JP2020117849A - Manufacturing process and its product in production line for hot air-through bonding nonwoven fabric with three-dimensional pattern - Google Patents

Abstract

To provide a manufacturing process and its product in a production line for hot air-through bonding nonwoven fabric with three-dimensional pattern for solving the problem of the prior art in which improvement for the tensile strength and the frictional resistance of a nonwoven fabric in a wet state or improvement for the moisture absorption or flexibility has been investigated but improvement in the structural part of the non-woven fabric and in the liquid inflow have never been investigated.SOLUTION: The invention provides a manufacturing process and its product in a production line for hot air-through bonding nonwoven fabric provided with three-dimensional pattern. A manufacturing method therefor includes the following steps. A step 1 is to form a fleece of initial fibers to form a web layer. Step 2 is to subject the web layer to a preheating treatment to produce an initially shaped web layer. Step 3 is to subject the initially shaped web layer to a heat-embossing treatment to form a plurality of three-dimensional cavities. Step 4 is to subject the web layer to a heating treatment to form a final shape to be adhesively bonded as a nonwoven fabric.SELECTED DRAWING: Figure 1

Description

The present invention relates to a hot air through bonding non-woven fabric and a method for producing the same, and more particularly to a process for producing a non-woven fabric having three-dimensional pores and having air permeability and water permeability, and a product thereof, which is preliminarily preheated to obtain a non-woven fabric having a first step It is characterized in that the non-woven fabric gives a three-dimensional effect to the three-dimensional holes by performing embossing after achieving the purpose of performing.

Presently, non-woven fabrics are already widely applied to household products such as disposable diapers, sanitary products, surgical clothes, and medical products. Nonwoven fabrics are generally composed of different layers of nets, and the manufacturing method thereof is formed by joining multiple net layers according to needs.

Below, some patent documents regarding nonwoven fabrics are presented.

JP 2014-263677 relates to a bulky nonwoven fabric containing heat-expandable particles, and discloses a bulky nonwoven fabric which is less likely to drop off of the heat-expandable particles and has improved strength, especially tensile strength and friction fastness when wet, and a method for producing the same. .. The method for manufacturing a bulky nonwoven fabric according to the invention includes Step A and Step B. Step A is a nonwoven fibrous sheet having a first surface and a second surface opposite to the first surface, the nonwoven fibrous sheet including expanded heat-expandable particles and fibers, and And a step of preparing the non-woven fiber sheet including the bulky non-woven fiber layer forming the above-mentioned first surface. Step B heats at least the first surface of the non-woven fibrous sheet with a hot roll or a hot embossing roll to remove the heat-expandable particles located in the surface layer portion of the non-woven fibrous sheet at least on the first surface side. This is the step of melting.

TW I632259 discloses a method for producing a nonwoven fabric having moisture absorption and transfer properties by a spunbond method. In the manufacturing method, a high molecular weight bio-polyamide (Bio-Polyamide) is used as a raw material to form a melt in the form of a melt by high-temperature solubilization at 250 to 280° C., and the melt is spunbonded from a spinning mouth. Extrude to form biopolyamide fibers. Further, it is stretched by an air drafting machine to form bio-polyamide fibers into uniform ultrafine fibers, which are deposited on a conveyor to form web-like fibers, and then N-methylmorpholine-N-oxide (N -Methylmorpholine-N-Oxide; NMMO) Solvent is added to pulp and mixed, and dissolved to form a mucus, which is extruded from the spinneret by a spunbond method to produce a natural raw material. After the yarn of fibers is formed, it is deposited on the web-like fibers on the above-mentioned conveyor. Finally, a nonwoven fabric having moisture absorption and transfer properties is manufactured through the steps of solidification regeneration, washing with water, hydroentangling, drying and winding.

JP 2012-207221 discloses a spunbonded non-woven fabric made of polypropylene fiber having excellent heat-sealing property and flexibility, which is suitable for absorbent topsheets, backsheets, side gathers and the like used for sanitary materials. The non-woven fabric is a non-woven fabric composed of fibers containing homopropylene as a main component, the MFR of the fibers is 30 g/10 min or more and 65 g/10 min or less, and the average single yarn fineness of the fibers is 0.5 dtex or more and 3.5 dtex or less, the basis weight of the nonwoven fabric is 5 g/m ² or more and 40 g/m ² or less, the thermocompression bonding area ratio of the nonwoven fabric is 5% or more and 15% or less, and the hot plate temperature is 136° C. The heat-sealing strength of the non-woven fabric measured under the above condition is 6 N/25 mm or more.

Some hygiene products are particularly absorbent and require liquids to be absorbed and spread quickly. For this reason, products of this type currently on the market are perforated by press punching in a production line of a normal manufacturing process, thereby perforating the web to facilitate the permeation of liquid. However, open-hole pressing is limited to the web layer on the surface, and it is difficult to penetrate deep into the web.
However, in the above technique, the characteristics are mainly that the tensile strength and abrasion resistance of the nonwoven fabric when wet are improved, or the moisture absorption is improved or the flexibility is increased. There is no such improvement regarding the structural part of the non-woven fabric and the liquid inflow.

Japanese Patent Application No. 2014-263677 Taiwan Patent No. 632259 Specification Japanese Patent Application No. 2012-207221

Therefore, it is an object of the present invention to provide a manufacturing process and a product thereof in a production line of a three-dimensional pattern hot air through bonding nonwoven fabric, which solves the above-mentioned drawbacks.

In order to solve the above problems, the present invention aims to provide a manufacturing process and a product thereof in a production line of a three-dimensional hot air through bonding non-woven fabric, and enhances the effect of the non-woven fabric due to the three-dimensional characteristics of the three-dimensional hole.

The manufacturing process in the production line of the hot air through bonding nonwoven fabric having a three-dimensional pattern of the present invention is characterized by achieving fluid flowability in the nonwoven fabric by improving the three-dimensional pore of the nonwoven fabric.

Furthermore, the manufacturing process in the production line of the three-dimensional pattern hot air through bonding nonwoven fabric of the present invention is characterized in that the hardness of the web layer is increased by preheat treatment to increase the three-dimensionality of the three-dimensional cavity.

Furthermore, the manufacturing process in the production line of the three-dimensional pattern hot air through bonding nonwoven fabric of the present invention is characterized by achieving the standard that cannot be achieved in the primary process by repeatedly performing the preheat treatment and the hot press treatment.

Furthermore, the manufacturing process in the production line of the three-dimensional pattern hot air through bonding nonwoven fabric of the present invention, if necessary, at the time of hot embossing treatment, adding reinforcing fibers on the web layer to enhance the durability of the nonwoven fabric. Is possible.

To achieve the above object, the main technical means used in the present invention are realized by the following techniques. The present invention is a manufacturing process in a production line of a three-dimensional pattern hot air through bonding nonwoven fabric, and includes the following steps. Step 1 is to fleece the initial fibers to form a web layer. In step 2, the web layer is preliminarily shaped by pre-heating the web layer. Step 3 is to form a plurality of three-dimensional pores in the initially shaped web layer by hot embossing. In step 4, the web layer is heat-treated and finally fixed to form a non-woven fabric for adhesive bonding.

In order to achieve the object of the present invention and solve the technical problem, the following techniques are sequentially implemented.

In the above-mentioned manufacturing process, the initial fiber is a composite fiber having at least two kinds of components, and at least one kind of these has a low melting point.

In the above manufacturing process, the preheat treatment temperature set in step 2 is higher than or equal to the melting point of the low melting point component in the initial fiber.

In the above-mentioned manufacturing process, the heat treatment temperature set in step 4 should not be higher than the melting points of the low melting point components in the initial fibers and further higher than the melting points of the other components in the initial fibers.

In the above-described manufacturing process, after step 3, steps 2 to 3 are executed again.

The above-described manufacturing process further comprises the step of assembling at least one reinforcing fiber on the solid cavity in step 3.

In the above-mentioned manufacturing process, the reinforcing fiber is a composite fiber having at least two kinds of components, and the melting point of at least one kind of component is low.

In the above-mentioned manufacturing process, the fiber is selected from a combination of polypropylene, polyethylene, polyethylene terephthalate, polybutylene terephthalate, polypropylene copolymer, polyethylene terephthalate copolymer, polybutylene terephthalate copolymer or polyamide. ..

In addition, the hot air through bonding nonwoven fabric product manufactured by the above manufacturing process includes a disposable diaper, a sanitary napkin or a panty liner.

The present invention has the following effects as compared with the conventional technology.
(1) To improve the effect of the non-woven fabric by increasing the three-dimensionality of the three-dimensional cavity.
(2) By improving the three-dimensional pores of the non-woven fabric, the fluidity of the non-woven fabric in the non-woven fabric is achieved.
(3) The preheat treatment increases the hardness of the web layer and increases the degree of solidity of the solid hole.

3 is a first flowchart showing a preferred embodiment of the present invention. 6 is a second flowchart showing a preferred embodiment of the present invention. 7 is a third flowchart showing a preferred embodiment of the present invention. It is sectional drawing which showed the state which the solid hole in this invention did not manufacture. It is sectional drawing which showed the prior art. It is a 1st sectional view in a suitable embodiment of the present invention. It is a 2nd sectional view in a suitable embodiment of the present invention. It is a 1st sectional view of the initial fiber in this invention. It is a 2nd sectional view of the initial fiber in this invention.

In order to clearly understand the objects, features and effects of the present invention, a first embodiment of the present invention will be shown and described below.

First, a description will be given with reference to the flowchart of FIG. FIG. 1 includes steps 1(1), 2(2), 3(3) and 4(4).

Among them, the step 1 (1) shown in FIG. 1 is a step of fleece forming the initial fiber to form the web layer 10.

The initial fiber is selected from a combination of polypropylene, polyethylene, polyethylene terephthalate, polybutylene terephthalate, polypropylene copolymer, polyethylene terephthalate copolymer, polybutylene terephthalate copolymer, polyamide or the like. The initial fiber listed in the present invention is shown in FIGS. 5a and 5b, and is composed of two layers, an outer fiber layer 20 and an inner fiber layer 21, respectively. Further, the initial fiber includes a composite fiber having at least two types of components, and at least one type of the components has a low melting point.

Fleece formation means that the initial fibers are manufactured and molded by a fiber supply device or a lifting device. The web layer 10 is shown in Figure 4a. The diaper material has a multi-layered structure and includes at least a three-dimensional gather layer, an absorption layer, and a back sheet in the case of a disposable diaper material.

Of these, as shown in FIG. 1, in the step 2 (2), the web layer 10 is preliminarily heat-treated to initially mold the web layer 10.

Generally, the preheat treatment means that heat treatment is applied between the multiple layers of the web layer 10 by using a heat treatment device so that the web layers 10 are adhered to each other. Of these, the preheating temperature set in step 2 (2) is slightly higher than the melting points of the low melting point components in the initial fibers, but should not be higher than the melting points of the other components in the initial fibers. Therefore, the low melting component receives heat and melts and sticks. The high melting point component still retains the softness of the fiber and keeps it soft. In this way, the layers of the web layer 10 are firmly fixed to each other, and the structure of the web layer 10 is harder than before being preheated.

As shown in FIG. 1, the step 3 (3) is a step of forming a plurality of three-dimensional pores 11 in the initially standardized web layer 10 by hot embossing.

The hot embossing is to form a plurality of three-dimensional cavities 11 on the surface of the web layer 10 by using a cylindrical device having a specific projection on the surface. Of these, the solid cavity 11 is shown in FIG. 4c. Its effect is to improve the flowability of the fluid in the nonwoven fabric.

As shown in FIG. 1, the step 4 (4) is a step in which the web layer 10 is subjected to a final mold by heat treatment to be adhesively formed as a nonwoven fabric.

The heat treatment means that the heat treatment device receives heat between the multiple layers of the web layer 10 to cause adhesive bonding. Of these, the heat treatment temperature set in step 4 (4) is higher than the melting points of the low melting point components in the initial fibers, but should not be higher than the melting points of the other components in the initial fibers. As a result, each layer of the web layer 10 is fixed, and the structure of the web layer 10 becomes a nonwoven fabric by adhesive bonding due to heat.

Further, description will be given by comparing FIGS. 4b and 4c. FIG. 4b is a finished non-woven fabric that is generally produced, and only steps 1(1), 3(3) and 4(4) of the present invention have been carried out, but steps 2(2) of the present invention have been performed. ) Is missing. It can be seen that the solid cavity 11 of Figure 4c is more stereoscopic than the solid cavity 11 of Figure 4b.

2 and 3 show a second embodiment of the manufacturing process in the production line of the three-dimensional pattern hot air through bonding nonwoven fabric of the present invention. In the first embodiment, the features described in FIGS. 1, 4a and 4c are the same as those in FIGS. 2, 3 and 4d, and thus the reference numerals or the omission of the reference numerals in FIGS. 2, 3 and 4d are omitted. Will not be described again. The second embodiment is different from the first embodiment in that FIG. 2 of the second embodiment is different from FIG. 1 of the first embodiment after step 3 (3) and again steps 2 (2) to 3 (3) is executed.

First, the flowchart shown in FIG. 2 includes steps 1(1), 2(2), 3(3) and 4(4).

Among them, as shown in FIG. 2, the step 1 (1) is a step of forming the web layer 10 by fleece forming the initial fibers.

As shown in FIG. 2, the step 2 (2) is a step of manufacturing the web layer 10 in which the web layer 10 is preliminarily standardized by preheating.

As shown in FIG. 2, the step 3 (3) is a step of forming a plurality of solid pores 11 in the initially standardized web layer 10 by heat embossing.

Next, after step 3(3), steps 2(2) to 3(3) are executed again.

Specifically, by performing the preheat treatment and the heat embossing treatment again, the solid cavity 11 with increased strength is manufactured.

Preferably, step 3a (3a) is added as shown in FIG. Step 3a (3a) includes assembling at least one reinforcing fiber 12 on the solid cavity 11 during step 3(3). Of these, the reinforcing fiber 12 includes a composite fiber having at least two types of components, and at least one of the components has a low melting point. As a result, when steps 2(2) to 3(3) are performed again, the influence of the material quality of the original web layer 10 is reduced, and the strength of the three-dimensional structure of the three-dimensional cavity 11 is increased. Referring to FIG. 4d, it can be seen that the reinforcing fibers 12 cover the surface of the web layer 10.

Of these, as shown in FIG. 2, in the step 4 (4), the web layer 10 is heat-treated and finally shaped to be adhesively bonded as a nonwoven fabric.

Therefore, the present invention has an effect different from that of a general method for manufacturing a nonwoven fabric.

Although the embodiments of the present invention have been described in detail above with reference to the drawings, the specific configuration is not limited to these embodiments, and there are design changes and the like within the scope not departing from the gist of the present invention. However, it is included in the present invention.

1 step 1
2 step 2
3 Step 3
3a Step 3a
4 Step 4
10 web layer 11 three-dimensional cavity 12 reinforcing fiber 20 outer fiber layer 21 inner fiber layer

Claims (10)

A manufacturing process in a production line of a three-dimensional pattern hot air through bonding nonwoven fabric,
Step 1 to fleece the initial fibers to form a web layer;
A step 2 of preliminarily stylizing the web layer by pre-heating the web layer;
A step 3 of forming a plurality of three-dimensional cavities by heat embossing on the initially shaped web layer;
And a step 4 in which the web layer is heat-treated and finally shaped so as to be adhesively bonded as a nonwoven fabric, the manufacturing process in the production line of the three-dimensional hot air through bonding nonwoven fabric. In the production line of a three-dimensional hot air through bonding nonwoven fabric according to claim 1, wherein the initial fiber is a composite fiber having at least two kinds of components, and at least one kind of the components has a low melting point. Manufacturing process. The preheat treatment temperature set in the step 2 should be slightly higher than or equal to the melting point of the low melting point component in the initial fiber and not higher than the melting points of the other components in the initial fiber. The manufacturing process in the production line of the hot air through bonding nonwoven fabric having a three-dimensional pattern according to claim 2. The heat treatment temperature set in the step 4 is higher than the melting points of the low melting point components in the initial fiber and not higher than the melting points of the other components in the initial fiber. A manufacturing process in the production line of the three-dimensional hot air through bonding nonwoven fabric described in. The manufacturing process in the production line of the three-dimensional hot air through bonding nonwoven fabric according to claim 1, wherein the step 2 to the step 3 are performed again after the step 3. The manufacturing process in a production line of a three-dimensional hot air through bonding nonwoven fabric according to claim 1, further comprising a step of assembling at least one reinforcing fiber on the three-dimensional cavity in the step 3. The production line for a three-dimensional hot air through bonding nonwoven fabric according to claim 6, wherein the reinforcing fiber is a composite fiber having at least two kinds of components, and the melting point of at least one kind of component is low. Manufacturing process in. The fiber is selected from a combination of polypropylene, polyethylene, polyethylene terephthalate, polybutylene terephthalate, polypropylene copolymer, polyethylene terephthalate copolymer, polybutylene terephthalate copolymer, polyamide or the like. Item 3. A manufacturing process in a production line of a three-dimensional pattern hot air through bonding nonwoven fabric according to Item 1. A three-dimensional hot air through bonding non-woven fabric,
A hot air through bonding non-woven fabric product manufactured by the manufacturing process in the production line of the three-dimensional hot air through bonding non-woven fabric according to claim 1. The hot air through bonding nonwoven fabric according to claim 9, wherein the hot air through bonding nonwoven fabric product includes a paper diaper, a sanitary napkin or a panty liner.