JP4711033B2 - Nonwoven fabric suitable for rugs - Google Patents

Nonwoven fabric suitable for rugs Download PDF

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Publication number
JP4711033B2
JP4711033B2 JP2001123340A JP2001123340A JP4711033B2 JP 4711033 B2 JP4711033 B2 JP 4711033B2 JP 2001123340 A JP2001123340 A JP 2001123340A JP 2001123340 A JP2001123340 A JP 2001123340A JP 4711033 B2 JP4711033 B2 JP 4711033B2
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JP
Japan
Prior art keywords
fiber
nonwoven fabric
melting point
composite fiber
point component
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
JP2001123340A
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Japanese (ja)
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JP2002317367A (en
Inventor
広治 吉田
守彦 大野
陽一 古河
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Toray Industries Inc
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Toray Industries Inc
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Filing date
Publication date
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Priority to JP2001123340A priority Critical patent/JP4711033B2/en
Publication of JP2002317367A publication Critical patent/JP2002317367A/en
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Publication of JP4711033B2 publication Critical patent/JP4711033B2/en
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  • Carpets (AREA)
  • Biological Depolymerization Polymers (AREA)
  • Nonwoven Fabrics (AREA)

Description

【0001】
【発明の属する技術分野】
本発明は、耐摩耗性及びクッション性に優れ、敷物として実用化できる不織布に関する。
【0002】
【従来の技術】
従来から、リサイクル可能なカーペットとして、熱融着繊維を使用し、ニードルパンチした不織布を使用することが知られている(特開平6−173149号公報及び特開平5−115347号公報)。
しかし、これらの公報に記載されるような不織布は、熱融着繊維を、ただ単に溶融してバインダーとして用いるだけであるため、摩耗による抜け毛等の問題があった。また、全体的に均質な板状となるため、カーペットとしての感触に欠け、実用性に乏しいものであった。
【0003】
【発明が解決しようとする課題】
本発明では、熱融着繊維を使用した不織布であって、摩耗による抜け毛等の問題がなく、敷物に好適な不織布、及び表裏で表情が異なり、カーペットとして感触よく使用できる不織布を提供することを課題とする。
【0004】
【課題を解決するための手段】
本発明では、熱融着繊維を使用し、ニードルパンチした不織布において、使用する繊維の組み合わせを工夫し、スパイラル状に捲縮した繊維を表面側に存在させることにより上記課題を解決した。
【0005】
本発明の不織布は、融点の異なる2種の熱可塑性樹脂成分からなる複合繊維Aと、前記複合繊維Aの低融点成分より高い融点を有する繊維Bとからなり、前記複合繊維Aの低融点成分の溶融により一体化された短繊維不織布であって、前記複合繊維Aが、偏心型の芯鞘構造を有すると共に、前記繊維Bに比して小さい繊度を有し、前記複合繊維Aの少なくとも一部がスパイラル状に捲縮し、前記複合繊維Aの平均捲縮数が少なくとも20ケ/25.4mmであり、ゴム硬度計で測定した際に該不織布の平均表面硬度が表裏で異なり、該不織布の一方の面が平坦で、他方の面に毛羽立ちが認められることを特徴とする。
【0006】
本発明によれば、複合繊維Aを芯鞘構造としたことで、ニードルパンチによる繊維の割れの問題が生じにくくなり、さらに偏心型としたことで、熱処理後の捲縮率が高くなり、容易にスパイラル状にすることができる。なお、この場合、芯鞘構造の鞘を低融点成分とするのがよい。
複合繊維Aの繊度は繊維Bの繊度よりも小さければよいが、前者が後者の1/2〜1/6程度であるのが好ましく、特に、複合繊維Aの単糸繊度が2〜4dtexであるのが好ましい。
【0007】
スパイラル状に捲縮した複合繊維Aの平均捲縮数は、少なくとも20ケ/25.4mmであればよいが、更に40ケ/25.4mm以上、特に80ケ/25.4mm以上であるのがよい。捲縮数が多いほど、敷物として用いた際の耐摩耗性及びクッション性に優れるからである。
本発明の不織布は、ゴム硬度計で測定した際に平均表面硬度が表裏で異なるが、この場合、硬度差が2.0以上であるのが好ましく、更に好ましくは3.0以上、特に好ましくは4.0以上である。
【0008】
スパイラル状に捲縮した複合繊維Aの数は、少なくとも不織布の一方の表面において、25ケ/cm2 以上の割合で存在していることが好ましい。捲縮繊維の割合が多いほど、敷物として用いた際の耐摩耗性及びクッション性に優れるからである。この捲縮した繊維の個数は、電子顕微鏡観察により測定することができる。
【0010】
複合繊維Aとして、偏心型の芯鞘構造を有すると共に、繊維Bに比して小さい繊度を有するものを用い、ニードルによりウエッブを貫く上下運動のうち、敷物の表面となる側に向かって貫く回数を、逆向きの回数より多くすることで、不織布の一方の側(敷物の表側)で、繊度が小さい複合繊維Aの密度が高まり、そこで複合繊維Aを繊維Bに点接着させた状態で、強く捲縮させることができるため、不織布の一方の面(敷物の表側となる面平坦であるが、他方の面は、毛羽立つ感触を有するものとなる。
この捲縮の発現(スパイラル化)は、複合繊維Aの熱処理温度(低融点成分を溶融するための温度)を、複合繊維Aの高融点成分の融点近くまで上げることによって、特に効果的に得られる。具体的には、低融点成分の融点を(a)℃、高融点成分の融点を(b)℃とした場合に、熱処理温度(x)℃が、
(a)+10≦(x)<(b)
となるように設定する。
【0011】
本発明の不織布を構成する糸の材質は特に限定されないが、車両用又は催物会場用等の各種敷物として使用し、使用後、環境問題を生ずることなく廃物処理するためには、全体に同一素材からなるものとするのが好ましい。
【0012】
本発明では、特に、不織布を構成する繊維、すなわち前記複合繊維A及び繊維B共に、ポリ乳酸系繊維からなるものとすることにより、生分解性を有する不織布として、廃物処理の問題なく、広く敷物類に使用できる製品を得ることが可能となる。ここに、ポリ乳酸系繊維とは、乳酸モノマー単独からなるポリ乳酸繊維だけでなく、生分解性を阻害しない範囲で、他の成分をブレンドまたは共重合して得た繊維も含まれる。
【0013】
従来、ポリ乳酸系繊維は、たとえばポリエチレンテレフタレート系繊維に比べて、脆く繊維が切れやすく、捲縮弾性率が低く、嵩が出難く、クッション性に乏しいので、敷物類に適用できるとは考えられていなかったが、本発明では、たとえば芯及び鞘共にポリ乳酸系成分からなる偏心型の芯鞘構造の複合繊維Aと、その芯成分とほぼ同一の融点を有するポリ乳酸系の繊維Bを組み合わせて使用し、しかも複合繊維Aをサイド・バイ・サイドに近いような偏心型の芯鞘構造とし、不織布製造における熱処理温度を、複合繊維Aの芯成分の融点近くまで(芯成分の融点との差が5〜15℃、特に7〜13℃程度となるまで)高めることによって、複合繊維Aを繊維Bに点接着させた状態で、強く捲縮させることができ、その結果全体にポリ乳酸系繊維からなる不織布でありながら、実用性ある耐摩耗性とクッション性を有する敷物に適した製品となることを可能とした。
【0014】
この場合、複合繊維Aと繊維Bの混合率は特に限定されないが、重量比率で、10〜50:90〜50であるのが好ましく、特に、20〜30:80〜70程度であるのが好ましい。
【0017】
【発明の実施の形態】
本発明の実施例を次に示す。なお、実施例において%とあるのは、特に断らない限り、重量%を示す。また、実施例に先だって、実施例で製造した不織布の物性の測定・評価方法を以下に記載する。
【0018】
(耐摩耗性試験方法)
JIS L1023−9
回転数1000回
【0019】
(不織布の厚さ)
JIS L1021−7.2.1
1.96kPa,加圧子10cm2
【0020】
(不織布の目付)
JIS L1021−7.3.1
【0021】
(平均表面硬度)
アスカーゴム硬度計(高分子計器)F型を用い、測定する。
【0022】
(防炎性)
消防法施行規則S36.4.1自治省令第6号 第4条の3(5)
【0023】
実施例1
融点130℃のポリ乳酸を鞘成分とし、融点170℃のポリ乳酸を芯成分とした単糸繊度が3.3dtex、繊維長が51mmである芯鞘構造の複合繊維Aと、融点170℃のポリ乳酸系繊維で単糸繊度が11dtex、繊維長が64mmである繊維Bを、重量比率で20:80の割合で混綿し、カード機、クロスレイヤー処理し、裏面側からニードルパンチした。そして、得られたシートを160℃で3分熱処理して、目付400g/m2 、厚さ3.5mmの不織布を得た。
この不織布は、一方の面(敷物とした際の表面)が平坦で、耐摩耗性試験における減量が18mgで、敷物としての実用の基準である50mg以下という条件を充分にクリアするものであった。また、他面(敷物とした際の裏面)側には、毛羽立ちが認められ、外観及びクッション性のよいカーペットとして使用できるものとなった。
【0024】
この不織布の平均表面硬度は、表側が78.0、裏側が71.8であり、この硬度差は、6.2であった。
【0025】
また、この製品は、消防法の防炎基準を満たし、インテリア床材防炎性に優れるものであった。
【0026】
更に、この製品は、全体に生分解性に優れたポリ乳酸系繊維からなるため、使用後の処理も、環境汚染を心配することなく実施できるので、催物会場のカーペット等として非常に有用である。
【0027】
【発明の効果】
本発明の不織布には、繊度の小さい熱接着性複合繊維Aがスパイラル状に捲縮したものが存在する。そのため、本発明の不織布は、耐摩耗性に優れた、敷物に適した不織布となる。
また、捲縮した繊維を、表側に偏らせた場合には、当該面は平坦となるため、他の素材と接着したりすることも容易であり、しかも、表側には、繊度の小さい複合繊維Aがスパイラル状に捲縮したものが存在するため、薄い不織布であっても、特に、反撥性(クッション性)のある製品となる。
特に、不織布全体を生分解性あるポリ乳酸系繊維からなるものとすることも可能で、この場合には、後処理の心配がないので、使い捨ての敷物として広く実用化できるので、屋内の敷物だけでなく、農業用シートや植生シート等として使用することも可能である。
[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a nonwoven fabric that is excellent in wear resistance and cushioning properties and can be practically used as a rug.
[0002]
[Prior art]
Conventionally, as a recyclable carpet, it is known to use a heat-bonded fiber and a needle punched nonwoven fabric (Japanese Patent Laid-Open Nos. 6-173149 and 5-115347).
However, the nonwoven fabrics described in these publications have problems such as hair loss due to abrasion because the heat-fusible fibers are merely melted and used as a binder. Moreover, since it became a uniform plate shape as a whole, the feel as a carpet was lacking and the practicality was poor.
[0003]
[Problems to be solved by the invention]
In the present invention, there is provided a non-woven fabric using heat-fusible fibers, which is free from problems such as hair loss due to wear, suitable for a rug, and a non-woven fabric that has a different expression on the front and back and can be used as a carpet with a good touch. Let it be an issue.
[0004]
[Means for Solving the Problems]
In the present invention, the above-mentioned problems have been solved by devising a combination of fibers to be used in a needle punched non-woven fabric using heat-bonded fibers and causing the fibers crimped spirally to be present on the surface side.
[0005]
The nonwoven fabric of the present invention comprises a composite fiber A composed of two types of thermoplastic resin components having different melting points, and a fiber B having a melting point higher than the low melting point component of the composite fiber A, and the low melting point component of the composite fiber A The composite fiber A has an eccentric core-sheath structure and a fineness smaller than that of the fiber B, and is at least one of the composite fibers A. And the average number of crimps of the composite fiber A is at least 20 / 25.4 mm, and the average surface hardness of the nonwoven fabric is different between the front and back when measured with a rubber hardness meter. One surface is flat and fluff is recognized on the other surface.
[0006]
According to the present invention, since the composite fiber A has a core-sheath structure, the problem of fiber breakage due to needle punching is less likely to occur, and further, the eccentric type increases the crimping rate after heat treatment and facilitates. Can be spiraled. In this case, the sheath having a core-sheath structure is preferably a low melting point component .
The fineness of the composite fiber A may be smaller than the fineness of the fiber B, but the former is preferably about 1/2 to 1/6 of the latter, and in particular, the single fiber fineness of the composite fiber A is 2 to 4 dtex. Is preferred.
[0007]
The average number of crimps of the composite fibers A was crimped in a spiral shape, should I Re least 20 Quai /25.4mm der, but is still 40 Quai /25.4mm or more, particularly 80 Quai /25.4mm more Is good. This is because the greater the number of crimps, the better the wear resistance and cushioning when used as a rug.
The non-woven fabric of the present invention has different average surface hardness when measured with a rubber hardness meter, but in this case, the hardness difference is preferably 2.0 or more, more preferably 3.0 or more, particularly preferably. 4.0 or more.
[0008]
The number of composite fibers A crimped in a spiral shape is preferably present at a rate of at least 25 / cm 2 on at least one surface of the nonwoven fabric. This is because the higher the proportion of crimped fibers, the better the wear resistance and cushioning properties when used as a rug. The number of crimped fibers can be measured by observation with an electron microscope.
[0010]
The composite fiber A has an eccentric core-sheath structure and has a fineness smaller than that of the fiber B. The number of times the needle penetrates toward the side of the rug in the vertical movement through the web by the needle. , By increasing the number of times in the opposite direction, the density of the composite fiber A having a small fineness is increased on one side of the nonwoven fabric (the front side of the rug), where the composite fiber A is point-bonded to the fiber B. Since it can be strongly crimped, one surface of the nonwoven fabric (the surface that is the front side of the rug ) is flat , while the other surface has a fluffy feel.
The expression of the crimp (spiralization) can be obtained particularly effectively by raising the heat treatment temperature of the composite fiber A (temperature for melting the low melting point component) to near the melting point of the high melting point component of the composite fiber A. It is done. Specifically, when the melting point of the low melting point component is (a) ° C. and the melting point of the high melting point component is (b) ° C., the heat treatment temperature (x) ° C. is
(A) + 10 ≦ (x) <(b)
Set to be.
[0011]
The material of the yarn constituting the nonwoven fabric of the present invention is not particularly limited, but it is used as various rugs for vehicles or entertainment venues, and after use, to treat waste without causing environmental problems, the same material as a whole It is preferable to consist of.
[0012]
In the present invention, in particular, the fibers constituting the nonwoven fabric, that is, the composite fiber A and the fiber B are both made of polylactic acid fiber, so that the nonwoven fabric having biodegradability can be widely used without waste disposal problems. It becomes possible to obtain a product that can be used in a similar manner. Here, the polylactic acid fiber includes not only a polylactic acid fiber composed of a lactic acid monomer alone but also a fiber obtained by blending or copolymerizing other components within a range not inhibiting biodegradability.
[0013]
Conventionally, polylactic acid fibers are brittle and easy to break compared to polyethylene terephthalate fibers, for example, and have low crimp elastic modulus, low bulk, and poor cushioning, so it is considered that they can be applied to rugs. However, in the present invention, for example, a composite fiber A having an eccentric core-sheath structure in which both the core and the sheath are composed of a polylactic acid-based component and a polylactic acid-based fiber B having substantially the same melting point as the core component are combined. In addition, the composite fiber A has an eccentric core-sheath structure close to side-by-side, and the heat treatment temperature in the production of the nonwoven fabric is close to the melting point of the core component of the composite fiber A (with the melting point of the core component). By increasing the difference until the difference is about 5 to 15 ° C., particularly about 7 to 13 ° C., the composite fiber A can be strongly crimped in the state of being point-bonded to the fiber B. Yet nonwoven fabric comprising fibers made it possible to be practical is wear-resistant and suitable products rug having cushioning property.
[0014]
In this case, the mixing ratio of the composite fiber A and the fiber B is not particularly limited, but is preferably 10 to 50:90 to 50, and particularly preferably about 20 to 30:80 to 70 by weight. .
[0017]
DETAILED DESCRIPTION OF THE INVENTION
Examples of the present invention will be described below. In the examples, “%” means “% by weight” unless otherwise specified. Prior to the examples, the methods for measuring and evaluating the physical properties of the nonwoven fabric produced in the examples are described below.
[0018]
(Abrasion resistance test method)
JIS L1023-9
Rotation speed 1000 times [0019]
(Thickness of nonwoven fabric)
JIS L1021-7.2.1
1.96 kPa, pressurizer 10 cm 2
[0020]
(Nonwoven fabric weight)
JIS L1021-7.3.1
[0021]
(Average surface hardness)
Measure using an Asker rubber hardness meter (polymer meter) F type.
[0022]
(Fireproof)
Fire Service Act Enforcement Regulations S36.4.1 Ministry of Home Affairs Ordinance No. 6 Article 4-3 (5)
[0023]
Example 1
A core-sheathed composite fiber A having a single yarn fineness of 3.3 dtex and a fiber length of 51 mm and a polylactic acid having a melting point of 170 ° C. and a polylactic acid having a melting point of 130 ° C. as a sheath component and a polylactic acid having a melting point of 170 ° C. as a core component. Fiber B, which is a lactic acid fiber and has a single yarn fineness of 11 dtex and a fiber length of 64 mm, was blended at a weight ratio of 20:80, card machine, cross-layered, and needle punched from the back side. And the obtained sheet | seat was heat-processed at 160 degreeC for 3 minute (s), and the nonwoven fabric of 400 g / m < 2 > of fabric weights and thickness 3.5mm was obtained.
This nonwoven fabric had a flat surface on one side, a weight loss of 18 mg in the abrasion resistance test, and sufficiently cleared the conditions of 50 mg or less, which is a practical standard for a rug. . Moreover, fuzz was recognized on the other side (the back side when it was used as a rug), and it was able to be used as a carpet having good appearance and cushioning properties.
[0024]
The average surface hardness of the nonwoven fabric was 78.0 on the front side and 71.8 on the back side, and the hardness difference was 6.2.
[0025]
In addition, this product met the fire prevention standards of the Fire Service Act, and was excellent in flame resistance of interior flooring.
[0026]
Furthermore, since this product is made of polylactic acid fiber with excellent biodegradability as a whole, after-use treatment can be carried out without worrying about environmental pollution, so it is very useful as a carpet for a venue. .
[0027]
【The invention's effect】
In the nonwoven fabric of the present invention, there is one in which the heat-adhesive conjugate fiber A having a small fineness is crimped in a spiral shape. Therefore, the nonwoven fabric of the present invention is a nonwoven fabric excellent in wear resistance and suitable for a rug.
In addition, when the crimped fiber is biased to the front side, the surface becomes flat, so it is easy to adhere to other materials, and on the front side, a composite fiber with small fineness Since there exists what crimped A to spiral shape, even if it is a thin nonwoven fabric, it becomes a product with repulsion (cushioning property) especially.
In particular, the entire nonwoven fabric can be made of biodegradable polylactic acid fiber. In this case, since there is no worry about post-processing, it can be widely used as a disposable rug, so only indoor rugs can be used. It can also be used as an agricultural sheet or a vegetation sheet.

Claims (6)

融点の異なる2種の熱可塑性樹脂成分からなる複合繊維Aと、前記複合繊維Aの低融点成分より高い融点を有する繊維Bとからなり、前記複合繊維Aの低融点成分の溶融により一体化された短繊維不織布であって、前記複合繊維Aが、偏心型の芯鞘構造を有すると共に、前記繊維Bに比して小さい繊度を有し、前記複合繊維Aの少なくとも一部がスパイラル状に捲縮し、前記複合繊維Aの平均捲縮数が少なくとも20ケ/25.4mmであり、ゴム硬度計で測定した際に該不織布の平均表面硬度が表裏で異なり、該不織布の一方の面が平坦で、他方の面に毛羽立ちが認められることを特徴とする不織布。The composite fiber A is composed of two thermoplastic resin components having different melting points, and the fiber B has a higher melting point than the low melting point component of the composite fiber A, and is integrated by melting the low melting point component of the composite fiber A. The composite fiber A has an eccentric core-sheath structure and a fineness smaller than that of the fiber B, and at least a part of the composite fiber A has a spiral shape. The average number of crimps of the composite fiber A is at least 20 / 25.4 mm, and when measured with a rubber hardness meter , the average surface hardness of the nonwoven fabric differs between the front and back surfaces, and one surface of the nonwoven fabric is flat. A non-woven fabric characterized in that fuzz is observed on the other surface. スパイラル状に捲縮した前記複合繊維Aが、少なくとも一方の表面において、25ケ/cmThe composite fiber A crimped in a spiral shape has 25 pieces / cm on at least one surface. 2 以上の割合で存在していることを特徴とする請求項1の不織布。The nonwoven fabric according to claim 1, wherein the nonwoven fabric is present in the above proportion. 前記複合繊維A及び前記繊維Bがいずれも、ポリ乳酸系繊維からなるものであることを特徴とする請求項1または請求項2の不織布。The nonwoven fabric according to claim 1 or 2, wherein both the composite fiber A and the fiber B are made of polylactic acid fiber. 前記複合繊維Aと繊維Bの混合率が重量比率で、10〜50:90〜50であることを特徴とする請求項1〜3いずれか1項の不織布。The mixing rate of the said composite fiber A and the fiber B is 10-50: 90-50 by weight ratio, The nonwoven fabric of any one of Claims 1-3 characterized by the above-mentioned. 請求項1〜4のいずれか1項の不織布からなることを特徴とする敷物。A rug comprising the nonwoven fabric according to any one of claims 1 to 4. 融点の異なる2種の熱可塑性樹脂成分からなる複合繊維Aと、前記複合繊維Aの低融点成分より高い融点を有する繊維Bとからなるウエッブをニードルパンチし、その後、前記低融点成分の融点以上の温度で熱処理して短繊維不織布を製造する方法において、前記複合繊維Aとして、偏心型の芯鞘構造を有し、かつ前記繊維Bに比して小さい繊度を有するものを使用し、ニードルによりウエッブを貫く上下運動のうち、敷物の表面となる側に向かって貫く回数を、逆向きの回数より多くし、さらに、前記複合繊維Aの低融点成分の融点を(a)℃、高融点成分の融点を(b)℃とした場合に、前記不織布の熱処理温度(x)℃を、A web consisting of a composite fiber A composed of two types of thermoplastic resin components having different melting points and a fiber B having a melting point higher than the low melting point component of the composite fiber A is needle punched, and then the melting point of the low melting point component or higher. In the method for producing a short fiber nonwoven fabric by heat treatment at a temperature of, the composite fiber A having an eccentric core-sheath structure and having a fineness smaller than that of the fiber B is used. Of the up and down movements through the web, the number of penetrations toward the surface of the rug is increased from the number of the opposite directions, and the melting point of the low melting point component of the composite fiber A is (a) ° C., the high melting point component When the melting point of the non-woven fabric is (b) ° C., the heat treatment temperature (x) ° C. of the nonwoven fabric is
(a)+10≦(x)<(b)(A) + 10 ≦ (x) <(b)
となるように設定することを特徴とする不織布の製造方法。It sets so that it may become. The manufacturing method of the nonwoven fabric characterized by the above-mentioned.
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