JP4189542B2

JP4189542B2 - Non-woven

Info

Publication number: JP4189542B2
Application number: JP2002293012A
Authority: JP
Inventors: 俊昭廣津
Original assignee: HONEY STEEL CO., LTD.
Current assignee: HONEY STEEL CO., LTD.
Priority date: 2002-10-04
Filing date: 2002-10-04
Publication date: 2008-12-03
Anticipated expiration: 2022-10-04
Also published as: JP2004122693A

Description

【０００１】
【発明の属する技術分野】
本発明は、家具その他の品物の包装シート、構築物や建物内外の養生シート、床敷物、タイルカーペット、テーブルカバー、食器下敷き、介護用ベッドシート、愛玩動物用ペッドシート、おむつカバー等、種々の物品を被覆保護するために使用される不織布に関するものである。
【０００２】
【従来の技術】
敷物裏面に散布した熱可塑性樹脂粉末を加熱押圧し、或いは、敷物裏面に重ね合わせた熱可塑性樹脂フィルムを加熱押圧して裏打層を形成することは公知である（例えば、特許文献１参照）。熱可塑性樹脂を加熱溶融し、Ｔダイ押出機よりフィルム状に押し出して敷物裏面に塗布融着させて裏打層を形成することは公知である（例えば、特許文献２参照）。
【０００３】
【特許文献１】
特公昭４８−１０３４号公報（特許請求の範囲、第１図）
【特許文献２】
特公昭６１−５５９６５号公報（特許請求の範囲）
【０００４】
家具その他の品物の包装シート、構築物や建物内外の養生シート、床敷物、タイルカーペット、テーブルカバー、食器下敷き、介護用ベッドシート、愛玩動物用ペッドシート、おむつカバー等、種々の物品を被覆保護するために使用される不織布には、その使用中に触れる雨水や飲料水等の液体が透過することがないように、防水処理を施しておくことが望まれる。その防水処理は、不織布原反に熱可塑性樹脂による防水層を積層することによって簡便に施すことが出来る。
【０００５】
熱可塑性樹脂による防水層は、（１）接着剤を介して熱可塑性樹脂フィルムを不織布原反に貼り合わせる接着法、（２）不織布原反に熱可塑性樹脂フィルムを重ねて加熱融着させるフィルム融着法、（３）熱可塑性樹脂粉末を不織布原反に散布積層して加熱押圧し樹脂フィルムとする樹脂散布法、（４）熱可塑性樹脂を加熱溶融させてＴダイ押出機よりフィルム状に押し出して不織布原反に塗布融着させるフローコート法の何れかによって不織布原反に積層することが出来る。
【０００６】
【発明が解決しようとする課題】
その何れの方法による場合でも、熱可塑性樹脂の積層された不織布は、その積層前の不織布原反に比して著しく粗硬になり、それによって被覆保護しようとする物品の形状に合わせて折曲変形し難しくなるので、その被覆保護材としての用途が大きく限定される。即ち、上記の接着法（１）では、熱可塑性樹脂フィルムが平滑で防水性を有するので、液状の接着剤を熱可塑性樹脂フィルムに厚く塗布して不織布原反に強固に貼り合わせることは出来ず、それを不織布原反に塗布するときは不織布原反内部に深く浸透し、その深く浸透した接着剤によって不織布原反内部の繊維間が接合されるので、不織布が粗硬に仕上がってしまう。上記のフィルム融着法（２）では、不織布原反を構成している繊維と熱可塑性樹脂フィルムが同質の場合は熱可塑性樹脂フィルムと共に不織布原反も熱溶融してフィルム状に変形して不織布としての体を成さず、他方、不織布原反を構成している繊維と熱可塑性樹脂フィルムが異質の場合は、それらの接着が熱可塑性樹脂フィルムの溶融物によるアンカリング効果に依存するだけのものであるため強固に貼り合わせることは出来ない。勿論、熱可塑性樹脂フィルムの熱溶融物を異質の不織布原反の繊維間に圧入させてアンカリング効果を高めることは可能であるが、そのためには、不織布原反の繊維間に圧入させるに必要な熱溶融物の分だけ厚い熱可塑性樹脂フィルムを使用しなければならず、又、その圧入される熱溶融物によって熱収縮変形しない程度に不織布原反を重厚に構成しなければならないので薄手の不織布には不向きであり、且つ又、圧入された熱溶融物によって不織布原反内部の繊維間の隙間が充填されると共に不織布原反内部の繊維間が接合されるので、不織布が粗硬に仕上がってしまう。このことは、上記の樹脂散布法（３）とフローコート法（４）の場合も同様である。
【０００７】
【発明の目的】
そこで本発明は、不織布原反の可撓性を損なうことなく表面に熱可塑性樹脂を積層して防水性を付与し、被覆保護を必要とする物品の立体的形状に合わせて自由に折曲変形することが出来、家具その他の品物の包装シート、構築物や建物内外の養生シート、床敷物、タイルカーペット、テーブルカバー、食器下敷き、介護用ベッドシート、愛玩動物用ペッドシート、おむつカバー等に適した不織布を得ることを目的とする。
【０００８】
【課題を解決するための手段】
本発明に係る不織布は、不織布原反と熱可塑性樹脂粉末の散布層と熱可塑性樹脂フィルムの順に積層されており、熱可塑性樹脂粉末が連続した溶融皮膜を形成することなく熱溶融して不織布原反と熱可塑性樹脂フィルムに融着しており、熱可塑性樹脂フィルムが熱可塑性樹脂粉末を介して不織布原反に部分的に接着しており、熱可塑性樹脂フィルムと不織布原反の間に熱可塑性樹脂粉末が介在せず剥離状態の未接着部分が部分的に存在しており、熱可塑性樹脂フィルムと不織布原反の間の接着部分と未接着部分が１ｃｍ平方内に混在していることを第１の特徴とする。
【０００９】
本発明に係る不織布の第２の特徴は、上記第１の特徴に加えて、不織布原反がニードルパンチングが施されて毛羽立った厚み１ｍｍ以上のニードルパンチング不織布であり、熱可塑性樹脂粉末の粒径が１ｍｍ以下であり、熱可塑性樹脂粉末の散布量が５００ｇｆ／ｍ² 以下であり、熱可塑性樹脂粉末が毛羽立った不織布原反の表面の毛羽と毛羽の間に入り込んで毛羽に融着しており、熱可塑性樹脂フィルムと不織布原反の間の未接着部分が熱可塑性樹脂粉末の介在しない空隙になっており、熱可塑性樹脂フィルムの厚みが５００μｍ以下である点にある。
【００１０】
本発明に係る不織布の第３の特徴は、上記第１および第２の何れかの特徴に加えて、熱可塑性樹脂フィルムが防滑性を有する点にある。
【００１１】
【発明の実施の形態】
本発明に係る不織布は、不織布原反１２に熱可塑性樹脂粉末（以下、単に「樹脂粉末」と言う。）１１を散布し、その散布面に熱可塑性樹脂フィルム（以下、単に「樹脂フィルム」と言う。）１３を重ね合わせ、更に、その樹脂フィルム１３の上に離形性シートを重ね合わせ、その離形性シートの上に加熱板を当てて軽く押圧して製造することが出来る。その場合、離形性シートを無端で連続循環するエンドレスベルトにし、不織布原反１２を下にして散布樹脂粉末１１と樹脂フィルム１３を順次積層し、その樹脂フィルム１３の上に離形性シート（エンドレスベルト）を重ねあわせ、それらを上側に位置する加熱板と下側に位置するバックアップ板の間に通すとよい。そうすると樹脂粉末１１が、加熱板から離形性シートと樹脂フィルム１３を介して伝わる熱によって溶融し、表面毛羽１４に絡み付くように不織布原反１２に融着すると共に樹脂フィルム１３に融着し、その樹脂粉末１１を介して不織布原反１２に樹脂フィルム１３が貼り合わされることになる。そのためには樹脂粉末１１に、樹脂フィルム１３よりも融点が低い低融点熱可塑性樹脂を用いる。樹脂フィルム１３は、低融点の熱可塑性樹脂と高融点の熱可塑性樹脂を積層した複層フィルムにするとよい。そのように積層された複層フィルム（１３）では、その低融点熱可塑性樹脂は、樹脂粉末１１よりも融点が低いものであってもよい。
【００１２】
樹脂粉末１１の散布量は、散布した樹脂粉末１１によって不織布原反１２の表面が完全に埋め尽くされることがなく、散布した樹脂粉末１１ａと樹脂粉末１１ｂの間から不織布原反の表面毛羽１４が現れる程度にする。そのためには樹脂粉末１１の粒径を１ｍｍ以下にし、粒径０．５〜１ｍｍの樹脂粉末では散布量を２００〜５００ｇｆ／ｍ² 、粒径０．５ｍｍ以下の樹脂粉末では散布量を１００〜３００ｇｆ／ｍ² にするとよい。そうすると、不織布原反１２の表面が毛羽立っているため、樹脂粉末１１の散布層は粒径に応じた厚みにはならず、ある部分では毛羽１４と毛羽１４の間には数個の樹脂粉末１１が一纏めになって転がり込み、他の部分では毛羽に遮られて毛羽１４と毛羽１４の間には樹脂粉末１１が入り込まないと言うように、不織布原反１２の表面に樹脂粉末１１の散布斑が細かく均等に生じ、その樹脂粉末１１の散布層に樹脂フィルム１３を重ねて加熱すると、不織布原反１２と樹脂フィルム１３の間に接着部分１１と未接着部分１５とが細かく均一に混在した不織布が得られる。仕上がった不織布の可撓性の点からすれば、樹脂フィルム１３の厚みを７５〜１２５μｍとし、樹脂粉末１１の散布量を１２０〜１７０ｇｆ／ｍ² にするとよい。
【００１３】
樹脂粉末１１の加熱は、その上に重ねた樹脂フィルム１３の上に更に重ねた離形性シートの上から行うので、樹脂粉末１１に熱が伝わり易く、樹脂粉末１１が熱溶融し易くする上でも、樹脂フィルム１３の厚みを５００μｍ以下にするとよい。又、樹脂粉末全体（１１）に熱が瞬時に伝わり、樹脂粉末全体（１１）が瞬時に熱溶融するようにするために、樹脂粉末１１の粒径を５００μｍ以下にするとよい。そのように粒径の細かい樹脂粉末１１は不織布原反表面の毛羽１４と毛羽１４の間に深く入り込み易く、その深く入り込んだ樹脂粉末１１の熱溶融物が複数本の繊維に絡み付くように融着するので、その熱溶融物（１１）を介した樹脂フィルム１３と不織布原反１２とのアンカリング効果が高まる。この点からして不織布原反には、ニードルパンチングが施されていて表面が嵩高に毛羽立って細かく起伏しているニードルパンチング不織布を適用することが推奨される。ニードルパンチング不織布は、繊維ウエブにニードルパンチングを施しただけのものでもよいし、基布に積層した繊維ウエブにニードルパンチングを施した基布付きニードルパンチング不織布でもよい。
【００１４】
樹脂フィルムを溶融させることなく樹脂粉末を溶融させるには、前記の通り、樹脂フィルムに離形性シートを重ね合わせ、その離形性シートに加熱板を当て、離形性シートと樹脂フィルムを介して樹脂粉末を加熱する。そうすると、仮に樹脂フィルムが熱溶融しても、その溶融物は離形性シートに密着してフィルムの形態を維持し、その冷却後に離形シートを剥離すれば元の樹脂フィルムの形態を回復することになる。従って、樹脂フィルムの厚みは５０〜１５０μｍ程度の極薄のものであってもよく、そのように極薄の樹脂フィルムを使用することによって、可撓性を損なうことなく不織布原反に防水性を付与することが出来る。
【００１５】
不織布は、前記の通り、家具その他の品物の包装シート、構築物や建物内外の養生シート、床敷物、タイルカーペット、テーブルカバー、食器下敷き、介護用ベッドシート、愛玩動物用ペッドシート、おむつカバー等、種々の物品を被覆保護するために使用される。その使用において例えば、包装シートとして使用する場合には、包装時に品物に密着してズレ動かず、包装し易くなり、又、床敷物、テーブルクロス、ベッドシート等として床面や机上や下敷きに重ね合わせて使用する場合には使用中にズレ動かなければ好都合である。従って、樹脂フィルム１３には、エチレン・酢酸ビニル共重合樹脂やスチレン・ブタジエン・スチレン・ブロック共重合樹脂、スチレン・ビニルイソプレン・スチレン・ブロック共重合樹脂等の防滑性を有する熱可塑性樹脂を使用するとよい。その防滑性は、樹脂フィルム１３を下向きにして水平なガラス板に載置した不織布に素手を当て、その不織布がガラス板の表面を移動するように、或いは、その不織布でガラス板の表面を拭くように素手を動かすとき、素手が不織布の表面を滑動するだけで、不織布が素手に副ってガラス板の表面で移動しない程度の防滑性であればよい。
【００１６】
【発明の効果】
本発明によると樹脂フィルム１３は、不織布原反１２に対して、点状に不織布原反１２の表面に散在する樹脂粉末１１ａと樹脂粉末１１ｂの間に架け渡された恰好になる。そのように不織布原反１２と樹脂フィルム１３が複層シートの如く完全に密着して一体化しておらず、部分的に点接着された状態にある。このため、樹脂フィルム側がＵ字状に窪むように不織布を折り曲げるとき、樹脂粉末１１ａと樹脂粉末１１ｂの間の未接着部分１５で樹脂フィルム１３が不織布原反１２から離れて隆起し、小皺が樹脂フィルム１３の全面に細かく分かれて均等に発生する。他方、不織布側がＵ字状に窪むように不織布を折り曲げるときは、樹脂フィルム１３が極薄であり、樹脂粉末１１が、不織布原反内部に深く入り込んで連続した皮膜を形成しておらず、部分的に不織布原反内部の繊維間を接合しているだけであり、不織布原反内部の繊維（１４）が樹脂粉末１１に束縛されることなく挙動し得る状態にあるので、樹脂フィルムと不織布原反が互に他方の伸縮を妨げることなく屈曲することになる。
【００１７】
樹脂フィルム１３と不織布原反１２は、樹脂粉末１１を介して部分的に点状に接着していても、その点状を成す樹脂粉末１１が不織布原反表面の毛羽１４と毛羽１４の間に深く入り込み、不織布原反内部において複数本の繊維に絡み付くように融着しているのでアンカリング効果が高く、その不織布原反内部において樹脂粉末１１が繊維に絡み付くように融着している接着部分（１１）と樹脂粉末１１の未接着部分１５が不織布の１ｃｍ平方内に混在するように不織布原反の全面にわたって細かく均等に分布しており、特に、ニードルパンチング不織布では樹脂粉末１１の融着している繊維が表面（樹脂フィルムの反対側）まで連続しているので、樹脂フィルム１３と不織布原反１２が容易には剥離せず、耐久性に富む不織布が得られる。
【００１８】
このように本発明によると、樹脂フィルム１３によって防水性が付与され、被覆保護を必要とする物品の立体的形状に合わせて自由に折曲変形することが出来、而も、樹脂フィルム１３によって防滑性が付与され、使用時にズレ動くことがなく、家具その他の品物の包装シート、構築物や建物内外の養生シート、床敷物、タイルカーペット、テーブルカバー、食器下敷き、介護用ベッドシート、愛玩動物用ペッドシート、おむつカバー等に適した防滑性不織布が得られる。
【００１９】
更に本発明の不織布では、その裁断口の繊維が樹脂フィルム１３で覆われているので、その裁断口から繊維が掻き出され難く、裁断口での繊維の解れ出しを防止する特別の処理を施すことなく、任意に裁断し、そのまま使用し得る点でも頗る実用的である。
【図面の簡単な説明】
【図１】本発明に係る不織布の断面図である。
【図２】本発明に係る不織布の樹脂フィルムを剥離した状態での平面図である。
【符号の説明】
１１樹脂粉末（接着部分）
１２不織布原反
１３樹脂フィルム
１４毛羽
１５未接着部分[0001]
BACKGROUND OF THE INVENTION
The present invention covers various articles such as packaging sheets for furniture and other items, curing sheets for structures and buildings, floor coverings, tile carpets, table covers, tableware, nursing bed sheets, pet sheet for pets, diaper covers, etc. The present invention relates to a nonwoven fabric used for covering protection.
[0002]
[Prior art]
It is known that a backing layer is formed by heating and pressing a thermoplastic resin powder spread on the back of a rug, or by heating and pressing a thermoplastic resin film superposed on the back of a rug (see, for example, Patent Document 1). It is known that a thermoplastic resin is heated and melted, extruded into a film form from a T-die extruder, and coated and fused to the back of the rug to form a backing layer (see, for example, Patent Document 2).
[0003]
[Patent Document 1]
Japanese Patent Publication No. 48-1034 (Claims, Fig. 1)
[Patent Document 2]
Japanese Examined Patent Publication No. 61-55965 (Claims)
[0004]
To cover and protect various items such as furniture and other packaging sheets, curing sheets inside and outside buildings, floor coverings, tile carpets, table covers, tableware, nursing bed sheets, pet bed sheets for pets, diaper covers, etc. It is desired that the nonwoven fabric used for the waterproofing is subjected to a waterproofing treatment so that liquids such as rain water and drinking water that are touched during use are not transmitted. The waterproof treatment can be easily performed by laminating a waterproof layer made of a thermoplastic resin on the nonwoven fabric.
[0005]
The waterproof layer made of thermoplastic resin is (1) an adhesive method in which a thermoplastic resin film is bonded to a nonwoven fabric through an adhesive, and (2) film fusion in which a thermoplastic resin film is layered on the nonwoven fabric and heat-sealed. (3) Resin spraying method in which thermoplastic resin powder is spread and laminated on the nonwoven fabric raw material and heated and pressed to form a resin film. (4) The thermoplastic resin is heated and melted and extruded from a T-die extruder into a film. Then, it can be laminated on the nonwoven fabric by any of the flow coating methods in which the nonwoven fabric is coated and fused.
[0006]
[Problems to be solved by the invention]
Regardless of which method is used, the laminated nonwoven fabric of the thermoplastic resin becomes significantly harder than the nonwoven fabric before lamination, so that it can be bent according to the shape of the article to be coated and protected. Since it becomes difficult to deform, its use as a covering protective material is greatly limited. That is, in the above bonding method (1), since the thermoplastic resin film is smooth and waterproof, it is impossible to apply a liquid adhesive thickly to the thermoplastic resin film and firmly bond it to the nonwoven fabric. When it is applied to the nonwoven fabric, it penetrates deeply into the nonwoven fabric, and the fibers inside the nonwoven fabric are joined by the deeply penetrated adhesive, resulting in a rough finish of the nonwoven fabric. In the above-mentioned film fusion method (2), when the fibers constituting the nonwoven fabric and the thermoplastic resin film are the same, the nonwoven fabric is also melted together with the thermoplastic resin film and deformed into a film shape. When the fibers constituting the nonwoven fabric and the thermoplastic resin film are different from each other, their adhesion depends only on the anchoring effect due to the melt of the thermoplastic resin film. Because it is a thing, it cannot be bonded firmly. Of course, it is possible to increase the anchoring effect by press-fitting a thermoplastic resin film melt between different nonwoven fabric fibers, but for this purpose, it is necessary to press-fit between the nonwoven fabric fibers. It is necessary to use a thermoplastic resin film that is thicker than the hot melt, and the nonwoven fabric must be made thick so that the hot melt does not cause heat shrinkage deformation. It is unsuitable for nonwoven fabrics, and the gap between the fibers inside the nonwoven fabric is filled and the fibers inside the nonwoven fabric are joined by the hot melt that has been press-fitted. End up. The same applies to the resin spraying method (3) and the flow coating method (4).
[0007]
OBJECT OF THE INVENTION
Therefore, the present invention provides a waterproof property by laminating a thermoplastic resin on the surface without impairing the flexibility of the nonwoven fabric, and freely bends and deforms according to the three-dimensional shape of the article that requires coating protection. Non-woven fabric suitable for packaging sheets for furniture and other items, curing sheets for structures and buildings, floor coverings, tile carpets, table covers, tableware, bed sheets for nursing care, pet sheets for pets, diaper covers, etc. The purpose is to obtain.
[0008]
[Means for Solving the Problems]
The nonwoven fabric according to the present invention is laminated in the order of a nonwoven fabric raw material, a dispersion layer of thermoplastic resin powder, and a thermoplastic resin film, and the thermoplastic resin powder is melted by heat without forming a continuous melt film. It is fused to the thermoplastic resin film, and the thermoplastic resin film is partly bonded to the nonwoven fabric through the thermoplastic resin powder, and the thermoplastic is between the thermoplastic resin film and the nonwoven fabric. It is confirmed that the unbonded part in the peeled state is partially present without the resin powder, and the bonded part and the unbonded part between the thermoplastic resin film and the nonwoven fabric raw material are mixed within 1 cm square. One feature.
[0009]
The second feature of the nonwoven fabric according to the present invention is, in addition to the first feature, a needle punched nonwoven fabric having a thickness of 1 mm or more, wherein the nonwoven fabric raw material is needle-punched and fluffed, and the particle size of the thermoplastic resin powder Is 1 mm or less, the spraying amount of the thermoplastic resin powder is 500 gf / m ² or less, and the thermoplastic resin powder penetrates between the fluffs on the surface of the nonwoven fabric with fuzzing and is fused to the fluffs. The unadhered portion between the thermoplastic resin film and the nonwoven fabric raw material is a void without the thermoplastic resin powder, and the thickness of the thermoplastic resin film is 500 μm or less.
[0010]
A third feature of the nonwoven fabric according to the present invention is that, in addition to any of the first and second features, the thermoplastic resin film has anti-slip properties.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
In the nonwoven fabric according to the present invention, a thermoplastic resin powder (hereinafter simply referred to as “resin powder”) 11 is applied to the nonwoven fabric 12 and a thermoplastic resin film (hereinafter simply referred to as “resin film”) is applied to the application surface. It can be manufactured by superposing 13 and then superposing a release sheet on the resin film 13 and applying a heating plate on the release sheet and pressing lightly. In that case, the releasable sheet is made into an endless belt that continuously circulates endlessly, and the spread resin powder 11 and the resin film 13 are sequentially laminated with the nonwoven fabric raw material 12 facing down, and the releasable sheet ( Endless belts) may be overlapped and passed between a heating plate located on the upper side and a backup plate located on the lower side. Then, the resin powder 11 is melted by the heat transmitted from the heating plate through the release sheet and the resin film 13, and is fused to the nonwoven fabric raw material 12 so as to be entangled with the surface fluff 14, and is fused to the resin film 13. The resin film 13 is bonded to the nonwoven fabric original fabric 12 through the resin powder 11. For this purpose, a low melting thermoplastic resin having a lower melting point than that of the resin film 13 is used for the resin powder 11. The resin film 13 is preferably a multilayer film in which a low-melting thermoplastic resin and a high-melting thermoplastic resin are laminated. In the multilayer film (13) laminated in such a manner, the low melting point thermoplastic resin may have a melting point lower than that of the resin powder 11.
[0012]
The spread amount of the resin powder 11 is such that the surface of the nonwoven fabric original fabric 12 is not completely filled with the dispersed resin powder 11, and the surface fluff 14 of the nonwoven fabric original fabric is between the dispersed resin powder 11 a and the resin powder 11 b. Make it appear. For this purpose, the particle size of the resin powder 11 is set to 1 mm or less, the spraying amount is 200 to 500 gf / m ² for the resin powder having a particle size of 0.5 to 1 mm, and the spraying amount is 100 to 100 for the resin powder having a particle size of 0.5 mm or less. 300 gf / m ² is preferable. Then, since the surface of the non-woven fabric 12 is fluffed, the spread layer of the resin powder 11 does not have a thickness corresponding to the particle diameter, and in some portions, several resin powders 11 are present between the fluff 14 and the fluff 14. As a result, the resin powder 11 is scattered on the surface of the nonwoven fabric 12 so that the resin powder 11 does not enter between the fluff 14 and the fluff 14. When the resin film 13 is superimposed on the spray layer of the resin powder 11 and heated, the bonded portion 11 and the non-bonded portion 15 are finely and uniformly mixed between the nonwoven fabric 12 and the resin film 13. Is obtained. From the viewpoint of the flexibility of the finished nonwoven fabric, the thickness of the resin film 13 is preferably 75 to 125 μm, and the spraying amount of the resin powder 11 is preferably 120 to 170 gf / m ² .
[0013]
Heating of the resin powder 11 is performed from above the release sheet that is further stacked on the resin film 13 stacked thereon, so that heat is easily transmitted to the resin powder 11 and the resin powder 11 is easily melted. However, the thickness of the resin film 13 is preferably 500 μm or less. Further, the particle diameter of the resin powder 11 is preferably 500 μm or less so that the heat is instantaneously transmitted to the entire resin powder (11) and the entire resin powder (11) is instantaneously melted by heat. The resin powder 11 having such a small particle size is easy to penetrate deeply between the fuzz 14 and the fuzz 14 on the surface of the nonwoven fabric, and the hot melt of the resin powder 11 that has entered deeply is fused so as to get entangled with a plurality of fibers. Therefore, the anchoring effect of the resin film 13 and the nonwoven fabric raw material 12 through the hot melt (11) is enhanced. From this point of view, it is recommended to apply a needle punching nonwoven fabric that has been subjected to needle punching and has a bulky and fluffy surface. The needle punching nonwoven fabric may be a needle web punched nonwoven fabric, or a needle punched nonwoven fabric with a base fabric obtained by needle punching a fiber web laminated on the base fabric.
[0014]
In order to melt the resin powder without melting the resin film, as described above, the release sheet is overlaid on the resin film, a heating plate is applied to the release sheet, and the release sheet and the resin film are interposed. Heat the resin powder. Then, even if the resin film is melted by heat, the melt adheres to the release sheet and maintains the form of the film. After the release sheet is peeled off, the original form of the resin film is restored. It will be. Accordingly, the thickness of the resin film may be as extremely thin as about 50 to 150 μm. By using such an extremely thin resin film, the nonwoven fabric can be made waterproof without impairing flexibility. Can be granted.
[0015]
Nonwoven fabrics are as described above, such as packaging sheets for furniture and other items, curing sheets for structures and buildings, floor coverings, tile carpets, table covers, tableware, bed sheets for nursing care, pet sheets for pets, diaper covers, etc. It is used to cover and protect other articles. In its use, for example, when used as a packaging sheet, it is easy to wrap without sticking to the product when it is packaged. Also, it can be stacked on the floor, desk or underlay as a floor covering, table cloth, bed sheet, etc. When using together, it is convenient if it does not move during use. Therefore, when the resin film 13 is made of a thermoplastic resin having anti-slip properties such as ethylene / vinyl acetate copolymer resin, styrene / butadiene / styrene / block copolymer resin, styrene / vinyl isoprene / styrene / block copolymer resin, or the like. Good. The anti-slip property is such that the non-woven fabric placed on a horizontal glass plate with the resin film 13 facing downward is applied with a bare hand so that the nonwoven fabric moves on the surface of the glass plate, or the surface of the glass plate is wiped with the non-woven fabric. When the bare hand is moved as described above, the non-slip property may be such that the bare hand slides on the surface of the nonwoven fabric and the nonwoven fabric does not move on the surface of the glass plate along with the bare hand.
[0016]
【The invention's effect】
According to the present invention, the resin film 13 becomes a shape that is stretched between the resin powder 11a and the resin powder 11b scattered on the surface of the nonwoven fabric raw material 12 in a dotted manner with respect to the nonwoven fabric raw material 12. As such, the nonwoven fabric 12 and the resin film 13 are not completely intimately integrated as in the case of a multilayer sheet, but are in a state of being partially point-bonded. For this reason, when the nonwoven fabric is bent so that the resin film side is recessed in a U shape, the resin film 13 protrudes away from the nonwoven fabric raw material 12 at the unbonded portion 15 between the resin powder 11a and the resin powder 11b, and the small wrinkles are resin film It is divided finely over the entire surface of 13 and is evenly generated. On the other hand, when the nonwoven fabric is bent so that the nonwoven fabric side is recessed in a U shape, the resin film 13 is extremely thin, and the resin powder 11 does not penetrate into the nonwoven fabric raw material so as to form a continuous film. Only the fibers inside the nonwoven fabric are joined together, and the fibers (14) inside the nonwoven fabric can behave without being constrained by the resin powder 11. Will bend without interfering with the other expansion and contraction.
[0017]
Even if the resin film 13 and the nonwoven fabric original fabric 12 are partially bonded in a spot shape via the resin powder 11, the resin powder 11 forming the dot shape is between the fluff 14 and the fluff 14 on the surface of the nonwoven fabric original fabric. Adhesion part which penetrates deeply and is fused so as to be entangled with a plurality of fibers inside the nonwoven fabric, so that the anchoring effect is high, and the resin powder 11 is fused so as to be entangled with the fibers inside the nonwoven fabric (11) and the non-bonded portion 15 of the resin powder 11 are finely and evenly distributed over the entire surface of the nonwoven fabric so that they are mixed within 1 cm square of the nonwoven fabric. In particular, in the needle punching nonwoven fabric, the resin powder 11 is fused. Since the fiber which has continued to the surface (opposite side of the resin film), the resin film 13 and the nonwoven fabric raw fabric 12 do not peel easily, and a nonwoven fabric rich in durability can be obtained.
[0018]
As described above, according to the present invention, the resin film 13 is provided with waterproofness, and can be freely bent and deformed according to the three-dimensional shape of an article that requires coating protection. It has a certain character and does not move when used, and is used for packaging sheets for furniture and other items, curing sheets for structures and buildings, floor coverings, tile carpets, table covers, tableware, nursing bed sheets, and pet seats for pets. An anti-slip nonwoven fabric suitable for diaper covers and the like is obtained.
[0019]
Further, in the nonwoven fabric of the present invention, the fiber at the cutting opening is covered with the resin film 13, so that the fiber is hardly scraped out from the cutting opening, and a special treatment for preventing the fiber from being released at the cutting opening is performed. It is also practical that it can be arbitrarily cut and used as it is.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a nonwoven fabric according to the present invention.
FIG. 2 is a plan view of the nonwoven fabric resin film according to the present invention in a peeled state.
[Explanation of symbols]
11 Resin powder (adhesive part)
12 Nonwoven fabric 13 Resin film 14 Fluff 15 Unbonded part

Claims

(A) The thermoplastic resin powder is sprayed on the nonwoven fabric, and the thermoplastic resin film is superimposed on the sprayed surface.
(B) The thermoplastic resin powder is melted by heat without forming a continuous melt film, and is fused to the nonwoven fabric and the thermoplastic resin film,
(C) The thermoplastic resin film is partially bonded to the nonwoven fabric through the thermoplastic resin powder,
(D) The thermoplastic resin powder does not intervene between the thermoplastic resin film and the nonwoven fabric raw material, and there is a partially unbonded part in a peeled state,
(E) The adhesive part and non-adhesive part between the thermoplastic resin film and the nonwoven fabric are mixed within 1 cm square,
(F) The non-woven fabric is a needle punched non-woven fabric having a thickness of 1 mm or more which is fluffed by needle punching,
(G) The particle size of the thermoplastic resin powder is 1 mm or less,
(H) The amount of the thermoplastic resin powder sprayed is 500 gf / m ² or less,
(I) The thermoplastic resin powder is interwoven between the fluffs on the surface of the nonwoven fabric with the fluff and entangled with the fluffs.
(J) The non-adhered portion between the thermoplastic resin film and the nonwoven fabric raw material is a void without the thermoplastic resin powder,
(K) A nonwoven fabric in which the thickness of the thermoplastic resin film is 500 μm or less.

The nonwoven fabric according to claim 1, wherein the thermoplastic resin film has anti-slip properties.