JP2021181649A - Compound nonwoven fabric, method of producing the same, and apparatus for producing compound non-woven fabric - Google Patents

Abstract

To provide a compound nonwoven fabric hard to generate a paper powder when dry, hard to break when using, hard to generate peeling off of a paper powder when using even in a humid time, and having a high wet strength, a method of producing the same, and an apparatus for producing the same.SOLUTION: The compound nonwoven fabric 1 comprises pulp fibers 2, and resin fibers 3 having a longer fiber length than that of the pulp fibers 2, and an average fiber diameter in a range of 0.5-10 μm, where the resin fibers 3 which irregularly meander and entangle each other, and the pulp fibers 2 distributed in a thickness direction are entangled mutually so that the resin fibers 3 and the pulp fibers 2 are entangled integrally and three-dimensionally.SELECTED DRAWING: Figure 1

Description

The present invention relates to, for example, a cleaning sheet (cleaning sheet), a wet tissue, a hand towel (wet towel), a body wipe, a non-woven fabric, a face mask, and a protective cloth used for cleaning, caring for, protecting, and polishing electrical appliances and floors. Fabrics, waterproof sheets, pillowcases, nursing sheets, paper diapers, pet sheets, hand towels, kitchen paper (kitchen towels), chemical miscellaneous cloths, automobile interiors, composite non-woven fabrics used for civil engineering and construction materials, and their manufacturing methods. It relates to a composite nonwoven fabric manufacturing apparatus, and more particularly to a composite nonwoven fabric made of pulp fiber and synthetic resin fiber, a method for producing the same, and a composite nonwoven fabric manufacturing apparatus.

Conventionally, as fibers constituting a non-woven fabric, for example, synthetic resin fibers such as polyester (PEs) and polypropylene (PP), and vegetable fibers such as rayon and pulp are known. Polyester-based and polypropylene-based synthetic resin fibers are strong, but generally have poor water absorption because they are hydrophobic. On the other hand, plant fibers such as rayon and pulp generally have good water absorption because they are hydrophilic, but their strength is poor. In particular, when wet, the bonding force between the fibers becomes brittle and the strength is greatly reduced.

Therefore, for example, in Patent Document 1, pulp fibers are supplied and laminated by a pulp airlaid on a synthetic fiber web of continuous filament formed by a spunbond method, and a synthetic fiber web layer and a pulp fiber layer are laminated by a water jet. A technique for obtaining a composite non-woven fabric by entanglement with water flow is disclosed. Such a composite non-woven fabric has both the strength of the synthetic fiber non-woven fabric and the absorbency of the paper sheet.

Japanese Unexamined Patent Publication No. 2018-16908

However, in the technique described in Patent Document 1, since the web of synthetic fibers is a continuous filament formed by the spunbond method, pulp fibers are laminated with pulp airlaid, and the pulp fiber layer and the synthetic fiber layer are treated with sparace. However, there is a problem that the entanglement of the pulp fiber with the synthetic fiber is weak, paper dust is generated at the time of use, and the pulp fiber is easily peeled off or torn due to falling off. In particular, when it gets wet, its strength becomes extremely weak. In addition, if the content of pulp fiber is increased in order to improve water absorption and water retention, paper dust is more likely to be generated during use, so there is a limit to the improvement of water absorption and water retention by pulp fiber. ..

Therefore, the present invention is a composite non-woven fabric having high wet strength, which is less likely to generate paper dust during drying and is not easily torn during use, and is less likely to cause paper dust to come off during use even when wet, and a method for producing the same. Another object is to provide a composite nonwoven fabric manufacturing apparatus.

The composite non-woven fabric of the invention of claim 1 is composed of a pulp fiber and a resin fiber having a fiber length longer than that of the pulp fiber and an average fiber diameter in the range of 0.5 to 10 μm, and the resin fiber is non-existent. The resin fibers and the pulp fibers are three-dimensionally and integrally entangled with each other in a regular manner and entangled with each other and entangled with the pulp fibers distributed in the entire thickness direction.

As the pulp of the above-mentioned pulp fiber, wood pulp made from wood is preferably used, but plant fibers other than wood such as grass, bamboo, cotton, flax, esparto, kenaf, milk weed, straw and bagasse are used. It may be non-wood pulp such as. Generally, wood pulp fibers have a flat ribbon shape.
This pulp fiber is shorter than the resin fiber, that is, the fiber length is shorter.

As the resin of the resin fiber, for example, polyolefins such as polypropylene and polyethylene, and synthetic resins such as nylon, vinylon, polyester and aramid are used.
The resin fiber has a longer fiber length than the pulp fiber and has an average fiber diameter of preferably 0.5 μm or more and 10 μm or less, more preferably 0.5 μm or more and 5 μm or less, still more preferably 1 μm. As mentioned above, it is within the range of 3 μm or less. For the average fiber diameter of the resin fibers, SEM images (× 700) of the front surface and the back surface of the composite non-woven fabric were taken using a scanning electron microscope, and all the fibers in the field of view were taken from the SEM images of each surface. The fiber diameter was measured one time at a time to obtain an average value, and the average value was rounded off to the nearest 10 nm to calculate the average fiber diameter (μm).

A large number of such resin fibers having a predetermined average fiber diameter meander irregularly (randomly), sometimes forming loops and being three-dimensionally entwined with each other everywhere, and in the entire thickness direction. It is three-dimensionally entwined with the distributed pulp fibers everywhere.
Here, the entanglement with the pulp fibers in which the resin fibers are distributed over the entire thickness direction means that the structure is not a laminated structure of the pulp fiber layer and the resin fiber layer, and is substantially the thickness from the front surface side to the back surface side of the composite nonwoven fabric. It means that the pulp fibers are distributed throughout and the pulp fibers are entangled with the resin fibers which are melt blow fibers. It should be noted that the distribution amount of the pulp fibers is not required to be uniform in the thickness direction. That is, the pulp fibers and the resin fibers are three-dimensionally entangled and integrated with each other in an irregular (random) orientation.

The composite nonwoven fabric of the invention of claim 2 has more pulp fibers on one surface side of the front and back surfaces of the composite nonwoven fabric than on the other surface side, and the one surface side in which a large amount of the pulp fibers is present. The meandering of the resin fiber is more present than that of the other surface side.
The front and back do not pursue and specify the front or back, but specify one of the two sides perpendicular to the thickness direction of the composite nonwoven fabric and the other side opposite to the other. .. Then, the abundance ratio, that is, the content of the pulp fiber on one surface (front surface or back surface) side of the front and back surfaces of the composite nonwoven fabric, rather than the other surface (back surface or front surface) side on the opposite side. In addition, the number of the meandering of the resin fiber is also large.

The pulp fiber of the composite nonwoven fabric of the invention of claim 3 is a fibrillated beaten wood pulp, and the average fiber length thereof is preferably in the range of 500 μm or more and 5000 μm or less, more preferably 600 μm or more and 4000 μm. It is within the following range, more preferably within the range of 750 μm or more and 3500 μm or less.

Here, the above-mentioned fibril formation refers to a phenomenon in which fibrils inside fibers appear on the surface due to frictional action, fluff, and fluff, and can be confirmed by an SEM image. In addition, "beating" means "pulp fiber by repeatedly compressing and releasing pulp by passing the pulp slurry between rotating blades of concavo-convex parts such as refiners and beaters. To cause swelling, fibrillation, and cleavage ”(The Chemical Society of Japan, ed.,“ Chemistry Handbook, Applied Chemistry (6th Edition), ”page 250, January 30, 2003, published by Maruzen Co., Ltd.). .. The beating method is not particularly limited, and may be fibrillated by a pulper, jetting of a pressurized water stream (water jet punching), or the like.
The average fiber length of the pulp fiber is such that the pulp fiber adheres to the adhesive surface of the tape when the cellophane tape (registered trademark) is adhered to each surface of the front surface and the back surface of the composite nonwoven fabric and peeled off. On the other hand, an SEM image (× 250) was taken using a scanning electron microscope, and the average fiber length was measured once for each fiber in the visual field from the SEM image on each surface to obtain the average value. , The average fiber diameter (μm) is calculated by rounding off the 10 nm position of the average value.

The resin fiber of the composite nonwoven fabric of the invention of claim 4 forms a focusing portion in which a plurality of single fibers are bundled and fused together in a part in the length direction thereof, and the focusing portion is formed. On both ends or one end, there is a branched structure with non-fused portions of single fibers.
Here, the focusing portion is formed by, for example, in the melt blow fibers formed by the melt blow method, the single fibers discharged from the mouthpiece of the die are fused and bonded to the adjacent fibers.

The composite non-woven fabric of the invention of claim 5 has a textured amount (basis weight) of preferably 30 g / m ² or more and 80 g / m ² or less, more preferably 35 g / m ² or more and 75 g /. It ^{is more preferably m 2} or less, more preferably 40 g / m ² or more and 70 g / m ² or less, and the specific volume is preferably 7 cm ³ / g or more and 70 cm ³ / g or less, more preferably. It is within the range of 10 cm ³ / g or more and 65 cm ³ / g or less, ^{more preferably 12 cm 3} / g or more and 60 cm ^{3 / g or less.}

In the method for producing a composite nonwoven fabric according to claim 6, a melt blown nonwoven fabric made of resin fibers is formed in the melt blown nonwoven fabric manufacturing step, and pulp fibers are placed on the melt blown nonwoven fabric placed on a net conveyor in the pulp fiber web forming step by an air-laid method. The web was formed, and the resin fiber of the melt blown nonwoven fabric and the pulp fiber of the pulp web formed on the resin fiber were integrated by water flow entanglement in the spunlace treatment step, and the integral entangled in the drying step. The resin fiber and the pulp fiber are dried.

Here, in the above-mentioned melt blow nonwoven fabric manufacturing process, the synthetic resin is melted and spun from a die having a large number of caps, and at the time of spinning, a high-speed high-temperature airflow is blown to traction thinning and traction thinning. This is a process of forming a non-woven fabric by a melt blow method in which the collected ultrafine resin fibers are collected on a net conveyor, accumulated in a sheet shape, and deposited. Air is usually used as the air flow (gas) to be blown during blow spinning, but it is also possible to use an inert gas such as nitrogen gas.
As the resin of the resin fiber, for example, polyolefins such as polypropylene and polyethylene, and synthetic resins such as nylon, vinylon, polyester and aramid are used.

In the pulp airlaid step, the defibrated (opened) pulp fibers are dispersed by the flow of air without using water, discharged, and collected by negative pressure on a melt blown non-woven fabric placed on a net conveyor. It is a step of forming a pulp fiber web on a melt blown non-woven fabric by a pulp airlaid method of depositing and accumulating, and the pulp fiber web side is the upper surface. As the airlaid method, for example, known methods such as the curl croyer method, the Danweb method, the J & J method, the KC method, and the quinocross method can be adopted.
As the pulp of the above-mentioned pulp fiber, wood pulp made from wood is preferably used, but plant fibers other than wood such as grass, bamboo, cotton, flax, esparto, kenaf, milk weed, straw and bagasse are used. It may be non-wood pulp such as. Generally, wood pulp fibers have a flat ribbon shape.

In the spunlace treatment step, a water jet is applied to the melt blown nonwoven fabric and the pulp fiber web supplied onto the melt blown nonwoven fabric, and preferably a jet water flow is applied from the upper surface of the pulp fiber web to the melt blown nonwoven fabric side. , The resin fiber of the melt blown nonwoven fabric and the pulp fiber of the pulp fiber web are integrated and bonded by water flow entanglement.

The drying step is a step of drying the water entwined with the water flow of the resin fiber constituting the melt blow nonwoven fabric and the pulp fiber web, and drying at a high temperature even with a heater or a heat roll. It may be air.

The method for producing a composite nonwoven fabric according to claim 7 is a roll process in which the melt blown nonwoven fabric and the pulp fiber web formed on the melt blow nonwoven fabric are pressed by a roll process between the pulp fiber web forming step and the spunlacing process. It has a process.
The thermal roll processing step calms the bulkiness of the pulp fiber web formed on the melt blow nonwoven fabric by pressing the melt blow nonwoven fabric and the pulp fiber web formed on the melt blow nonwoven fabric through the rolls. This is a process for fixing pulp fibers.

The method for producing a composite nonwoven fabric according to claim 8 is to apply a jet water flow from the upper surface of the pulp fiber web to the melt blow nonwoven fabric side in the span race treatment step with respect to the melt blow nonwoven fabric and the pulp fiber web formed on the melt blow nonwoven fabric. It is given and entangled with the water flow.

The method for producing a composite nonwoven fabric according to claim 9 includes a heat embossing step by embossing a hot embossed roll before or after the drying step.
The heat embossing step is a step of partially fusing and fusing the fibers by embossing the heat embossing roll to form an embossed pattern. It may be between the spunbonding step and the drying step, or after the drying step.

In the composite nonwoven fabric manufacturing apparatus according to claim 10, a melt blown nonwoven fabric made of resin fibers is formed in the melt blown nonwoven fabric manufacturing section, and the melt blown nonwoven fabric placed on a net conveyor in the pulp fiber web forming section is made of pulp fibers by an air raid method. The web is formed, and the resin fiber of the melt-blow non-woven fabric and the pulp fiber of the pulp fiber web formed on the resin fiber are integrated by water flow entanglement in the spunlace processing portion, and the integral entanglement is performed in the drying portion. The resin fiber and the pulp fiber are dried.

Here, the Melt-Blow Nonwoven Fabric Manufacturing Department melts the synthetic resin, extrudes it into a thread from a die having a large number of caps, and spins it, and at the same time, blows a high-temperature air stream at a high speed to obtain an ultrafine resin fiber. , The non-woven fabric is formed by the melt blow method, which collects it on a net conveyor and accumulates it in the form of a sheet. Air is usually used as the air flow (gas) to be blown during blow spinning, but it is also possible to use an inert gas such as nitrogen gas.
As the resin of the resin fiber, for example, polyolefins such as polypropylene and polyethylene, and synthetic resins such as nylon, vinylon, polyester and aramid are used.

In the pulp airlaid part, the defibrated (opened) pulp fibers are dispersed by the flow of air without using water, discharged, and collected by negative pressure on the melt blown non-woven fabric placed on the net conveyor. A web of pulp fibers is formed on a melt-blown non-woven fabric by a pulp airlaid method of depositing and accumulating, and the pulp web side is the upper surface. As the airlaid method, for example, known methods such as the curl croyer method, the Danweb method, the J & J method, the KC method, and the quinocross method can be adopted.
As the pulp of the above-mentioned pulp fiber, wood pulp made from wood is preferably used, but plant fibers other than wood such as grass, bamboo, cotton, flax, esparto, kenaf, milk weed, straw and bagasse are used. It may be non-wood pulp such as. Generally, wood pulp fibers have a flat ribbon shape.

The spunlace processing section applies a water jet to the melt blown nonwoven fabric and the pulp fiber web supplied on the melt blown nonwoven fabric, and preferably imparts a jet water flow from the upper surface of the pulp fiber web to the melt blown nonwoven fabric side. The resin fiber of the melt blown non-woven fabric and the pulp fiber of the pulp fiber web are integrated and bonded by water flow entanglement.

The drying portion dries the water entangled with the water flow of the resin fibers constituting the melt blow nonwoven fabric and the pulp fibers constituting the pulp fiber web, and is dried at a high temperature even with a heater or a heat roll. It may be air.

The composite nonwoven fabric manufacturing apparatus according to claim 11 is a roll processing unit that presses the melt blow nonwoven fabric and the pulp fiber web formed on the melt blow fabric between the pulp fiber web forming unit and the span lace processing unit by roll processing. It has.
The heat roll processing portion calms the bulkiness of the pulp fiber web formed on the melt blow nonwoven fabric by pressing the melt blow nonwoven fabric and the pulp fiber web formed on the melt blow nonwoven fabric through the rolls. This is a process for fixing pulp fibers.

The composite nonwoven fabric manufacturing apparatus according to claim 12 imparts a jet water flow from the upper surface of the pulp fiber web to the melt blow nonwoven fabric side of the melt blow nonwoven fabric and the pulp fiber web formed on the melt blow nonwoven fabric. The water flow is entangled.

The composite nonwoven fabric manufacturing apparatus according to claim 13 has a heat embossed portion by embossing a heat embossed roll before or after the dried portion.
The heat embossed portion partially fuses and fuses fibers by embossing a heat emboss roll to form an embossed pattern. The term "before or after" the dried portion means that the heat embossed portion is arranged on the downstream side of the span race portion and between the upstream sides of the dried portion or on the downstream side of the dried portion. ..

According to the composite non-woven fabric according to the invention of claim 1, the pulp fiber and the fiber length are longer than the pulp fiber, and the average single fiber diameter is preferably in the range of 0.5 to 10 μm, more preferably 0.5. The pulp fibers are composed of resin fibers in the range of about 5 μm, more preferably in the range of 1 to 3 μm, and the resin fibers are irregularly meandering and entangled with each other, and are distributed over the entire thickness direction. The resin fibers and the pulp fibers are entangled and entangled in a three-dimensional manner.

According to the composite nonwoven fabric according to the invention of claim 1, the ultrafine resin fibers are irregularly meandering and entangled with each other, and the resin fibers are ultrafine with a predetermined diameter and have a large surface area. There are many entanglements in which the pulp fibers are trapped in the resin fibers, and the pulp fibers are firmly held by the resin fibers. Therefore, the pulp fiber is hard to fall off, paper dust is hard to be generated when it is dried (when it is not wet), and it is hard to be peeled off and torn even when it is used. In addition, the paper dust does not easily come off during use even when wet, and has high wet strength. Further, even in the case of ultrafine resin fibers, they are entangled with each other and also with pulp fibers, so that both softness and mechanical strength are compatible.

According to the composite nonwoven fabric according to the invention of claim 2, the pulp fiber is present more on one surface side of the front and back surfaces of the composite nonwoven fabric than on the other surface side, and the pulp fiber is present in a large amount. Since more of the meandering or loops of the resin fiber is present on the surface side of the resin fiber than on the other surface side, even if more pulp fiber is present on one surface side, the resin fiber is said to be present on the surface side. Since there is a lot of meandering, the entanglement of the pulp fiber with the resin fiber can be increased, and the wet strength can be increased. Therefore, even if a large amount of water absorption and water retention occurs on the surface side where a large amount of pulp fibers are present, it is unlikely to peel off or tear. Therefore, in addition to the effect described in claim 1, even if the directionality at the time of use is not specified, it is difficult for peeling or tearing to occur at the time of use.

According to the composite nonwoven fabric of the invention of claim 3, the pulp fiber is a fibrillated beaten wood pulp, and the average fiber length thereof is preferably in the range of 500 μm or more and 5000 μm or less, more preferably 600 μm. Since it is within the range of 4000 μm or less, more preferably 750 μm or more and 3500 μm or less, the entanglement with the resin fiber is improved, and in addition to the effect according to claim 1 or 2. , Pulp fibers are less likely to fall off, and paper dust generation, peeling, and tearing can be further prevented. Moreover, it is possible to improve the mechanical strength.

According to the composite nonwoven fabric of the invention of claim 4, since the resin fiber has a focusing portion in which a plurality of single fibers are bundled and fused together in a part in the length direction thereof, the fiber strength is improved. Moreover, at the end of the focusing portion, the single fibers have a branched structure of a non-fused portion in which the fibers are not fused to each other. Therefore, it is possible to improve the entanglement of pulp fibers even with the branched structure. Therefore, in addition to the effect according to any one of claims 1 to 3, it is possible to further improve the mechanical strength. In addition, it is possible to further prevent the pulp fibers from falling off, the generation of paper dust, peeling, and tearing.

According to the composite nonwoven fabric of the invention of claim 5, the basis weight (basis weight) is preferably in ^{the range of 30 to 80 g / m 2} , and the specific volume is preferably 7 to 70 cm ³ /. It is within the range of g.
When the basis weight is large and the specific volume is small, the pulp fibers do not penetrate between the resin fibers and the amount of pulp is small, so that the water absorption and water retention are small. On the other hand, a material having a small basis weight and a large specific volume has a small mechanical strength because the pulp fibers and the resin fibers are less entangled.
The texture (basis weight) of the composite non-woven fabric is preferably in the range of 30 to 80 g / m ² , more preferably 35 to 75 g / m ² , and further preferably 40 to 70 g / m ² . specific volume, preferably, 7~70cm ³ / g, more preferably, 10~65cm ³ / g, more preferably, within the range of 12~60cm ³ / g, of claims 1 to 4 In addition to the effects described in any one, water absorption, water retention and mechanical strength can be achieved at the same time.

According to the method for producing a composite nonwoven fabric according to the invention of claim 6, the melt blown nonwoven fabric made of resin fibers is formed in the melt blow nonwoven fabric manufacturing step, and the melt blow nonwoven fabric is placed on a net conveyor in the pulp fiber web forming step. A pulp fiber web is formed on the pulp fiber web by an air raid method, and in a spunlace treatment step, the resin fiber of the melt blown nonwoven fabric and the pulp fiber of the pulp fiber web formed on the resin fiber are integrated by water flow entanglement. In the drying step, the resin fibers and the pulp fibers integrally entangled in the spunlace processing section are dried.

According to the melt blow method, the resin fibers are extremely fine, and it is possible to form a non-woven fabric that meanders irregularly and is entangled with each other. In the case where the pulp fibers are deposited on the melt blow non-woven fabric (by spraying with an air flow) and the resin fibers and the pulp fibers are spunlaced, the pulp fibers supplied by the airlaid method are in the form of deflated fine powder. Since the hydrogen bonds between the fibers are also weak, even a melt blown non-woven fabric in which ultrafine resin fibers are tightly entwined can be penetrated between the resin fibers, and the resin fibers meander and are entangled with each other, so that the pulp The fibers are easily trapped between the resin fibers and easily entangled. Therefore, the number of entanglement points between the resin fiber and the pulp fiber can be increased, and the pulp fiber can be firmly held by the resin fiber. Therefore, the pulp fibers are less likely to fall off, paper dust is less likely to be generated during drying (non-wet), peeling or tearing is less likely to occur during use, and paper dust is less likely to be peeled off during use even when wet. A composite nonwoven fabric having wet strength can be obtained. Further, even in the case of ultrafine resin fibers, they are entangled with each other and also with pulp fibers, so that a composite nonwoven fabric having both softness and mechanical strength can be obtained.

According to the method for producing a composite nonwoven fabric according to the invention of claim 7, a roll is made with respect to the melt blown nonwoven fabric and the pulp fiber web formed on the melt blow nonwoven fabric between the pulp fiber web forming step and the spunlacing treatment step. Since it has a roll processing step of pressing with a cloth, it is possible to fix the pulp fiber before the spunlacing processing step. Therefore, in addition to the effect according to claim 6, the entanglement of the pulp fiber with the resin fiber can be increased, and the pulp fiber can be less likely to fall off. In addition, during transfer by a net conveyor or when a water jet is jetted in a subsequent spunlace processing process, pulp fibers and paper dust can be prevented from flying up and washed away, and the yield can be improved.

According to the method for producing a composite nonwoven fabric according to the invention of claim 8, in the span race treatment step, a jet water flow is applied from the upper surface of the pulp fiber web to the melt blown nonwoven fabric side and the water flow is entangled, so that the pulp fiber web side is entangled. The pulp fiber can be entangled by being caught in the resin fiber on the melt blown non-woven fabric side. Therefore, in addition to the effect according to claim 6 or 7, the entanglement of the pulp fiber with the resin fiber can be improved, and the pulp fiber can be further prevented from falling off. Moreover, it is possible to improve the mechanical strength.

According to the method for producing a composite nonwoven fabric according to the invention of claim 9, it has a heat embossing step of embossing with a hot embossing roll between the spunlacing treatment step and the drying step, or after the drying step. In addition to the effect according to any one of claims 6 to 8, it is possible to effectively prevent the fibers from falling off, increase the mechanical strength, enable bulkiness, and further suppress elongation. ..

According to the composite nonwoven fabric manufacturing apparatus according to the invention of claim 10, the melt blown nonwoven fabric manufacturing section forms a melt blown nonwoven fabric made of resin fibers, and the pulp fiber web forming section is placed on the melt blown nonwoven fabric on a net conveyor. A pulp fiber web is formed by an air raid method, and the resin fiber of the melt blown nonwoven fabric and the pulp fiber of the pulp fiber web formed on the resin fiber are integrated by water flow entanglement in a spunlace processing section. The resin fibers and the pulp fibers integrally entangled in the spunlace-treated portion are dried in the drying portion.

According to the melt blow method, the resin fibers are extremely fine, and it is possible to form a non-woven fabric that meanders irregularly and is entangled with each other. In the case where the pulp fibers are deposited on the melt blow non-woven fabric (by spraying with an air flow) and the resin fibers and the pulp fibers are spunlaced, the pulp fibers supplied by the airlaid method are in the form of deflated fine powder. Since the hydrogen bonds between the fibers are also weak, even a melt blown non-woven fabric in which ultrafine resin fibers are tightly entwined can be penetrated between the resin fibers, and the resin fibers meander and are entangled with each other, so that the pulp The fibers are easily trapped between the resin fibers and easily entangled. Therefore, the number of entanglement points between the resin fiber and the pulp fiber can be increased, and the pulp fiber can be firmly held by the resin fiber. Therefore, the pulp fibers are less likely to fall off, paper dust is less likely to be generated during drying (non-wet), peeling or tearing is less likely to occur during use, and paper dust is less likely to be peeled off during use even when wet. A composite nonwoven fabric having wet strength can be obtained. Further, even in the case of ultrafine resin fibers, they are entangled with each other and also with pulp fibers, so that a composite nonwoven fabric having both softness and mechanical strength can be obtained.

According to the composite nonwoven fabric manufacturing apparatus according to the invention of claim 11, the melt blown nonwoven fabric and the pulp fiber web formed on the melt blow nonwoven fabric are rolled between the pulp fiber web forming portion and the spunlacing processing portion. Since it has a roll-processed portion to be pressed, the pulp fiber can be fixed in front of the spunlace-processed portion. Therefore, in addition to the effect according to claim 10, it is possible to increase the entanglement of the pulp fiber with the resin fiber and further prevent the pulp fiber from falling off. In addition, during transfer by a net conveyor or when a water jet is jetted in a subsequent spunlace processing process, pulp fibers and paper dust can be prevented from flying up and washed away, and the yield can be improved.

According to the composite nonwoven fabric manufacturing apparatus according to the invention of claim 12, in the spunlace processing unit, a jet water flow is applied from the upper surface of the pulp fiber web to the melt blown nonwoven fabric side and entangled with the water flow, so that the pulp fiber web side is used. Pulp fibers can be entangled by being caught in the melt blow resin fibers on the melt blow non-woven fabric side. Therefore, in addition to the effect according to claim 10 or claim 11, the entanglement of the pulp fiber with the resin fiber can be improved, and the pulp fiber can be further prevented from falling off. Moreover, it is possible to improve the mechanical strength.

According to the composite nonwoven fabric manufacturing apparatus according to the thirteenth aspect of the present invention, there is a heat embossing part to be embossed with a heat embossing roll between the spunlace processing part and the drying part or after the drying part. In addition to the effect according to any one of claims 10 to 12, it is possible to effectively prevent the fibers from falling off, increase the mechanical strength, enable bulkiness, and further suppress elongation.

FIG. 1 is a scanning electron micrograph (× 100) of one surface (front surface, upper surface) of the front and back surfaces of the composite nonwoven fabric according to the embodiment of the present invention. FIG. 2 is a scanning electron micrograph (× 250) of one surface (front surface, upper surface) of the front and back surfaces of the composite nonwoven fabric according to the embodiment of the present invention. FIG. 3 is a scanning electron micrograph (× 500) of one surface (front surface, upper surface) of the front and back surfaces of the composite nonwoven fabric according to the embodiment of the present invention. FIG. 4 is a scanning electron micrograph (× 250) of the other surface (back surface, lower surface) of the front and back surfaces of the composite nonwoven fabric according to the embodiment of the present invention. FIG. 5 is a scanning electron micrograph (× 500) of the other surface (back surface, lower surface) of the front and back surfaces of the composite nonwoven fabric according to the embodiment of the present invention. FIG. 6 is a scanning electron micrograph (× 30) of a cross section of the composite nonwoven fabric according to the embodiment of the present invention. FIG. 7 is a scanning electron micrograph (× 50) of a cross section of the composite nonwoven fabric according to the embodiment of the present invention. FIG. 8 is a scanning electron micrograph (× 100) of a cross section of the composite nonwoven fabric according to the embodiment of the present invention. FIG. 9 is a scanning electron micrograph (× 250) of a cross section of the composite nonwoven fabric according to the embodiment of the present invention. FIG. 10 is a scanning electron micrograph (× 500) of a cross section of the embossed portion of the composite nonwoven fabric according to the embodiment of the present invention. FIG. 11 is a scanning electron micrograph (× 700) of a cross section of the embossed portion of the composite nonwoven fabric according to the embodiment of the present invention. FIG. 12 is a conceptual diagram showing a manufacturing process of the composite nonwoven fabric according to the embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the embodiment, the same symbol and the same reference numeral in the illustration are the same or corresponding functional parts, and therefore the overlapping description thereof will be omitted here.

First, the composite nonwoven fabric according to the embodiment of the present invention will be described with reference to the electron micrographs of FIGS. 1 to 11.
In the composite nonwoven fabric 1 of the present embodiment, the melt blow resin fiber 3 made of a flat ribbon-shaped short fiber-like pulp fiber 2 and an ultrafine elongated fiber-like (filament-like) synthetic resin fiber is three-dimensionally entangled integrally. It is made up of.

Here, as described later, the melt blow resin fiber 3 made of the resin fiber constituting the composite nonwoven fabric 1 of the present embodiment melts and spins a synthetic resin, and the spun fiber is made extremely fine by hot air at a high temperature. It is formed by the melt blow method, and is an ultrafine fiber having a predetermined fiber diameter.

As shown in FIGS. 1 to 11, the melt blow resin fibers 3 of this embodiment irregularly (randomly) meander, bend, or form a loop and are three-dimensionally entangled with each other. ..
Further, in the composite nonwoven fabric 1 of the present embodiment, there is a focusing portion 3a in which a plurality of single fibers are focused and fused together in a part or all of the melt blow resin fibers 3 in the length direction. In particular, if a plurality of single fibers are bundled and fused together in a part of the melt blow resin fiber 3 in the length direction, the single fibers are fused to each other on both sides or one side of the bundled portion 3a. By not wearing it, it has a branched structure.

As the melt blow resin fiber 3, synthetic resins such as nylon, vinylon, polyester, polyethylene, polypropylene, polyolefin, aramid, acrylic, and polystyrene are used, and are selected according to the use, purpose, and the like of the composite nonwoven fabric 1. Depending on the selection of raw materials and ingenuity in the manufacturing process, it may be a composite type of polypropylene (PP) and polyethylene (PE), a biodegradable type based on polylactic acid (PLA), etc., and a core sheath structure composed of multiple resins. , Parallel structure, split fiber structure may be used. The fiber shape is generally round, but may be elliptical, rhombic, triangular, T-shaped, well-shaped, or the like.
In particular, since polypropylene is an environmentally friendly material and a soft long fiber, it is desirable to use a copolymer polypropylene as a raw material as a base material.

In the present embodiment, as will be described later, the long fibrous melt blow resin fiber 3 obtained by spinning and jetting hot air has an average fiber diameter of preferably 0.5 to 10 μm.
According to the experimental research by the present inventors, if the fiber diameter is too large, the capture and entanglement of the pulp fiber 2 is lowered due to the decrease in the fiber density and the high surface area of the fiber. On the other hand, even if the fiber diameter is too small, the capture and entanglement of the pulp fiber 2 is lowered due to the high density of the fiber and the decrease of the curvature of the fiber.
Preferably, if the average fiber diameter of the melt blow resin fiber 3 is in the range of 0.5 to 10 μm, many serpentines, curves, and loops for irregularly (randomly) entwining the pulp fibers 2 can be formed. The pulp fibers 2 can be entangled with each other and can be strengthened. It is more preferably in the range of 0.5 to 8 μm, still more preferably in the range of 0.5 to 5 μm.
The fiber diameter of the melt blow resin fiber 3 is controlled by the hole diameter of the nozzle cap of the nozzle die 15 for ejecting the fiber, their spacing, the amount of resin ejected, the height of the nozzle die 15, and the like, as will be described later.

Then, in the composite nonwoven fabric 1 of the present embodiment, the melt blow resin fibers having a predetermined average fiber diameter that are irregularly (randomly) meandering, curved, or looped and entangled with each other three-dimensionally. The pulp fibers 2 are irregularly (randomly) three-dimensionally entangled with each other, and the pulp fibers 2 are three-dimensionally entangled with each other, so that the melt blow resin fibers 3 and the pulp fibers 2 are integrated.

As the pulp fiber 2, for example, coniferous trees such as cedar, hinoki, karamatsu, douglas fur, southern pine, radiata pine, slush pine, spruce, lodge ball pine, and broad-leaved wood such as eucalyptus and acacia are used by the craft method and monkeys. Chemical pulp steamed by a fight method, a soda method, a polysulfite method or the like, mechanical pulp such as ground pulp (crushed wood pulp) or thermomechanical pulp, or recycled pulp is used. Softwood pulp and softwood pulp may be mixed and used, and if the content of softwood-derived pulp is high, a composite non-woven fabric 1 having a soft texture and a good texture can be obtained. When the content of pulp derived from coniferous trees such as bleached pulp (NUKP) is high, it is possible to form a composite non-woven fabric 1 having high strength and good yield with less fiber shedding. Either virgin pulp or recycled pulp can be used, but recycled pulp tends to have more short fibers, and it is possible to form a composite nonwoven fabric 1 that is soft and has a better texture.

Further, as can be seen from FIGS. 2 and 3, the pulp fiber 2 of the present embodiment is fibrillated by beating and has a shorter fiber length than the resin fiber 3 which is a long fiber, and its average fiber length is , Preferably in the range of 0.5 to 5 mm.
If the average fiber length of the pulp fiber 2 is too long, the texture is deteriorated. On the other hand, if the average fiber length is too short, the entanglement of the pulp fibers 2 is lowered, the entanglement capable of suppressing the generation of paper dust cannot be obtained, and the mechanical strength is also lowered.
When the average fiber length of the pulp fiber 2 is preferably in the range of 0.5 to 5 mm, the entanglement of the pulp fiber 2 is also good, the mechanical strength is good, the pulp fiber 2 is less likely to fall off, and the pulp fiber 2 is less likely to fall off. , The texture is also good. It is more preferably in the range of 0.6 to 4 mm, and even more preferably in the range of 0.75 to 3.5 mm.

Here, in the composite nonwoven fabric 1 of the present embodiment, as shown in the micrographs of the composite nonwoven fabric 1 in FIGS. 6 and 7, the pulp fibers 2 are distributed substantially in the entire thickness direction of the composite nonwoven fabric 1. Of the upper and lower front and back surfaces of the composite nonwoven fabric 1 in those figures, the pulp fibers 2 are densely present on the upper surface side of the lower surface side, and the abundance ratio of the pulp fibers 2 is high.
Here, for convenience of explanation, the upper side where the pulp fibers 2 are densely present is the front surface side, and the opposite side is the back surface side, but the directionality at the time of use is not specified. In the composite nonwoven fabric 1 of the present embodiment, the abundance ratio of the pulp fibers 2 is higher on the upper front surface side than on the lower back surface side. Here, the upper surface side where the pulp fibers 2 are densely present is the surface side on which the pulp fibers 2 are supplied (laminated) to the melt blow resin fibers 3 of the melt blow nonwoven fabric 110 in the manufacturing process of the composite nonwoven fabric 1 described later. This is the surface side to which the water jet jet is applied during the spunlacing process.

Further, in the composite nonwoven fabric 1 of the present embodiment, FIGS. 2 and 3 are electron micrographs of one surface of the front and back surfaces of the composite nonwoven fabric 1, and FIGS. 2 and 3 are electron micrographs of the other surface on the opposite side. As can be seen from the comparison with 4 and FIG. 5, the random meandering, bending, or random loop of the melt blow resin fiber 3 is present on one side of the front and back surfaces of the composite nonwoven fabric 1 more than the other side. doing. Here, the surface of the melt blow resin fiber 3 having many random meanders, curves, or loops is the upper side in FIGS. 6 and 7, that is, the surface side, and the random meander of the melt blow resin fiber 3 is formed. The side with less curvature or loop presence is the lower side in FIGS. 6 and 7, i.e. the back side.

That is, in the composite nonwoven fabric 1 of the present embodiment, the presence ratio of the pulp fiber 2 is higher on one surface side (front surface side) of the front and back surfaces than on the other surface side (back surface side) on the opposite side. Moreover, the number of meandering or loops of the melt blow resin fiber 3 is large.

As described above, the composite non-woven fabric 1 of the present embodiment is in the form of ultrafine long fibers in which the average fiber diameter of the melt blow resin fibers 3 is preferably in the range of 0.5 to 10 μm, and the surface area when accumulated is large. , Melt blow resin fibers 3 irregularly (randomly) meander, curve, or form a loop and are entangled with each other three-dimensionally, so that the melt blow resin fibers 3 are entangled with each other in a three-dimensionally complicated manner. Further, the pulp fibers 2 are irregularly (randomly) entangled with the melt blow resin fibers 3 in three dimensions, and the pulp fibers 2 are also entangled with each other in three dimensions, so that the melt blow resin fibers 3 and the pulp fibers 2 are entangled with each other in three dimensions. Are intricately intertwined and integrated. As a result, the melt blow resin fibers 3 and the pulp fibers 2 are firmly held, and the pulp fibers 2 are less likely to fall off or fall off even in a dry state (non-wet state) or in a wet state, and paper dust is generated. It's difficult to do.

In particular, the composite non-woven fabric 1 of the present embodiment is a beaten wood pulp in which the pulp fiber 2 is fibrillated, and the average fiber length thereof is preferably in the range of 0.5 to 5 mm, and the melt blow resin fiber 3 is used. Has a focusing portion 3a in which a plurality of single fibers are focused, and at the end of the focusing portion 3a, the single fibers have a branched structure in which the single fibers are not fused to each other. , Melt blow resin fiber 3 has many entanglement points where the pulp fiber 2 is entangled irregularly (randomly), or the entanglement is strong, and the pulp fiber 2 is difficult to fall off during use in a dry state and a wet state, and is torn. It is hard to peel off and has high mechanical strength.

Further, in the composite nonwoven fabric 1 of the present embodiment, the pulp fibers 2 are more present on the front surface side than on the back surface side, but the meandering or loops of the melt blow resin fibers 3 are more on the front surface side than on the back surface side. Since it is present, even if the abundance ratio of the pulp fiber 2 is large on the surface side, the pulp fiber 2 is easily entangled with the melt blow resin fiber 3, and the pulp fiber 2 is entangled well. Therefore, since there is no difference in the falling off of the pulp fibers 2 on the front and back surfaces, paper dust is generated, torn, and peeled off even if the direction at the time of use is not specified. That is, even if a large amount of water is absorbed on the side (surface side) where the abundance ratio of the pulp fiber 2 is large, the melt blow resin fiber 3 and the pulp fiber 2 are often entangled, so that the mechanical strength is such that tearing and peeling are unlikely to occur. ..

The texture of the composite nonwoven fabric 1 formed by entwining the pulp fibers 2 and the melt blow resin fibers 3 ^{is preferably in the range of 30 to 80 g / m 2} , and the specific volume of the composite nonwoven fabric 1 is 7 to 70 cm ^3. It is preferably in the range of / g.
If the amount of grain is too large and the specific volume is too small, the penetration of the pulp fibers 2 between the melt blow resin fibers 3 is small, the amount of the pulp fibers 2 is small, and the water absorption and water retention are small. On the other hand, if the basis weight is too small and the specific volume is too large, the pulp fibers 2 and the melt blow resin fibers 3 are less entangled, and the mechanical strength is impaired.
When the basis weight of the composite nonwoven fabric 1 is preferably in ^{the range of 30 to 80 g / m 2} and the specific volume is preferably in ^{the range of 7 to 70 cm 3} / g, the flexibility is high. Moreover, it has good water absorption, water retention and mechanical strength.
Basis weight of the composite nonwoven fabric 1 is more preferably in a range of 35~75g / m ^2, still more preferably in the range of 40~70g / m ^2. Further, the specific volume of the composite nonwoven fabric 1 is more preferably in the range of 10~65cm ³ / g, still more preferably in the range of 12~60cm ³ / g.

In this way, the composite nonwoven fabric 1 of the present embodiment contains the melt blow resin fibers 3, and the pulp fibers 2, the melt blow resin fibers 3, and the pulp fibers 2 and the melt blow resin fibers 3 are three-dimensionally and complicatedly entangled with each other. As a result, the fibers are strongly entangled with each other, so that paper dust is less likely to be generated and the mechanical strength is excellent. Further, since the melt blow resin fiber 3 is extremely fine, the water absorption and water retention are high due to the capillary pressure and the inclusion of the pulp fiber 2 due to the predetermined narrow opening pattern between the fibers. Further, the flexibility due to the inclusion of the ultrafine melt blow resin fiber 3 is also high.

Therefore, the composite non-woven fabric 1 of the present embodiment has, for example, protection of the floor material, cleaning of the floor material such as polishing, home appliances such as TV, personal computer, refrigerator, kitchen surroundings, optics such as glasses and lenses. Cleaning sheets (cleaning sheets, disposable wipes, chemical wipes such as wipers) used for cleaning equipment, windows, cars, etc., wet wipes, disposable hand towels (wet towels), body wipes, makeup removers, face masks, surgical gowns, etc. Protective clothing fabrics, waterproof sheets, pillowcases, nursing sheets, paper diapers, pet sheets, hand towels, kitchen paper (kitchen towels), table covers, dinner mats and other miscellaneous goods sheets, drip absorbers, packaging materials, automobiles It can be suitably used for interiors, civil engineering and construction materials, various filters, industrial masks, wiping cloths, etc.
Among them, the flexibility and high surface area of the ultra-fine melt blow resin fibers 3, the small pore size between the fibers, and the water absorption and water retention of the pulp fibers make it possible to use wipers, filters, surgical gowns, protective clothing fabrics, waterproof sheets, and pillows. Suitable for covers, nursing sheets and sanitary materials. Further, the melt blow resin fibers 3 that are three-dimensionally intricately entwined are extremely fine, and the pulp fibers 2 are three-dimensionally intricately entangled with the melt blow resin fibers 3, so that the composite nonwoven fabric 1 of the present embodiment can be obtained. Therefore, since the airtightness can be increased and the air permeability can be reduced, it is suitable for collecting and blocking fine dust, bacteria and the like as a filter for medical masks and air cleaning.

In these applications, if desired, wetting agents such as water and propylene glycol, antibacterial agents such as alcohols, paraoxybenzoic acid esters and benzalkonium chloride, antifungal agents, agents such as fragrances, and the like. , Cosmetics and the like may be applied and used, but in the composite nonwoven fabric 1 of the present embodiment, the pulp fibers 2 and the melt blow resin fibers 3 are strongly entangled and integrated, so that the liquids permeate. Even so, there is little decrease in mechanical strength, and it is hard to tear during work or use.
Further, according to the composite nonwoven fabric 1 of the present embodiment, the three-dimensional entanglement of the melt blow resin fibers 3 having a predetermined diameter forming a meandering or loop, and the three dimensions of the pulp fibers 2 to the melt blow resin fibers 3 Since the structure is such that the fibers do not easily fall off due to the entanglement and the mutual three-dimensional entanglement of the pulp fibers 2, paper dust is unlikely to be generated even when the amount of the pulp fibers 2 is increased. Therefore, it is possible to improve water absorption and water retention by increasing the content of the pulp fiber 2 without impairing the drop-off resistance in which the pulp fiber 2 is hard to peel off. That is, even in applications where water, chemicals, cosmetics, etc. are added and used in a wet state, high water absorption, water retention and strength, and dropout resistance can be achieved at the same time because the fibers are hard to fall off. In addition, according to the composite nonwoven fabric 1 of the present embodiment, since the airtightness can be increased and the air permeability can be reduced, it is possible to prevent the absorbed moisture from evaporating and make it difficult to dry.

In addition, even if it is used for wiping off moisture such as disposable rags and wipers, and for absorbing moisture in waterproof sheets, pillowcases, nursing care sheets, disposable diapers, and pet sheets, as described above, moisture and liquid content. Since there is little decrease in strength due to absorption of diapers, it is difficult to tear during work or use. Further, it is possible to improve the overall water absorption and water retention by blending a large amount of the pulp fiber 2 without impairing the dropout resistance of the pulp fiber 2. In addition, since the resin fiber is the ultra-fine melt blow resin fiber 3, it is soft and has a good texture.

Further, as shown in FIGS. 6, 10 and 11, the composite nonwoven fabric 1 of the present embodiment has an embossed portion 5 in which fibers are partially fused and fused to improve mechanical strength. In addition, bulkiness and cushioning properties can be imparted. Further, the fiber dropout resistance is improved by fusing and fusing the fibers in the embossed portion 5. Further, the embossed portion 5 can impart designability and decorativeness, and can improve functionality such as scraping property of dust and the like, adsorptivity, and water retention. Since the pulp fiber 2 and the melt blow resin fiber 3 are not fused to each other except for the embossed portion 5, the number of voids can be increased to provide softness, bulkiness, and elasticity. In the composite nonwoven fabric 1 of the present embodiment, the concave embossed portion 5 is provided when viewed from the surface side thereof. However, when the present invention is carried out, the shape and pattern of the embossing are not particularly limited.
In the embossed portion 5, the fiber diameter of the melt blow resin fiber 3 cannot be confirmed due to the fusion and fusion of the fibers. Therefore, the average fiber diameter of the melt blow resin fiber 3 is calculated excluding the embossed portion 5.

Next, a suitable production of the composite nonwoven fabric 1 of the present embodiment will be described with reference to FIG.
As shown in FIG. 12, a suitable composite nonwoven fabric manufacturing apparatus 100 used for manufacturing the composite nonwoven fabric 1 of the present embodiment mainly includes a melt blow nonwoven fabric manufacturing section 10, a pulp airlaid section 20, and a bonding processing section 30. Has.

The melt-blow nonwoven fabric manufacturing section 10 constituting the composite nonwoven fabric manufacturing apparatus 100 of the present embodiment forms a melt-blow nonwoven fabric 110 which is a sheet-shaped resin fiber aggregate by spinning molten resin from a die nozzle 15 with high-temperature compressed air. It is something to do.

Specifically, the melt blown nonwoven fabric manufacturing unit 10 includes a hopper 11 that supplies rice granular resin pellets having a diameter of about 3 to 5 mm, an extruder 12 that melts and extrudes the raw material resin pellets supplied to the hopper 11. A measuring pump 13 that continuously weighs and sends out the molten resin extruded from the extruder 12, an air passage 14 that sends heated high-speed compressed air, and a molten resin sent out from the measuring pump 13 are spun and simultaneously spun out. It has a nozzle die 15 that blows out the resin into a net conveyor (collector) NC1 as ultrafine fibrous spinning by blowing high-speed hot air from the air passage 14. Further, in the net conveyor NC1 of the melt blow nonwoven fabric manufacturing unit 10, a suction unit (suction unit) 16 that sucks air into the inside by a depressurizing means is arranged below the nozzle die 15, and the net conveyor is provided by an air pump arranged outside. The melt blow resin fibers 3 spun by suction from the upper surface of the NC1 toward the lower surface are easily collected on the upper surface of the net conveyor NC1.

The spinning conditions at this time are appropriately set according to the application of the composite non-woven fabric 1, desired characteristics, and the like. For example, the diameter of the linearly arranged nozzle cap of the nozzle die 15 is preferably 0.05 mm to 0.4 mm. Is set within the range of 0.1 mm to 0.3 mm, and the spacing between the plurality of small holes is 0.01 to 6 mm, preferably 0.1 to 3 mm, more preferably 0.15 to 2 mm. The discharge rate of a single hole is 0.2 g / min to 1 g / min, preferably 0.3 g / min to 0.6 g / min. The temperature of the air blown during spinning is, for example, in the range of 200 to 500 ° C, preferably 250 to 450 ° C, and the pressure of the air is 0.1 to 6 kgf / cm ² , preferably 0.2 to 5 kgf. It is within the range of / cm ^2.

In such a melt blow nonwoven fabric manufacturing unit 10, the molten resin extruded from the extruder 12 and sent out by the measuring pump 13 is spun from the nozzle die 15, and the spun filament is spun out from the air passage 14 at a high temperature and high speed. By blowing it off, the filaments stretched into ultrafine fibers are accumulated on the net conveyor NC1 and entangled with each other, and in some cases, single fibers are fused, and the melt blow resin fibers 3 are sheet-shaped by self-adhesion. , That is, the melt blow nonwoven fabric 110 is formed.

That is, the ultrafine resin fibers continuously ejected from the nozzle die 15 by the melt blow nonwoven fabric manufacturing unit 10 are collected on the upper surface of the net conveyor NC1 and deposited and accumulated in a web shape, and the fibers are entangled and fused. The melt-blow resin fibers 3 are accumulated in a sheet shape and self-adhesive to form the melt-blow nonwoven fabric 110. The melt-blown nonwoven fabric manufacturing unit 10 of the present embodiment is an apparatus for directly manufacturing a nonwoven fabric from spinning, and consistently processes from spinning to forming the nonwoven fabric, and the production speed is increased.
As described above, in the present embodiment, first, a melt blow nonwoven fabric manufacturing process is carried out in which the raw material resin chips are melted and spun, and the long fibers micronized by the high-speed and high-temperature air flow are deposited on the net conveyor NC1. To obtain the melt blow nonwoven fabric 110.

Then, in the present embodiment, the melt blow nonwoven fabric 110 thus formed on the upper surface of the net conveyor NC1 is mounted on the net conveyor NC2 on the downstream side by the transportation of the net conveyor NC1 and is mounted on the next pulp airlaid portion 20. Sent.

Here, in the present embodiment, the average fiber diameter of the melt blow resin fiber 3 of the melt blow nonwoven fabric 110 spun by such a melt blow method is preferably in the range of 0.5 to 10 μm. Within the range, many meandering, bending, and loops for randomly entwining the melt blow resin fibers 3 and the pulp fibers 2 can be formed, and the melt blow resin fibers 3 and the pulp fibers 2 and the melt blow resin fibers 3 can be formed. The entanglement of the pulp fibers 2 can be increased and strengthened. It is more preferably in the range of 0.5 to 5 μm, still more preferably in the range of 1 to 3 μm.
The fiber diameter of the melt blow resin fiber 3 is controlled by the hole diameter of the nozzle cap of the nozzle die 15 for ejecting the fiber, their spacing, the amount of the fiber ejected, the height of the nozzle die 15, and the like. Further, it is possible to adjust various characteristics of the composite nonwoven fabric 1 by controlling the fiber diameter of the melt blow resin fiber 3.

Then, in the melt-blow nonwoven fabric 110 of the present embodiment thus formed, the melt-blow resin fibers 3 having a predetermined average fiber diameter constituting the melt-blow nonwoven fabric 110 irregularly meander, curve, or loop. They are integrated in a state where they are three-dimensionally intertwined with each other.
In particular, in the present embodiment, filamentous resin fibers continuously ejected from the nozzle die 15 are deposited on the support net body of the net conveyor NC1 to form a sheet-shaped melt blow nonwoven fabric 110, but the net conveyor NC1 Melt blow resin on the opposite side (front side) of the front and back surfaces of the melt blow nonwoven fabric 110, that is, on the opposite side (front side) of the support net side of the net conveyor NC1. There are many irregular serpentines, curves, and loops in the fiber 3.

The melt-blown nonwoven fabric 110 of the present embodiment as described above preferably has a basis weight (basis weight) of 5 to ^{90 g / m 2.}
According to the experimental studies of the present inventors, if the basis weight is too large, the pulp fibers 2 penetrate between the melt blow resin fibers 3 and are difficult to be entangled with each other, and easily fall off. On the other hand, the amount of grain is too low, the pulp fibers 2 easily pass through the melt-blown non-woven fabric 110 from the melt-blown nonwoven fabric 110 and are easily washed away by the span lace treatment, and the pulp fibers 2 are less entangled and the yield is deteriorated. In addition, the mechanical strength is insufficient.
By setting the texture amount of the melt blow nonwoven fabric 110 to preferably in ^{the range of 5 to 90 g / m 2} , the pulp fibers 2 can be entangled more and more strongly while ensuring mechanical strength, and the fibers can be dropped. It is difficult to make, and high wet strength can be obtained. More preferably, it has a basis weight (basis weight) of 15 to 75 g / m ^2.
The amount of texture of the melt blown nonwoven fabric 110 is determined by the type of resin used as the raw material, the temperature, pressure, and speed of air during spinning, the nozzle hole diameter of the die nozzle 15, the nozzle spacing, the suction force of the suction unit 16, and the net conveyor. It is determined by the speed of NC1 and the like.

The pulp airlaid section 20 arranged on the downstream side of the melt blown nonwoven fabric manufacturing section 10 blows the defibrated pulp fiber 2 from the pulp airlaid machine 23 by an air flow to the melt blown nonwoven fabric 110 mounted on the net conveyor NC2. , The pulp fiber 2 is supplied from one of the front and back surfaces, that is, from the upper surface side (front surface side), and the pulp fiber 2 is deposited on the melt blown nonwoven fabric 110 to form a pulp fiber web. Is.

Specifically, the pulp air-laid portion 20 is a known solution for defibrating (opening) block-shaped raw pulp by a rotor, a stirring impeller, a tubular screen and a needle roll, a picker rotor, a hammer mill, a disc mill, or the like. The fiber means 21, the duct 22 of a feeder or the like for sending the defibrated pulp fiber 2, and the defibrated pulp fiber 2 sent from the duct 22 are uniformly dispersed by an air flow, and a flat screen or a rotating cylinder is formed. It has a pulp air raid machine 23 that blows air from a small hole screen on the surface of a screen (forming drum) to a net conveyor (collector) NC2. Further, in the net conveyor NC2 of the pulp air raid unit 20, a suction unit (suction unit) 24 that sucks air into the inside by a decompression means is arranged below the pulp air array machine 23, and a net is provided by an air pump arranged outside. The pulp fibers 2 blown out from the pulp air raid machine 23 by sucking from the upper surface of the conveyor NC2 toward the lower surface are easily collected on the melt blown non-woven fabric 110 placed on the upper surface of the net conveyor NC1 due to the soaring of the defibrated pulp fibers 2. It prevents falling out and outflow.

In the pulp air-laid portion 20, a block-shaped raw material pulp obtained by mechanically and chemically treating raw materials such as wood and used paper into pulp is defibrated (opened) by a defibrating means 21, and a duct of a feeder or the like is used. The defibrated pulp fiber 2 sent to the air-laid machine 23 via the air 22 descends while being dispersed by the air flow from the duct 22 in a dry state in the pulp air-laid machine 23, and blows out toward the net conveyor (collector) NC2. Will be done. Then, the pulp fibers 2 blown out from the pulp air raid machine 23 descend while being sucked by the suction portion (suction portion) 24, and are stacked on the melt blow nonwoven fabric 110 mounted on the upper surface of the net conveyor NC2.
The pulp fiber 2 at this time is preferably beaten pulp. In the case of beaten pulp, the fibrillated fibers are easily entangled with the ultrafine melt blow resin fibers 3, the entanglement and strength can be improved, and the pulp fibers 2 can be further prevented from falling off.

That is, the pulp air-laid portion 20 disperses the pulp air-laid portion 20 by placing it on the air flow in a dry state by the pulp air-laid machine 23 with the air flow from the duct 22, and the defibrated (open fiber) pulp fiber 2 ejected is the net conveyor NC2. It is collected by the suction unit 24 under negative pressure on the melt blown non-woven fabric 110 placed on the upper surface, and is deposited and accumulated in the form of a web. In this way, the pulp air-laid portion 20 supplies the defibrated pulp fiber 2 dispersed by the air flow on the melt-blown nonwoven fabric 110 mounted on the net conveyor NC2 by the air-laid method, and is in a dry state on the melt-blown nonwoven fabric 110 ( The defibrated pulp fiber 2 is deposited in a non-wet state) to form a pulp fiber web.

As a result, the web-like laminate 120 is formed by depositing the powder of the defibrated pulp fiber 2 on the melt-blow nonwoven fabric 110 made of the melt-blow resin fiber 31 and forming the accumulated pulp fiber web. That is, by carrying out a pulp fiber web forming step of depositing and accumulating defibrated pulp fibers 2 dispersed by an air flow on a melt blown nonwoven fabric 110 placed on a net conveyor NC2 by an air flow method to form a pulp fiber web. A laminated body 120 in which a pulp fiber web is laminated on a melt blown nonwoven fabric 110 is obtained.

Then, in the present embodiment, the laminate 120 composed of the layer of the melt blown nonwoven fabric 110 and the layer of the pulp fiber web formed by depositing and accumulating the pulp fibers 2 on the melt blow nonwoven fabric 110 on the net conveyor NC2 in this way is , Is sent to the coupling processing unit 30 on the downstream side by the net conveyor NC2. The melt-blow resin fiber 3 of the melt-blow nonwoven fabric 110 and the pulp fiber 2 stacked on the melt-blow resin fiber 3 are a dry web-like laminate 120 in a non-wet state, that is, a dry state.

In the present embodiment, the bonding processing section 30 arranged on the downstream side of the pulp airlaid section 20 is a roller processing section for pressing and fixing the pulp fibers 2 by passing the web-shaped laminate 120 through the smoothing rollers 31A and 31B. 31 and a spun-lace processing unit 32 that is arranged downstream of the roll processing unit 31 and water-flow entangles the melt blow resin fibers 3 and the pulp fibers 2 of the web-like laminate 120 that has passed through the rolls 31A and 31B, and the spun-lace processing. A drying section 33 for drying the entangled and accumulated fibers (composite non-woven fabric) in a wet state, and a heat embossing section 34 for thermally embossing the dried entangled and accumulated fibers (composite nonwoven fabric) with the heat embossing rollers 34A and 34B. Consists of.

The roller processing portion 31 is composed of smoothing rollers 31A and 31B made of specific curved surfaces, and the powder of the pulp fiber 2 deposited on the melt blow nonwoven fabric 110 is melt blown by the smoothing rollers 31A and 31B. It is pressed so as to enter between the resin fibers 3.

That is, when the laminated body 120 passes between the smoothing rollers 31A and 31B of the roller processing portion 31, the laminated body 120 is pressed by the smoothing rollers 31A and 31B, so that the pulp formed on the melt blow nonwoven fabric 110 The powder of the pulp fibers 2 of the fiber web penetrates a lot or deeply into the melt blow resin fibers 3 of the melt blow nonwoven fabric 110, and the fixability of the pulp fibers 2 to the melt blow nonwoven fabric 110 is improved and stabilized.
Then, the laminated body 120 that has passed between the smoothing rollers 31A and 31B is sent out to the net conveyor NC3 on the downstream side, placed on the net conveyor NC3, and conveyed to the span race processing unit 32.

In the span race processing unit 32, a plurality of span race nozzles (N ₁ , N ₂ , ... N _n ) are arranged in multiple stages along the transport direction of the net conveyor NC3, and these span race nozzles are arranged. A water jet is applied from (N ₁ , N ₂ , ... N _n ) toward the net conveyor NC3. In particular, in the present embodiment, the jet of the water jet penetrates the melt blow nonwoven fabric 110 from the side where the pulp fibers 2 are deposited, that is, from above the pulp fiber web forming side toward the melt blow nonwoven fabric 110 side. Inject a jet stream. The water column flow ejected from the span race nozzles (N ₁ , N ₂ , ... N _n ) is perpendicular to the traveling direction of the net conveyor NC3. The water jet nozzles (N ₁ , N ₂ , ... N _n ) have, for example, a nozzle diameter (φ) of 0.01 mm to 3 mm, preferably 0.5 mm to 1.5 mm, and more preferably 0.75. It has a plurality of nozzle holes (orifices) within the range of ~ 1.25 mm, and the plurality of orifices are provided at intervals of, for example, 0.3 to 10 mm, preferably 0.5 to 2 mm. At this time, _{the number of nozzles (N 1} , N ₂ , ... N _{n ) along the transport direction (1 , 2 , ... n} ), the capacity of the nozzles (N 1, N 2, ... N n), etc. , The composite nonwoven fabric 1 is appropriately set according to the intended use and desired characteristics.

Further, from the nozzles of the water jet (N ₁ , N ₂ , ... N _n ), for example, water having a water pressure of about ^{1 × 10 6 to} 1.5 × 10 ^{7 Pa can be discharged.} A mani-hold is placed in the conduit of the span race processing unit 32, and _{the pressure of the nozzles (N 1} , N ₂ , ... N _n ) is adjusted by the mani-hold to entangle the melt blow resin fiber 3. It is also possible to adjust the energy of the spunlace of the pulp fiber 2 to be caused. It can also be adjusted by the hole diameter of the nozzle. Further, in the span race treatment using a plurality of span race nozzles (N ₁ , N ₂ , ... N _n ), a water column flow may be applied from the upstream side to the downstream side at the same water pressure, but it is preferable. Gradually increase the water pressure from the upstream side to the downstream side. In particular, in the nozzle N ₁ of the first water jet, preferably, ^{the water has a low water pressure of about 1 × 10 6} to 2 × 10 ⁶ Pa, so that the powder of the pulp fiber 2 is scattered by the jet injection of the water jet. It can prevent soaring and improve the texture and yield. More preferably, the laminate 120 may be sprayed with water from the deposition side of the pulp fiber 2 before the jet of the water jet. This makes it possible to more effectively prevent the pulp fibers 2 and paper dust from flying up due to the jet flow of the water jet, and to improve the texture and yield. Moisture at this time may also be sucked and drained by the suction and drainage unit 36 described later.

A suction drainage section (suction section) 36 for sucking and removing water is installed below the net conveyor NC3 of the span race processing section 32, and is one of the front and back surfaces of the melt blow nonwoven fabric 110, that is, The pulp fiber 2 supplied from the upper surface side is caught between the melt blow resin fibers 3 to facilitate entry. In addition, the water that has fallen by the water jet can be easily recovered.
In particular, in the present embodiment, the laminate 120 is passed between the smooth rolls 31 and 32 to promote the fixation of the pulp fiber 2, and further, the presence of the meandering, bending, and loop of the melt blow resin fiber 3 causes the melt blow resin. Since the pulp fibers 2 are easily captured and entangled between the fibers 3, the paper dust of the pulp fibers 2 is less likely to fly up, scatter, and flow out when the water column flow of the water jet is applied. For this reason, even when the water after use of the water jet is collected, filtered by a filter, and reused for the water jet, there is little fiber contamination in the collected water, which causes clogging of the filter and the load of filter maintenance. Can be reduced. Furthermore, continuous workability can be improved. In addition, even when the wastewater is drained without being collected, the environmental load is small because the amount of fibers mixed is small.

In this way, the spunlace processing unit 32 injects a jet jet of a water jet from above the pulp fiber 2 side so as to penetrate the melt blow resin fiber 3 of the melt blow nonwoven fabric 110 and the pulp fiber 2 deposited on the melt blow resin fiber 3. As a result, the pulp fibers 2 move due to the water column flow of the water jet and are entangled with the melt blow fibers 3 of the melt blown nonwoven fabric 110, and the pulp fibers 2 are also entangled with each other, so that the melt blow resin fibers 3 and the pulp fibers 2 are entangled with each other. It is intricately entwined in a three-dimensional manner. That is, the fibers of the pulp fiber 2 and the melt blow resin fiber 3 are entangled with each other while jetting the jet jet of the water jet from top to bottom.

The wet composite aggregate (nonwoven fabric) of the melt blow resin fibers 3 and the pulp fibers 2 integrally entangled by such a water jet treatment is further conveyed to the drying portion 33 on the downstream side by the net conveyor NC3. That is, the sheet-like composite aggregate (nonwoven fabric) composed of the melt blow resin fibers 3 and the pulp fibers 2 that have passed through the spunlace processing section 32 and are integrally entangled by the transportation of the net conveyor NC3 is in a wet state (wet) wet with water. Since it is in such a state), it is dried by a drying portion 33 arranged on the downstream side (outlet side) of the spunlace processing portion 32 to remove water.

As the drying method in the drying unit 33, a dryer such as an air through dryer (hot air ventilation method), a heater (air drying process), an infrared radiation method, a steam can, a vacuum dehydration method, a supersonic energy method, an ultrashort wave energy method, etc. Non-contact type (non-compression type) drying may be used, or contact type (compression type) drying such as a drying roller or a Yankee dryer (hot plate crimping method) may be used. You can choose according to your needs. For example, in an air-through dryer, a large number of through holes are provided on the peripheral surface of a rotating roller of a cylindrical body, and hot air is blown out from the through holes to perform drying, so that a bulky finish is possible.

When the drying in the drying portion 33 is completed, the composite nonwoven fabric 1 which is a composite aggregate in a dry state in which the melt blow resin fibers 3 and the pulp fibers 2 are integrally entangled is obtained.
Further, in the present embodiment, the dried composite nonwoven fabric 1 is sent to the heat embossing unit 34 for heat embossing.

The heat embossed portion 34 is composed of a heat embossed convex portion roller 34A forming a convex portion of a shape and a pattern, and a heat smoothing roller 34B made of a specific curved surface.
By embossing by the heat rollers 34A, 34b of the embossing of the heat embossing portion 34, in the present embodiment, in the composite nonwoven fabric 1, the fibers partially correspond to the embossing molds of the heat rollers 34A, 34b. Is fused and fused by thermocompression bonding, and unevenness is imparted. For example, a concave embossed portion 5 (see FIG. 6) when viewed from the surface side thereof is imparted, and an embossed composite nonwoven fabric 1 is obtained.

Then, in the composite nonwoven fabric manufacturing apparatus 100 of the present embodiment, the composite nonwoven fabric 1 embossed at the end thereof is wound by the winding rod portion to complete a series of steps.
The support nets of the above-mentioned net conveyors NC1, NC2, and NC3 are not particularly limited, but generally, a wire of 20 to 100 mesh such as a plain weave made of synthetic resin or metal warp and weft is used. It is a mesh-like support such as a punching plate or a porous support such as a punching plate. The support net body of the net conveyor NC3 may be configured to impart a pattern to the composite nonwoven fabric 1 by the pattern and shape of the warp threads and the weft threads.

In this way, in the bonding processing section 30 of the present embodiment, the laminate 120 made of the melt blow nonwoven fabric 110 and the pulp fiber web formed on the melt blow nonwoven fabric 110 by the airlaid method is passed through the smoothing rollers 31A and 31B of the roller processing section 31. After that, the melt blow resin fiber 3 and the pulp fiber 2 are entangled with water by applying a water jet at the spunlace processing unit 32, and the water entangled with water is removed at the drying unit 33, and further. By heat embossing in the heat embossing section 34, the composite nonwoven fabric 1 in which the melt blow resin fibers 3 and the pulp fibers 2 are three-dimensionally integrally entangled is formed.

That is, in the present embodiment, after the above-mentioned melt blow nonwoven fabric manufacturing step and pulp fiber web forming step are carried out, the laminate 120 composed of the melt blow nonwoven fabric 110 layer and the pulp fiber web layer mounted on the net conveyor NC2 is formed. After passing through the roller processing step of fixing the passp fibers 2 by pressing with the rollers 31A and 31B and the rollers 31A and 31B, the melt blow resin fibers 3 of the melt blow nonwoven fabric 110 and the pulp fibers 2 of the pulp fiber web in the laminate 120 are pressed. The composite nonwoven fabric 1 is obtained by carrying out a spunlace treatment step integrated by water flow entanglement, a drying step of drying the integrally entangled melt blow resin fibers 3 and pulp fibers 2, and a thermal embossing process of heat embossing after drying. Be done.

As described above, in the composite nonwoven fabric 1 of the present embodiment, the raw material resin chips are melted and spun, and the melt blow resin fibers 3 made into ultrafine fibers by high-speed hot air are formed into ultrafine fibers by a net-like (for example, plastic or stainless steel) belt conveyor. A melt blown nonwoven fabric manufacturing process of depositing on a net conveyor NC1 to form a melt blown nonwoven fabric 110, and a defibrated non-woven fabric 2 dispersed on the melt blown nonwoven fabric 110 mounted on the net conveyor NC2 by an airlaid method are deposited on the pulp fibers. A pulp fiber web forming step for forming the web, a roller processing portion for performing roller processing on the laminate 120 composed of the melt blow nonwoven fabric 110 and the pulp fiber web formed on the melt blow nonwoven fabric 110, and a melt blow on the net conveyor NC2 after the roller processing. The spunlace treatment step of integrating the melt blow resin fiber 3 of the non-woven fabric 110 and the pulp fiber 2 of the pulp fiber web by the water flow entanglement treatment, and the melt blow resin fiber 3 and the pulp fiber 2 integrally entangled on the net conveyor NC2 are dried. It can be manufactured by a drying step of performing and a heat embossing step of performing heat embossing after drying.

Further, in the composite nonwoven fabric 1 of the present embodiment, the raw material resin chips are melted and spun, and the melt blow resin fibers 3 made into ultrafine fibers by high-speed hot air are deposited on the net conveyor NC1 which is a net-like belt conveyor to deposit the melt blow nonwoven fabric. Melt-blow non-woven fabric manufacturing unit 10 forming 110 and pulp fiber web forming unit for forming pulp fiber web by depositing defibrated non-woven fabric 2 dispersed by the air-laid method on the melt-blow non-woven fabric 110 placed on the net conveyor NC2. The melt blown nonwoven fabric 110 is subjected to roller processing on the laminate 120 composed of the melt blown nonwoven fabric 110 and the pulp fiber web formed on the melt blown nonwoven fabric 110, and the melt blown nonwoven fabric 110 on the net conveyor NC2 after the roller processing. Dry the melt blow resin fiber 3 and the pulp fiber 2 integrally entwined on the net conveyor NC2 and the spunlace processing unit 32 that integrates the melt blow resin fiber 3 of the above and the pulp fiber 2 of the pulp fiber web by the water flow entanglement treatment. It can be manufactured by the drying portion 33 and the heat embossing portion 34 which is heat-embossed after drying.

In the composite nonwoven fabric 1 of the present embodiment thus obtained, as shown in FIGS. 1 to 11, ultrafine melt blow resin fibers 3 having a predetermined fiber diameter are irregularly meandering, curved, or , Forming loops and entwining with each other, and also entwining with pulp fibers 2 having a predetermined length, which is distributed substantially in the thickness direction and has a flat ribbon shape, and pulp fibers 2 also entangle with each other and melt blow resin fibers 3 And the pulp fiber 2 are three-dimensionally entwined together. In a general manufacturing process, the melt blow resin fiber 3 is formed of a discontinuous (finite length) filament.

Then, in the composite nonwoven fabric 1 of the present embodiment thus obtained, as shown in the micrographs of the cross sections of the composite nonwoven fabric 1 in FIGS. 6 and 7, pulp is substantially entirely covered in the thickness direction of the composite nonwoven fabric 1. Although the fibers 2 are distributed, the abundance ratio of the pulp fibers 2 is higher in the upper front surface side in FIGS. 6 and 7 than in the lower back surface side. Further, from the comparison between FIGS. 2, 3 and 4 and 5, the number of meandering and loops of the melt blow resin fiber 3 on the front surface side of the composite nonwoven fabric 1 is larger than that on the back surface side on the opposite side. The surface side of the composite nonwoven fabric 1 at this time is the pulp fiber 2 side supplied onto the melt blow nonwoven fabric 110 on the net conveyor NC2, and is the side to which the water jet jet is applied during the span race treatment. be.

In this way, the composite nonwoven fabric 1 of the present embodiment is laminated by spraying the defibrated pulp fiber 2 with air by the pulp airlaid method on the melt blown nonwoven fabric 110 made of the melt blow resin fiber 3 obtained by the melt blow method, and further, these melt blow resins are laminated. The fiber 3 and the pulp fiber 2 are integrated by water flow entanglement by the spunlace method.

In the non-woven fabric obtained by the melt-blow method, that is, the melt-blow non-woven fabric 110, ultrafine long fibers are randomly accumulated by blowing high-temperature compressed air at high speed during spinning. In particular, in the present embodiment, a predetermined weight and inertial force are applied to the spun long fibers by spinning from the nozzle hole of the die 15 having a predetermined diameter or from a predetermined height, and the fibers are spun on the net conveyor NC1. The melt blow resin fibers 3 irregularly meander or form loops and are randomly accumulated, and the average fiber diameter thereof is 0.5 μm to 10 μm. At this time, the number of meandering, bending, and loops is larger toward the integrated upper surface side, and the curvature is smaller or the straight length distance is larger toward the resin fiber 3 on the lower surface side closer to the support of the net conveyor NC1. do. Further, in the present embodiment, the nozzle holes of the dies 15 are ejected from one nozzle hole at a predetermined interval, and in a part of the melt blow resin fiber which is a long fiber, a part or the whole in the length direction of the fiber. The fibers fuse with the single fibers discharged from another adjacent nozzle hole to form a focused portion 3a. In particular, at the end of the focusing portion 3a in which the single fibers are focused in this way in a part in the length direction of the fibers, the end portion has a branched structure due to the non-fused portion 3b in which the fibers are not fused.

Then, in the present embodiment, the average fiber diameter is in the range of 0.5 to 10 μm, and the melt blow resin fibers 3 which meander irregularly or form a loop are irregularly (randomly) entangled and accumulated. Pulp fibers 2 defibrated by the pulp airlaid method are blown with air to deposit and laminate the pulp blown nonwoven fabric 110 to form a pulp fiber web on the melt blown nonwoven fabric 110. In the present embodiment, the defibrated pulp fiber 2 is supplied to the upper surface side of the melt blow resin fiber 3 having many meandering, bending, and loops in the melt blow nonwoven fabric 110. According to the pulp fiber web formed by such a pulp airlaid method, the defibrated pulp fibers 2 are in the form of fine powders, the directions of the pulp fibers 2 are irregular and non-oriented, and the fibers are accumulated together. Since the hydrogen bond is also weak, the pulp fibers 2 easily move in the jet water column flow of the water jet and easily enter between the melt blow resin fibers 3 of the melt blow non-woven fabric 110. In addition, the melt blow resin fibers 3 of the melt blow nonwoven fabric 110 meander, form loops, have branches, and are entangled with each other, so that the pulp fibers 2 are easily captured between the melt blow resin fibers 3. Easy to get entangled. In particular, the pulp fibers 2 deposited on the melt blown nonwoven fabric 110 are produced by the airlaid method and are in the form of fine powder that has been defibrated. Therefore, the melt blown resin fibers 3 of the melt blown nonwoven fabric 110 are fine and intimately entangled with each other. However, the fine powdery pulp fibers 2 defibrated between the resin fibers 3 intrude and are easily entangled. Further, the pulp fibers 2 entwined with the melt blow resin fibers 3 are also easily entangled with each other. Therefore, the pulp fibers 2 are intricately and irregularly entangled with the melt blow resin fibers 3 to have many entanglement points and are strongly entangled, so that the melt blow resin fibers 3 and the pulp fibers 2 are firmly held. NS.

Thus, according to the method for producing the composite nonwoven fabric 1 of the present embodiment, the melt blow fibers 3 have a predetermined average fiber diameter, meander irregularly, and form a loop with respect to the melt blow nonwoven fabric 110. Above, the pulp fibers 2 defibrated by the airlaid method are dispersed by an air flow, supplied and deposited, and the melt blow fibers 3 and the pulp fibers 2 are water-entangled by a water jet to obtain a composite nonwoven fabric 1. It is a thing.

According to the method for producing the composite nonwoven fabric 1 of the present embodiment, the melt blow resin fibers 3 having a predetermined average fiber diameter, irregularly meandering, and forming loops by the melt blow method 3 A dimensional entanglement can be formed. Further, since the pulp fibers 2 deposited on the melt blow nonwoven fabric 110 made of such melt blow resin fibers 3 are supplied by the air raid method and are in the form of fine powder that has been defibrated, the melt blow resin fibers 3 are formed. Even if the fibers are thin and closely entangled with each other, the defibrated fine powdery pulp fibers 2 can be penetrated between the melt blow resin fibers 3. The melt blow resin fibers 3 meander irregularly and form loops, and further, the pulp fibers 2 have a predetermined average fiber diameter and a high surface area, so that the pulp fibers 2 become melt blow resin fibers 3. Easy to get entangled. In addition, the pulp fibers 2 entwined with the melt blow resin fibers 3 are also easily entangled with each other. Therefore, the melt blow resin fibers 3 and the pulp fibers 2 are often intricately entangled with each other in three dimensions, and the pulp fibers 2 are less likely to fall off. As a result, a composite nonwoven fabric 1 having high wet strength is obtained, in which paper dust is less likely to be generated during drying and tearing is less likely to occur during use, and paper dust is less likely to peel off during use even when wet.

In particular, in the present embodiment, the pulp fibers 2 deflated by the pulp airlaid method are accumulated on the melt blow non-woven fabric 110, so that the pulp fibers 2 easily move in the jet water column flow of the water jet, that is, that is, Much of the energy of the water column flow is not consumed to defibrate the pulp fiber 2, and the energy of the water column flow can be efficiently used for the movement and movement of the pulp fiber 2 and the entanglement of the pulp fiber 2 and the melt blow resin fiber 3. Therefore, a large amount of pulp fibers 2 can be entangled with the melt blow resin fibers 3 to increase the amount of entanglement and entanglement points, and the formation of the texture of the pulp fibers 2 can be improved. Further, even if the content of the pulp fiber 2 is increased, the pulp fiber 2 is likely to be entangled with the melt blow resin fiber 3, so that the pulp fiber 2 is contained without causing the pulp fiber 2 to fall off and the generation of paper dust to increase. It is possible to obtain the effect of improving water retention and water absorption by increasing the amount. In addition, since the pulp fiber 2 is easily moved by the water column flow of the water jet, even if the processing speed is increased, a good texture can be obtained and the productivity can be increased.

Further, in the present embodiment, since the jet water flow is applied from the upper surface of the pulp fiber web formed on the melt blown nonwoven fabric 110 toward the melt blown nonwoven fabric 110 side, the pulp fiber 2 is transferred from the pulp fiber web side to the melt blown nonwoven fabric 110 side. Since it can be entangled and fixed by being caught in the melt blow resin fiber 3 of the above, a large amount of pulp fiber 2 can be entangled with the melt blow resin fiber 3 to increase the amount of entanglement and the entanglement point, and the formation of the pulp fiber 2 is also good. can. Since the pulp fiber 2 is likely to be entangled with the melt blow resin fiber 3 even if the content of the pulp fiber 2 is increased, the content of the pulp fiber 2 is suppressed while suppressing the dropping of the pulp fiber 2 and the generation of paper dust. It is possible to obtain the effect of improving water retention and water absorption due to the increase.

In addition, in the present embodiment, since the laminate 120 made of the melt blow nonwoven fabric 110 and the pulp fiber web formed on the melt blow nonwoven fabric 110 is passed through the rolls 31A and 31B before the span lace treatment, the fixation of the pulp fiber 2 is improved. do. Therefore, since the amount of entanglement of the pulp fiber 2 with the melt blow resin fiber 3 and the entanglement point can be increased, the effect of suppressing the falling off of the pulp fiber 2 and the generation of paper dust can be enhanced, and the water retention of the composite nonwoven fabric 1 can be enhanced. , Enables improvement of water absorption. Further, when the pulp fibers 2 are transferred by the net conveyors NC2 and NC3 or when the water jet is jetted in the subsequent span race processing step, the pulp fibers 2 can be prevented from being scattered, the paper dust can be blown up, and the water jet can be washed away, and the yield can be improved. Therefore, it can be manufactured at low cost.

Further, in the present embodiment, the pulp fibers 2 are deposited on the upper side (surface side) where the melt blow resin fibers 3 have many meandering and loops in the melt blow nonwoven fabric 110, and the pulp fibers 2 are deposited from the upper surface side of the pulp fibers 2 toward the melt blow nonwoven fabric 110 side. The jet water flow is applied, and the abundance ratio of the pulp fiber 2 is higher on the upper surface side (front surface side) to which the jet water flow is applied than on the lower surface side (back surface side), and the meandering and loops of the melt blow resin fiber 3 are formed. many. Therefore, even if the abundance ratio of the pulp fiber 2 is larger on the front surface side than on the back surface side, more meandering or loops of the melt blow resin fiber 3 are present on the front surface side than on the back surface side. Pulp fibers 2 are easily entangled, and many pulp fibers 2 are entangled. Further, there are many pulp fibers 2 and many entanglement points of the pulp fibers 2. Therefore, even if a large amount of water is absorbed and retained on the surface side where a large amount of pulp fiber 2 is present, the pulp fiber 2 is well entangled with the melt blow resin fiber 3, so that the pulp fiber 2 is hard to fall off and has high wet strength. Therefore, even if the direction at the time of use is not specified, it is difficult for paper dust to be generated and peeled off at the time of use.

Further, according to the method for producing the composite nonwoven fabric 1 or the composite nonwoven fabric manufacturing apparatus 100 of the present embodiment, the pulp fibers 2 are accumulated on the spunbonded nonwoven fabric 110 by the pulp airlaid method, and the pulp fibers 2 are spunlaced. Therefore, the concentration of the pulp fiber 2 can be easily adjusted, and the concentration and the amount of the pulp fiber 2 laminated on the spunbonded nonwoven fabric 110 can be easily adjusted at low cost. Therefore, it is easy to arbitrarily set the characteristics such as basis weight, mechanical strength, water retention, water absorption, and bulky processing according to the purpose and application of the composite nonwoven fabric 1. Depending on the application of the composite nonwoven fabric 1, the mixing ratio of the resin fiber 3 and the pulp fiber 2 and the switching when changing the material can be easily performed.
In addition, since the pulp air raid device is small, space can be saved, and unlike a wet device, a large amount of water is not used, which saves energy. Therefore, it is possible to manufacture at low cost.

Thus, according to the composite nonwoven fabric 1 of the present embodiment, the melt blow resin fibers 3 irregularly meander or form loops, and also have a predetermined average fiber diameter and have a high surface. Therefore, the pulp fibers 2 are likely to be entangled with the melt blow resin fibers 3 which are irregularly entangled, and the pulp fibers 2 are entangled with the melt blow resin fibers 3 in a large amount, so that the pulp fibers 2 are less likely to fall off. That is, the pulp fibers 2 are three-dimensionally and complicatedly entangled and integrated with the melt blow resin fibers 3 that meander irregularly or form a loop, and the entanglement points of the pulp fibers 2 and the melt blow resin fibers 3 are formed. There are many and they are strongly intertwined. Therefore, it is difficult for paper dust to be generated during drying (in a non-wet state), and it is difficult for paper dust to come out or tear during use. Further, peeling is unlikely to occur even when wet, and high wet strength can be obtained. That is, the wet strength can be satisfied even when a liquid such as water, a chemical, or a cosmetic amount is infiltrated, the strength does not decrease much even in the wet state when the liquid is absorbed, and it is difficult to peel or tear. Therefore, it is excellent in strength and morphological stability during use.

The composite nonwoven fabric 1 of the present embodiment has good water absorption due to the hydrophilicity of the pulp fiber 2, and further has good oil absorption and water absorption due to the synthetic resin fiber such as polypropylene and the capillary pressure due to its ultrafine formation. It is a thing. That is, the small pore size between the resin fibers 3 increases the capillary pressure, and the water absorption and the water absorption rate can be increased. Further, since the resin fiber 3 has a predetermined average fiber diameter, that is, an ultrafine melt blow fiber, it is soft at the time of use. In addition, due to the compounding of the resin fiber 3 and the multi-entanglement of the pulp fiber 2 and the resin fiber 3, the decrease in strength and rigidity is suppressed even when a liquid such as water or oil is absorbed, and the hardness is appropriate. , Has morphological stability and is easy to use. Since the pulp fiber 2 is entangled with the resin fiber 3 in large quantities, the water absorption rate (oil absorption rate) is improved, and the water absorption (oil absorption) and water retention (retention) are also high. Therefore, it is possible to improve the filtration speed if the application has filter performance.

Further, in the present embodiment, since the melt blow resin fiber 3 of the melt blow nonwoven fabric 110 and the pulp fiber 2 accumulated by the air raid method are integrated by water flow entanglement, the fibers are entangled without applying an adhesive. A predetermined strength is obtained by the method, and the absorbency is better than that of bonding with an adhesive. In addition, since the resin fiber 3 is an ultrafine melt blow fiber, it is possible to form a composite nonwoven fabric 1 that is soft when used and has a soft and soft feel and texture even in a non-wet state or a wet state. Therefore, when it is gripped, it has a soft and soft feel, and when it is used for soft objects such as the human body, it is soft to the touch, feels good on the skin, has no fluff, and is mild and soft to the touch. can. In addition, for cleaning that removes foreign substances such as dust, hair, solid dust, stains, and adhering liquid on the floor, and for floor maintenance such as floor protection and polishing, objects to be cleaned and cleaned. It is possible to follow the uneven shape, etc., adhere to it, wipe it off with a light force, and obtain a high maintenance effect.

Further, the melt-blown nonwoven fabric 110 formed of the resin fibers 3 has a small orientation of the fibers in the vertical and horizontal directions, and the pulp fibers 2 accumulated on the melt-blown nonwoven fabric 110 by the airlaid method also have a small orientation. Therefore, in the obtained composite nonwoven fabric 1, the melt blow resin fibers 3 and the pulp fibers 2 are irregularly entangled, and the dry tensile strength is longitudinally and laterally without natural longitudinal elongation (Y-axis direction) and lateral shrinkage (X-axis direction). The ratio difference is also extremely small.

According to the composite nonwoven fabric 1 of the present embodiment as described above, the wet strength measured by JIS P 8135 is preferably 2N / 25 mm or more and 50N due to the large number of entanglements between the melt blow resin fibers 3 and the pulp fibers 2. High wet strength within the range of / 25 mm or less, more preferably 3N / 25 mm or more and 50N / 25 mm or less, still more preferably 5N / 25 mm or more and 50N / 25 mm or less can be obtained. If it is within the range, the pulp fibers 2 are more abundant than the ultrafine melt blow resin fibers 3 and are strongly entangled with each other. Therefore, both softness and strength that is hard to tear even when wet are achieved. It has both wet strength, water absorption, and water retention, and is versatile and easy to handle.

According to the composite nonwoven fabric 1 of the present embodiment as described above, the melt blow resin fibers 3 irregularly meander or form loops, and also have a predetermined average fiber diameter and high height. Since the pulp fiber 2 is easily entangled with the melt blow resin fiber 3 due to the surface area, the pulp fiber 2 is entangled well with the melt blow resin fiber 3 even if the content of the pulp fiber 2 is large. Therefore, it is possible to improve the water absorption and water retention by increasing the content of the pulp fiber 2 while maintaining the retention and the dropout resistance of the pulp fiber 2.

For example, in the present embodiment, the content of the pulp fiber 2 in the composite nonwoven fabric 1 is preferably in the range of 30 to 70% by mass, more preferably in the range of 35 to 65% by mass, and more preferably in the range of 35 to 65% by mass. The content of the melt blow resin fiber 3 is in the range of 40 to 60% by mass, more preferably in the range of 30% by mass to 70% by mass, more preferably in the range of 35 to 65% by mass, and further preferably 40. It is in the range of ~ 60% by mass. When the content of the pulp fiber 2 is low and the content of the melt blow resin fiber 3 is high, the desired water retention and water absorption cannot be obtained, while the content of the pulp fiber 2 is high and the content of the melt blow resin 3 is low. Then, the desired strength cannot be obtained. In the present embodiment, the pulp fiber 2 is easily entangled with the melt blow resin 3 and the number of entanglement points can be increased, so that a predetermined strength can be secured with a small content of the pulp fiber 2. In particular, a predetermined wettability can be ensured even when wet.
Further, in the present embodiment, since the pulp fiber 2 is entangled with the melt blow resin 3 in a large amount, paper dust is unlikely to be generated. Therefore, the blending amount of the pulp fiber 2 is not limited to a small amount, and the ratio of the pulp fiber 2 is wide. Can be set to, and a wide range of characteristics can be added.

Further, according to the composite nonwoven fabric 1 of the present embodiment, since the embossing process is performed, the fibers are fused and fused in the embossed portion 5, so that the overall mechanical strength can be increased. Further, the dropping of the pulp fiber 2 and the generation of paper dust are further prevented. Furthermore, it is possible to increase the bulkiness.

As described above, the composite non-woven fabric 1 of the present embodiment includes the pulp fiber 2 and the resin fiber 3 having a longer fiber length than the pulp fiber 2 and an average fiber diameter in the range of 0.5 to 10 μm. In the composite non-woven fabric 1 made of, the resin fibers 3 are irregularly meandering and entangled with each other, and the pulp fibers 2 distributed in the entire thickness direction are entangled with the resin fibers 3 and the pulp fibers 2 in a three-dimensional manner. It is intertwined.

Therefore, according to the composite non-woven fabric 1 of the present embodiment, the ultrafine resin fibers 3 meander irregularly and sometimes form loops and are entangled with each other, so that the pulp fibers 2 are captured by the resin fibers 3. Since the pulp fibers 2 entwined with the resin fibers 3 are entangled with each other and there are many entanglement points between the resin fibers 3 and the pulp fibers 2, the pulp fibers 2 are firmly held by the resin fibers 3. Therefore, the pulp fiber 2 is hard to fall off. Therefore, it is difficult for paper dust to be generated when it is dried (when it is not wet), and it is difficult for paper dust to come off or tear during use. Further, even when wet, the paper dust does not easily come off or tear during use, and has high wet strength. Since the resin fiber 3 is extremely fine, it is soft at the time of use, and even if the resin fiber 3 is extremely fine, they are entangled with each other, and further, because they are also entangled with the pulp fiber 2, they have good mechanical strength. Both softness and mechanical strength are compatible.

In particular, the composite nonwoven fabric 1 of the present embodiment has a focusing portion 3a in which a plurality of single fibers are bundled and fused together in a part of the resin fiber 3 in the length direction, so that the fiber strength is improved. Moreover, since the end portion of the focusing portion 3a has a branched structure due to the non-fused portion 3b in which the single fibers are not fused to each other, the entanglement of the pulp fibers 2 can be enhanced. Therefore, the pulp fiber 2 is less likely to fall off, and the mechanical strength can be improved.

Further, in the present embodiment, the pulp fiber 2 of the composite nonwoven fabric 1 is a fibrillated beaten wood pulp, and the average fiber length thereof is preferably in the range of 0.5 to 5 mm. The entanglement of 2 with the resin fiber 3 is improved, and the pulp fiber 2 is less likely to fall off. In addition, the mechanical strength can be improved. However, when the present invention is carried out, unbeaten pulp may be used because suitable entanglement can be obtained even with unbeaten pulp.

Further, the composite fiber fiber 1 of the present embodiment is made of pulp on one surface side (front surface side in the above description) of the front and back surfaces thereof and on the other surface side (back surface side in the above description) on the opposite side. Since there are more meandering and loops of the resin fiber 3 on one surface side (front surface side) where a large amount of fiber 2 is present and on the other side surface side (back surface side) where a large amount of pulp fiber 2 is present, the pulp fiber 2 is present. Even if a large amount of water is absorbed and retained on the surface side (surface side) where a large amount is present, the pulp fibers 2 are often entangled due to the large number of meandering and loops of the resin fiber 3, and high wet strength can be obtained. Therefore, even if the direction at the time of use is not specified, it is difficult for the paper dust to fall off, peel off or tear at the time of use.

Further, in this embodiment, the basis weight of the composite nonwoven fabric 1 (basis weight) is preferably, 30 to 80 g / m ^2, more preferably, 35~75g / m ^2, more preferably, 40~70g / m is in the ² range, and specific volume, preferably, 7~70cm ³ / g, more preferably, in the range of 10~65cm ³ / g, more preferably in the range of 12~60cm ³ / g If it is, the water absorption, water retention and strength are good.

Further, in the present embodiment, the wet strength measured by JIS P 8135 of the composite nonwoven fabric 1 is preferably 2N / 25 mm or more, 50N / 25 mm or less, more preferably 3N / 25 mm or more, 50N / 25 mm or less, still more preferable. In the range of 5N / 25mm or more and 50N / 25mm or less, a large amount of pulp fibers 2 are strongly entangled with the ultrafine resin fibers 3, so that both softness and strength that is hard to tear even when wet are achieved. It is versatile and easy to handle.

Further, in the above embodiment, the melt blown nonwoven fabric 110 for forming the melt blown nonwoven fabric 110 made of the melt blow resin fiber 3 is formed, and the web of the pulp fiber 2 is formed on the melt blown nonwoven fabric 110 placed on the net conveyor NC2 by the airlaid method. The pulp fiber web forming step and the spunlace processing step of integrating the melt blow resin fiber 3 of the melt blown nonwoven fabric 110 and the pulp fiber 2 of the pulp fiber web formed on the melt blow resin fiber 3 by water flow entanglement were integrally entangled. It can also be regarded as an invention of a method for producing a composite nonwoven fabric 1 including a drying step of drying the resin fiber 3 and the pulp fiber 2.

Further, in the above embodiment, the web of the pulp fiber 2 is placed on the melt blown nonwoven fabric manufacturing unit 10 for forming the melt blown nonwoven fabric 110 made of the melt blow resin fiber 3 and the melt blown nonwoven fabric 110 placed on the net conveyor NC2 by the airlaid method. A spunlace processing unit 32 that integrates the pulp airlaid 20 as the pulp fiber web forming portion to be formed, the melt blow resin fiber 3 of the melt blown nonwoven fabric 110, and the pulp fiber 2 of the pulp fiber web formed on the melt blow resin fiber 3 by water flow entanglement. It can also be regarded as an invention of the composite nonwoven fabric manufacturing apparatus 100 including the melt blow resin fiber 3 integrally entwined by the spunlace processing section 32 and the drying section 33 for drying the pulp fiber 2.

According to the method for producing the composite nonwoven fabric 100 and the composite nonwoven fabric 1 of the above embodiment, the melt blow resin fibers 3 irregularly meander by the melt blow method and form loops to be entangled with each other, that is, the melt blow nonwoven fabric. The 110 can be formed, and the pulp fibers 2 defibrated by the airlaid method are dispersed in air (sprayed with an air flow) on such a melt blown nonwoven fabric 110, and the pulp fibers 2 are deposited on the melt blown nonwoven fabric 110. Then, since the melt blow resin fibers 3 and the pulp fibers 2 are spunlaced, the pulp fibers 2 supplied by the airlaid method are in the form of finely woven fabric and the hydrogen bonds between the fibers are weak, so that the melt blow is performed. In addition to easily entering between the melt blow resin fibers 3 of the nonwoven fabric 110, the melt blow resin fibers 3 of the melt blow nonwoven fabric 110 meander and form loops and are entangled with each other, so that the pulp fibers 2 are captured between the melt blow resin fibers 3. Easy to get entangled. Therefore, the entanglement between the resin fiber 3 and the pulp fiber 2 can be increased, and the pulp fiber 2 can be firmly held by the resin fiber 3. Therefore, the pulp fiber 2 is less likely to fall off, paper dust is less likely to be generated during drying (non-wet), tearing or peeling is less likely to occur during use, and paper dust is less likely to come off during use even when wet. It is possible to obtain a composite nonwoven fabric 1 that is unlikely to occur and has high wettability.

In particular, according to the composite nonwoven fabric manufacturing method of the above embodiment, the melt blow nonwoven fabric 110 and the laminate 120 made of the pulp fiber web formed on the melt blow nonwoven fabric 110 are rolled between the pulp fiber web forming step and the spunlacing treatment step. It has a roll processing step of pressing with 31A and 31B.
Further, according to the composite nonwoven fabric manufacturing apparatus 100 of the above embodiment, the melt blown nonwoven fabric 110 and the pulp fibers formed on the melt blow nonwoven fabric 110 are formed between the pulp fiber web forming portion (pulp airlaid portion) 20 and the spunlace processing portion 32. It has a roll processing portion 31 that presses the laminated body 120 made of web by the rolls 31A and 31B.
Therefore, before the spunlace treatment, the pulp fibers 2 can be fixed, and the pulp fibers 2 can be easily entangled with the melt blow resin fibers 3. Therefore, the entanglement of the pulp fibers 2 with the melt blow resin fibers 3 can be increased, and the pulp fibers 2 can be made less likely to fall off. It also makes it possible to improve the mechanical strength. Further, during transfer by the net conveyors NC1 and NC2 and when the water jet is jetted in the subsequent spunlace processing step, the pulp fiber 2 and the paper dust can be prevented from flying up and washed away, and the yield can be improved.

Further, according to the method for producing a composite nonwoven fabric of the above embodiment, in the spunlace treatment step, a jet water flow is applied from the upper surface of the pulp fiber web in the laminate 120 to the melt blow nonwoven fabric 110 side and entangled with the water flow.
Further, according to the composite nonwoven fabric manufacturing apparatus 100 of the above embodiment, in the span race processing unit 32, a jet water flow is applied from the upper surface of the pulp fiber web in the laminate 120 to the melt blow nonwoven fabric 110 side and entangled with the water flow.
Therefore, since the pulp fiber 2 can be caught and entangled with the melt blow resin fiber 3 on the melt blow non-woven fabric 110 side from the pulp fiber web side, the entanglement of the pulp fiber 2 with the melt blow resin fiber 3 can be improved, and the pulp fiber 2 can be prevented from falling off. It can be even less likely to occur. It also makes it possible to improve the mechanical strength.

In addition, according to the method for producing a composite nonwoven fabric of the above embodiment, it has a heat embossing step of embossing with a hot emboss roll after the drying step.
Further, according to the composite nonwoven fabric manufacturing apparatus 100 of the above embodiment, there is a heat embossing unit 34 embossed with a heat embossing roll on the downstream side of the drying unit 33.
Therefore, it is possible to effectively prevent the fibers from falling off, increase the mechanical strength, give a thick feeling and a bulky feeling, and further suppress the elongation.

When carrying out the present invention, the drying section 33 may be dried by a hot embossing roll to be embossed, or the hot embossing section 34 may be provided in front of the drying section 33. When heat embossing is performed after the drying portion 33 as in the present embodiment, the shape retention of the embossing is good. In addition, it is possible to more effectively prevent the fibers from falling off, improve the processing suitability, and suppress the elongation.

By the way, in the schematic view of FIG. 12, it is described that the melt-blow nonwoven fabric 110 manufactured by the melt-blow nonwoven fabric manufacturing section 10 is continuously processed by being continuously conveyed to the pulp airlaid section 20, but when the present invention is carried out, it is described. For example, the melt blow nonwoven fabric 110 manufactured by the melt blow nonwoven fabric manufacturing unit 10 is once wound into a roll, transported in a roll shape to a place where the pulp airlaid portion 20 is located, and the melt blow nonwoven fabric 110 wound there is developed. May be supplied to the pulp airlaid section 20.

Further, when the present invention is carried out, the melt blow resin fiber 3 is not limited to the thermoplastic resin fiber, and may be a mixed resin fiber in which different kinds of resins such as an elastomer resin are mixed. It is also possible to compose a plurality of types of fibers by ejecting different types of resin with a nozzle.

In carrying out the present invention, the composition, components, blending, manufacturing method and the like of other parts of the composite nonwoven fabric 1 are not limited to the above examples.
In addition, all of the numerical values given in the embodiments of the present invention do not indicate critical values, and certain numerical values are values determined from the manufacturing cost, easy-to-manufacture form, etc., and are suitable for implementation. Since it indicates a value, even if the above value is slightly changed within the permissible value, its implementation is not denied.

1 Composite non-woven fabric 2 Pulp fiber 3 Melt blow resin fiber 3a Focusing section 10 Melt blow non-woven fabric manufacturing section 20 Pulp airlaid section (pulp fiber web forming section)
31 Roller processing part 32 Span lace processing part 33 Drying part 34 Thermal embossing part 100 Composite non-woven fabric manufacturing equipment 110 Melt blow non-woven fabric 120 Laminated fabric

Claims (13)

A composite non-woven fabric composed of pulp fibers and resin fibers having a fiber length longer than that of the pulp fibers and having an average fiber diameter in the range of 0.5 to 10 μm.
The resin fibers meander irregularly and are entangled with each other, and are entangled with the pulp fibers distributed over the entire thickness direction.
A composite non-woven fabric characterized in that the resin fibers and the pulp fibers are three-dimensionally entangled integrally. The resin is present on one surface side of the front and back surfaces of the composite nonwoven fabric in a larger amount than on the other surface side, and on the one surface side in which the pulp fibers are present in a larger amount than on the other surface side. The composite nonwoven fabric according to claim 1, wherein a large amount of the meandering fibers are present. The composite nonwoven fabric according to claim 1 or 2, wherein the pulp fiber is a fibrillated beaten wood pulp, and the average fiber length thereof is in the range of 0.5 to 5 mm. The invention according to any one of claims 1 to 3, wherein the resin fiber has a focusing portion in which a plurality of single fibers are focused and fused together in a part of the length direction thereof. Composite non-woven fabric. Claims 1 to 4, wherein the composite nonwoven fabric has a basis weight in ^{the range of 30 to 80 g / m 2} and a specific volume in the range of ^{7 to 70 cm 3 / g.} The composite nonwoven fabric according to any one. Melt-blow non-woven fabric manufacturing process for forming melt-blow non-woven fabric made of resin fibers,
A pulp fiber web forming step of forming a pulp fiber web on the melt blow nonwoven fabric placed on a net conveyor by an air raid method,
A spunlace treatment step of integrating the resin fiber of the melt blow nonwoven fabric and the pulp fiber of the pulp fiber web formed on the resin fiber by water flow entanglement.
A method for producing a composite nonwoven fabric, which comprises a drying step of drying the resin fibers and the pulp fibers integrally entwined. The sixth aspect of claim 6 is characterized in that the melt blown nonwoven fabric and the roll processing step of pressing against the pulp fiber web formed on the melt blow nonwoven fabric are provided between the pulp fiber web forming step and the spunlacing treatment step. Method for manufacturing composite non-woven fabric. The method for producing a composite nonwoven fabric according to claim 6 or 7, wherein in the spunlace treatment step, a jet water flow is applied from above the pulp fiber web and the water flow is entangled. The method for producing a composite nonwoven fabric according to any one of claims 6 to 8, further comprising a heat embossing step of performing the heat embossing before or after the drying step. Melt-blow non-woven fabric manufacturing department that forms melt-blow non-woven fabric made of resin fibers,
A pulp fiber web forming portion for forming a pulp fiber web by an air raid method on the melt blow nonwoven fabric placed on a net conveyor, and a pulp fiber web forming portion.
A span lace processing unit that integrates the resin fiber of the melt blow nonwoven fabric and the pulp fiber of the pulp fiber web formed on the resin fiber by water flow confounding.
A composite nonwoven fabric manufacturing apparatus comprising the resin fiber entwined integrally and a drying portion for drying the pulp fiber. 10. The tenth aspect of the present invention is characterized in that the melt blown nonwoven fabric and the roll processing portion that presses against the pulp fiber web formed on the melt blow nonwoven fabric are provided between the pulp fiber web forming portion and the span lace processing portion. Composite non-woven fabric manufacturing equipment. The composite nonwoven fabric manufacturing apparatus according to claim 10 or 11, wherein in the spunlace processing unit, a jet water flow is applied from above the pulp fiber web and the water flow is entangled. The composite nonwoven fabric manufacturing apparatus according to any one of claims 10 to 12, further comprising a heat-embossed portion for which heat embossing is performed before or after the dried portion.

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