc = 4.5 mm, Lm = 0.75 mm, R = 26.7% , and the distance between the bases of the protrusions is 1. The same as Example 1 except for 1 mm .
In Example 5, H = 2.0 mm, Wpm = 3.1 mm, Phm = 20.0 mm, Phc = 10.0 mm, φm = 7.0 mm, φc = 8.5 mm, Lm = 3.5 mm, R = 34 %, Which is the same as that of Example 1 except that Rts = 0.5 mm.

In Example 6, Ppc = 3.0 mm, H = 4.0 mm, Phc = 3.0 mm, φm = 3.5 mm, φc = 1.5 mm, Lm = 0 mm, and the protrusion-to-base distance is 1.5 mm . Other than the above, the second embodiment is the same as the first embodiment.

Example 7 is the same as Example 1 except that Wpc = 3.0 mm, φc = 2.0 mm, Lm = −0.5 mm, R = 28%, and the distance between the bases of the protrusions is 0.1 mm .
Example 8 is different from Example 1 except that Ppc = 10.0 mm, Wpc = 3.0 mm, Phc = 10.0 mm, φc = 7.0 mm, Lm = 2 mm, and the distance between the bases of the protrusions is 2.1 mm. It is the same.
Example 9 is Example 1 except that Ppc = 10.0 mm, Phc = 10.0 mm, φc = 8.5 mm, Lm = 3.5 mm, R = 34% , and the distance between the bases of the protrusions is 3.7 mm. It is the same.

In Example 10, Ppc = 6.5 mm, Wpc = 3.0 mm, Phc = 6.5 mm, Lm = 0.25 mm, R = 21.5% , the distance between the bases of the protrusions is 0.6 mm , and the MD direction The outer shape of the projection 12 projected from is the same as that of Example 1 except that it is a triangle (Δ) having a roundness (R) with a roundness radius Rt = 0.6 mm at the tip.

[Comparative Example 1-2]
Comparative Example 1 is an integrally formed product made of aluminum. The thickness T b of the plate-like body 11 is 1.5 mm. A large number of holes 13 are arranged between the protrusions 12. In other words, the support is disclosed in Patent Document 1.
Each dimension is as follows. Ppm = 3.0 mm, Ppc = 3.0 mm, H = 0.8 mm, Wpm = 2.0 mm, Wpc = 2.0 mm. The gap between the protrusions is 1.0 mm.
The holes 13 have an MD pitch of Phm = 1.2 mm, a CD direction pitch of Phc = 1.2 mm, an MD direction diameter of φm = 0.4 mm, and a CD direction diameter of φc = 0.4 mm.
The arrangement pattern of the holes 13 is a square.
The overlap length of the projected images of the holes 13 arranged in the MD direction projected from the CD direction is Lm = −0. 2 mm, and the projected images of the holes 13 arranged in the MD direction projected from the CD direction do not overlap. Further, the open porosity is R = 9.0%.

Next, the evaluation method will be described. The evaluation was performed by examining the formability of the nonwoven fabric as processability and the performance of the nonwoven fabric as sheet performance. The fibers used were 2.2 dtex PET / PE fibers and those having a fiber length of 51 mm (ES fiber vision, ETC fibers). The nonwoven fabric was evaluated under the condition that the basis weight of the nonwoven fabric was 25 gsm ± 1 gsm.
Workability, "fiber blow on Banai", "fiber entanglement", "formation of the shaped nonwoven fabric", "peeling of shaping a nonwoven fabric from the support", etc. "wind speed required shaping" evaluated.

As is clear from the results shown in Tables 1 and 2, the respective supports 10 of Examples 1 to 6 obtained good results (evaluation of ◎ or ○) in any evaluation item. .
Each of the supports 10 of Examples 1 to 10 was integrally molded, and the thickness of the rod-like body 11 was Tb = 3 mm and the width was Wb = 3.0 mm.
In addition, the pitch in the MD direction of the protrusion 12 is Ppm = 10.0 mm, the pitch in the CD direction is Ppc = 3.0 mm to 10.0 mm, the height of the protrusion 12 is H = 2.0 mm to 7.5 mm, MD direction The base width of the protrusion 12 was Wpm = 3.1 mm to 5.0 mm, and the base width of the protrusion 12 in the CD direction was Wpc = 1.5 mm to 3.0 mm.
The pitch of holes 13 in the MD direction is Phm = 10.0 mm to 20.0 mm, the pitch in the CD direction is Phc = 3.0 mm to 10.0 mm, the diameter in the MD direction is φm = 2.0 mm to 7.0 mm, CD direction The diameter was φc = 1.5 mm to 8.5 mm.
Further, the overlapping length of the projected images of the holes 13 arranged in the MD direction projected from the MD direction is Lm = −0.5 mm to 3.5 mm, and the holes 13 arranged in the MD direction projected from the MD direction. The projected images of were touching or overlapping.
The open area ratio was R = 21.5 % to 34%.
Therefore, the shaping which has the outstanding result (evaluation of (double-circle) or (circle)) in each said evaluation item by shape-treating a fiber web using the support body 10 made in the said range, and manufacturing a shaped nonwoven fabric. A non-woven fabric can be made.

DESCRIPTION OF SYMBOLS 10 Support body 11 Rod-shaped body 11S Upper surface 12 Protrusion 12SA 1st surface 12SB 2nd surface 12C 3rd surface (side surface)
13 hole 14, 14A, 14B Protrusion line D interval (interval of protrusion line)
Tb Thickness of rod
Wb Width of rod
H Projection height
Ppm Pitch of MD direction of protrusion
Ppc Projection pitch in CD direction
Phm Hole pitch in MD direction
Phc Pitch in CD direction of hole
Rts Round radius of the top of projection side projected from CD direction
Round radius of the top of the projection projected from the Rt MD direction
Wpm Base width of MD protrusion
Wpc Base width of protrusion in CD direction
φm Length of MD direction (or diameter) of hole
φc Length of CD hole (or diameter)
Lm Overlapping length of projected images of holes arranged in the MD direction projected from the MD direction
R Opening ratio of a hole having a value obtained by dividing the total area of holes within a predetermined area in plan view by the predetermined area

Claims (7)

A plurality of rods arranged in parallel;
A plurality of protrusions disposed between the rod-shaped bodies;
A hole existing in a region surrounded by the protrusions adjacent to each other between the adjacent rod-shaped bodies and in the longitudinal direction of the rod-shaped bodies;
The protrusions and the holes are alternately arranged in a first direction and a second direction orthogonal to the first direction, and the protrusions are arranged at a predetermined interval,
The said protrusion is a support body for nonwoven fabric manufacture which has the 1st surface and 2nd surface which oppose. The support for producing a nonwoven fabric according to claim 1 , wherein a distance between a projection row of the projections arranged in the direction of the first surface and another projection row adjacent to the projection row in parallel is 1 mm or more and 3 mm or less. . 3. The nonwoven fabric production according to claim 1, wherein an opening ratio occupied by the area of the hole obtained by dividing the total area of the holes within a predetermined area in plan view by the predetermined area is 30% or more and 35% or less . Support. The support for nonwoven fabric production according to claim 1, 2 or 3 , wherein a base width of the protrusion in a direction orthogonal to the direction of the first surface is 1 mm or more and 2 mm or less . The protrusion has a third surface connected to each surface between the first surface and the second surface;
The support for nonwoven fabric manufacture according to any one of claims 1 to 4, wherein an outer peripheral edge of the third surface viewed from a normal direction of the first or second surface exists inside a cycloid curve. . The support for nonwoven fabric manufacture according to any one of claims 1 to 5, wherein at least one surface constituting the protrusion is roughened. A fiber web containing thermoplastic fibers is transported onto a support having a plurality of protrusions and a plurality of holes, and hot air is blown to form a concave-convex shape on the fiber web along the support. A method for producing a shaped nonwoven fabric,
For the support,
In a region surrounded by a plurality of rod-shaped bodies arranged in parallel, a plurality of projections arranged between the rod-shaped bodies, and the projections adjacent between the adjacent rod-shaped bodies and in the longitudinal direction of the rod-shaped body Have existing holes,
The protrusions and the holes are alternately arranged in a first direction and a second direction orthogonal thereto, and the protrusions are spaced apart from each other,
The said protrusion is a manufacturing method of the shaping nonwoven fabric using what has the 1st surface and 2nd surface which oppose.

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