JP4893256B2 - Method for producing fluid-entangled nonwoven fabric and method for producing leather-like sheet comprising fluid-entangled nonwoven fabric obtained thereby - Google Patents

Description

  The present invention relates to a method for producing a fluid-entangled nonwoven fabric that reduces continuous uneven lines due to high-speed fluid treatment, has a uniform surface, and is excellent in wear resistance, and a leather-like sheet comprising a fluid-entangled nonwoven fabric obtained thereby About.

  Hydroentangled nonwoven fabrics manufactured by a processing method using a high-speed fluid such as a water jet punch are highly productive. In recent years, they are not only used for manufacturing functional nonwoven fabrics such as wipers, separators, and masks, but also synthetic leather. It is used for the production of non-woven fabrics for a wide range of applications, such as the production of sensitive fabrics such as leather and artificial leather.

  However, in the method of injecting a high-speed fluid and intertwining the fibers, in order to improve the tensile strength and durability against friction, etc., when the fibers are highly intertwined by injecting the high-pressure fluid, the fluid hits. There is a problem that unevenness is easily formed in a place that does not hit the place, and it is difficult to obtain a uniform surface.

In order to solve this problem, for example, a fabric having an air flow rate of 300 cc / cm ² / sec or more is inserted between two layers of paper-made non-woven fabric composed of ultrafine fibers having an aspect ratio of 1400 to 4000, and 100 kg / m ² or more is inserted. A method in which both surfaces are treated at least once with a columnar water flow at a pressure of 1 to give a total energy of 1 to 6 kWh / kg / m (for example, refer to Patent Document 1), or the sum of the diameters of the injection holes of the columnar water flow A method of efficiently treating the fabric with 70% or more of the treatment width of the fabric (see, for example, Patent Document 2) has been proposed.

  However, when the fibers constituting the papermaking nonwoven fabric are entangled with a high-speed fluid to make a base fabric of artificial leather, the fiber length of the fibers forming the papermaking nonwoven fabric is short, so even if a binder such as urethane is applied, the friction of There was a problem that the fibers were easily pulled out by the action and the durability was poor. In addition, when the sum of the diameters of the injection holes of the columnar water flow is 70% or more of the fabric, it is necessary to supply a large amount of water, so a pump with a large pumping amount is required, and it is difficult to treat with a high-pressure water flow. There were problems such as expensive equipment.

On the other hand, in order to obtain an artificial leather having durability such as abrasion resistance without using a binder such as a polymer elastic body, one side of the artificial leather is needle punched nonwoven fabric and the other side is made of non-woven fabric. There have been proposed a method of inserting a woven or knitted fabric between non-woven fabrics and treating with a high-speed fluid, and a method of grinding the surface with sandpaper having a fine particle size after the high-speed fluid treatment (see, for example, Patent Documents 3 and 4). However, these methods can provide artificial leather with excellent durability, but uneven lines formed by hydroentanglement may remain, and there is a limit to obtaining a uniform surface.
Japanese Patent No. 3277046 JP 2004-52156 A JP 2006-70423 A JP 2006-274454 A

An object of the present invention is to provide a fluid-entangled nonwoven fabric and a leather-like method for producing a fluid-entangled nonwoven fabric having a uniform surface in which continuous uneven lines due to high-speed fluid are reduced on the product surface of the fluid-entangled nonwoven fabric and having excellent wear resistance. It is intended to provide a sheet manufacturing method .

In order to solve the above-described problems, the present invention has the following configuration. That is,
[1] In the high-speed fluid treatment of the fluid entangled nonwoven fabric, the fluid power per hole of the nozzle is 10 w or more from the front side of the nonwoven fabric A and the fluid diameter is 0 at least twice from the back side of the nonwoven fabric A. Fluid confounding characterized in that high-speed fluid treatment is performed at least twice at a work rate of fluid per nozzle hole of 4 to 35 W using a nozzle with a cover factor of 25 or more at 0.05 to 0.14 mm Nonwoven fabric manufacturing method.

  [2] The total energy applied by the treatment from the front side of the nonwoven fabric A is 1.5 kWh / kg / m or more, and the total energy applied by the treatment from the back side of the nonwoven fabric A is 0.8 to 3.5 kWh. It is / kg / m, The manufacturing method of the fluid entangled nonwoven fabric as described in said [1] characterized by the above-mentioned.

[3] Nonwoven fabric A is a dry nonwoven fabric composed of ultrafine fibers having an average single fiber fineness of 0.001 to 0.5 dtex on the front side, and a basis weight of 30 to 150 g / m ² and an air flow rate of 150 cc / cm ^2. [1] or [2], characterized in that the nonwoven fabric has a woven or knitted fabric of / sec or more and a papermaking nonwoven fabric composed of ultrafine fibers having an average single fiber fineness of 0.1 to 0.5 dtex on the back side. The manufacturing method of the fluid entangled nonwoven fabric of description.

  [4] The non-woven fabric A has a paper-made non-woven fabric disposed on one side of the woven or knitted fabric, and the total energy applied using a nozzle having a pore diameter of 0.05 to 0.14 mm is 0.05 to 2.0 kWh / kg / Any one of the above [1] to [3], which is obtained by applying a high-speed fluid treatment from the surface of the paper-made nonwoven fabric to m, and then overlaying a dry nonwoven fabric on the opposite surface of the woven or knitted fabric The manufacturing method of the fluid entangled nonwoven fabric of description.

[5] The method for producing a fluid-entangled nonwoven fabric according to [3] or [4], wherein the dry nonwoven fabric is a dry nonwoven fabric satisfying the following conditions (1) to (5).
(1) It is produced by the needle punch method.
(2) It is an ultrafine fiber having an average fiber length to average fiber diameter ratio (aspect ratio) of 6500 to 220,000.
(3) The basis weight is 30 to 200 g / m ² .
(4) The density is 0.2 to 0.3 g / cm ³ .
(5) The elongation rate is 3% or more.

[6] The method for producing a fluid-entangled nonwoven fabric according to any one of [3] to [5], wherein the woven or knitted fabric is a woven or knitted fabric that satisfies the following conditions (i) and (ii): .
(I) The different type polyester polymer is constituted by a composite fiber arranged in a side-by-side type or an eccentric core-sheath type.
(Ii) The elongation in the vertical direction and the horizontal direction is 15 to 40%.

  [7] The method for producing a fluid entangled nonwoven fabric according to any one of the above [1] to [6], wherein the fluid entangled nonwoven fabric is subjected to raising treatment with sandpaper having a particle size of 400 to 1500.

  [8] The method for producing a fluid-entangled nonwoven fabric according to any one of [1] to [7], wherein the fluid-entangled nonwoven fabric is further processed by a liquid dyeing machine.

[9] The method for producing the above [1] to [8] leather-like sheet, which comprises using a fluid entangling the nonwoven fabric as a base cloth was Yura by the manufacturing method of one of the fluid entangling nonwoven.

  According to the above-described production method of the present invention, the artificial leather base fabric used as a skin material for clothing materials and sheets has a uniform surface with reduced uneven lines caused by high-speed fluid treatment on the product surface of the fluid entangled nonwoven fabric. It is possible to provide a fluid-entangled nonwoven fabric excellent in durability such as wear resistance, which is suitable as

The method for producing a fluid-entangled nonwoven fabric according to the present invention includes performing fluid treatment twice or more from the front side of the nonwoven fabric A at least under specific conditions, and having a pore diameter of 0.05 to 0.14 mm and covering from the back side of the nonwoven fabric A This is a method for producing a nonwoven fabric in which high-speed fluid treatment is performed at least twice at a work rate of fluid per hole of the nozzle of 4 to 35 W using a nozzle having a factor of 25 or more.
The nonwoven fabric A is not particularly limited, and is a dry nonwoven fabric obtained by a needle punch method, a melt blow method, a spunbond method, a paper nonwoven fabric obtained by a papermaking method, or a laminate of these nonwoven fabric and a woven fabric or a knitted fabric. Etc. can be used. Moreover, the front side of the nonwoven fabric A refers to the side that finally becomes the product surface.

  As the high-speed fluid treatment, a water jet punch treatment using a water flow is preferable because it is inexpensive as a fluid and does not require a special device in terms of the working environment. In the high-speed fluid treatment on the front side of the nonwoven fabric A, the high-speed fluid treatment is performed at least twice under the conditions of the nozzle hole diameter and water pressure such that the work rate per hole of the fluid discharged from the nozzle is 10 W or more. . In the present invention, the passage under one nozzle head that discharges fluid is defined as one high-speed fluid treatment, and the term “two or more times high-speed fluid treatment” herein refers to passage under two nozzle heads. To do. For example, four high-speed fluid treatments are to pass under four nozzle heads.

  The fluid power can be calculated from the following equations 1 to 3.

V = (2.times.g.times. (P1-P2) .times.10000 / (. Rho..times.1000)) ^{1 /} 2.times.60 (Equation 1) where V: flow velocity of fluid discharged from the nozzle (m / min)
g: Gravitational acceleration, 9.8 m / s ²
P1: Fluid water pressure (kgf / cm ² )
P2: Atmospheric pressure (kgf / cm ² )
ρ: density of fluid (g / cm ³ ).

F = (S / 100) × V × 100 (Expression 2)
Here, F: flow rate of fluid discharged from one hole of the nozzle (cm ³ / min)
S: Area of the fluid discharged from one hole of the nozzle (mm ² )
V: Flow rate (m / min) of the fluid discharged from the nozzle.

W = P1 × (F / 100) × 0.163 (Expression 3)
Where W: work rate of fluid per nozzle hole (W)
P1: Fluid water pressure (kgf / cm ² )
F: Flow rate (cm ³ / min) of fluid discharged from one hole of the nozzle.

  The high-speed fluid treatment from the front side of the nonwoven fabric A has a high effect of three-dimensionally entanglement of the fibers of the nonwoven fabric that is the product surface, and when the fluid entanglement structure is highly formed by this fluid treatment, Since the fibers are hardly pulled out even when rubbed, high wear resistance can be obtained. Therefore, it is important to sufficiently form a structure in which the fibers of the nonwoven fabric serving as the product surface are intertwined three-dimensionally by high-speed fluid treatment from the front side. In order to obtain such an entangled structure, it is important to perform high-speed fluid treatment twice or more at a work rate of fluid per nozzle hole of 10 W or more, and high-speed fluid treatment twice or more at 20 W or more. It is more preferable in that the fibers are easily entangled. In addition, when using a nonwoven fabric with a high fabric weight as the nonwoven fabric A, since the entanglement efficiency by high-speed fluid processing falls, it is preferable to process at a higher power, but when the power exceeds 100 W, the fluid flow is too strong. Then, the surface of the nonwoven fabric is roughened, so that it is preferable to treat the fluid with a work rate of 100 W or less. In addition, when the fluid power is less than 10 W, uneven lines due to the fluid tend not to be formed easily, and a uniform surface is easily obtained, but the fiber entanglement structure is not sufficiently formed, so that wear resistance is increased. Tends to be low, and it becomes difficult to obtain a fluid-entangled nonwoven fabric excellent in wear resistance, which is an object of the present invention. The upper limit of the number of high-speed fluid treatments from the front side of the nonwoven fabric A is not particularly limited, but the number of high-speed fluid treatments is usually preferably 10 times or less in order to make the production facility compact, and is preferably 3 times or more. More preferably, it is 6 times or less. In addition, in a mist-like fluid in which a fluid colliding with the nonwoven fabric A is diffused over a wide range, it is preferable that the fluid ejected from the nozzle head reaches the nonwoven fabric A with a columnar shape because the entanglement effect of the fibers of the nonwoven fabric is low.

  The nozzle used in the high-speed processing on the front side of the nonwoven fabric A is not particularly limited, but when a nozzle having a large hole diameter and a wide pitch is used, uneven lines formed by fluid processing are conspicuous, and fiber entanglement Since the structure is not sufficiently formed, it is preferable to use a nozzle having a hole diameter of 0.05 to 0.14 mm and a pitch of 0.2 to 0.8 mm. In addition, the injection holes may be arranged in a single row or a plurality of rows, but when the injection holes are arranged in a plurality of rows, the injection holes are inclined in a staggered manner so as not to overlap rather than overlapping each other. It is preferable that they are arranged.

In order to perform the treatment on the front side of the nonwoven fabric A under the above conditions, for example, using a nozzle in which the hole diameter is 0.12 mm, the pitch is 0.6 mm, and the injection holes are arranged in a row, the fluid water pressure is 170 kgf / in cm ² may be performed three times processing.

  Next, the nonwoven fabric A is subjected to high-speed fluid treatment from the front side, and then subjected to high-speed fluid treatment from the back side of the nonwoven fabric A. This high-speed fluid treatment from the back side not only forms the fiber entanglement structure, but also has the effect of reducing the uneven lines on the front side of the non-woven fabric A formed by the high-speed fluid treatment, and the product surface targeted by the present invention This is an important process for obtaining a fluid-entangled nonwoven fabric having a uniform surface. By treating from the back side of the non-woven fabric A, the uneven lines on the front side of the non-woven fabric are reduced, and the front side of the non-woven fabric A is pressed against the net conveyor or the like when the non-woven fabric A is conveyed by the fluid, and the net pattern is on the front side. It is thought that this is due to the fact that the uneven streaks are not easily noticeable and the fibers on the front side are rearranged when the fluid penetrates from the back side of the nonwoven fabric A to the front side. Therefore, high-speed fluid treatment from the back side of the nonwoven fabric A is difficult to obtain unless the fluid power per nozzle hole is processed at 4 W or more, but at 35 W or more, uneven stripes are clearly visible on the front side of the nonwoven fabric A. To form. Therefore, in order to reduce the uneven lines on the front side of the non-woven fabric A, the diameter of the nozzle used in the fluid treatment from the back side of the non-woven fabric A, the cover factor, and the work rate of the fluid per hole of the nozzle are important.

  The nozzle diameter at the time of high-speed fluid treatment from the back side of the nonwoven fabric A is preferably 0.05 mm or more, more preferably 0.08 mm or more. Moreover, it is preferable that it is 0.14 mm or less, More preferably, it is 0.12 mm or less. When the nozzle diameter is smaller than 0.5 mm, nozzle clogging is likely to occur. When the nozzle diameter is larger than 0.14 mm, the discharged water flow becomes thicker, and the fibers tend to become difficult to be entangled. Since uneven lines are easily formed, it is not preferable.

  In addition, the nozzle cover factor is a ratio of the sum of the diameters of the nozzle holes arranged in the sheet width direction and the ratio of the sheet width in the figure in which the nozzle holes are projected onto the sheet as shown in FIGS. That is. When the nozzles have the same pitch, the cover factor can be calculated from the pitch of the holes arranged in the same row as the nozzle hole diameter and the number of holes arranged by the following equation (4). When a plurality of holes are arranged in the nozzle and the pitches of the holes in each row are different, it can be obtained by calculating the cover factor of each row and adding all the cover factors of each row.

  In the nozzle head arranged at an angle with respect to the sheet as shown in FIG. 2, the apparent pitch R is narrower than the actual pitch. In this case, the apparent pitch R is a value. Is used. The number of nozzle holes arranged in FIG.

C = (D / R) × L × 100 (Formula 4)
Where C: Nozzle cover factor
D: Diameter per nozzle hole (mm)
R: Nozzle hole pitch
L: Number of nozzle holes arranged.

  When the cover factor of the nozzle used for high-speed fluid processing from the back side of the nonwoven fabric A is small, the area where the fluid is ejected is small, and the range that can be covered with the uneven stripes on the nonwoven fabric front side is reduced, which is sufficient to reduce uneven stripes. The effect is not obtained. In order to reduce uneven stripes, it is important that the nozzle cover factor is 25 or more. In addition, since the effect of reducing uneven stripes increases as the cover factor increases, there is no particular upper limit. However, the higher the cover factor, the greater the amount of fluid that is discharged. It becomes necessary and fluid tends to accumulate on the nonwoven fabric, and the energy of the columnar fluid flow is attenuated. Therefore, this is not limited as long as the fluid supply and drainage pumps are sufficient, but normally, the nozzle cover factor is preferably 65 or less. In the present invention, the cover factor is particularly required to be 25 or more, preferably 30 or more, more preferably 40 or more, and further preferably 60 or less. Within this range, the nozzle injection holes may be arranged in a single row or in a plurality of rows.

  In addition, when high-speed fluid processing is performed from the back side of the nonwoven fabric A, if the fluid power per hole of the nozzle is less than 4 W, the fluid cannot penetrate all the way to the front side of the nonwoven fabric A, and the effect of reducing uneven stripes cannot be obtained. When the work rate exceeds 35 W, fluid traces from the back side of the nonwoven fabric are formed on the front side of the nonwoven fabric, and it becomes difficult to reduce uneven stripes. Therefore, in order to reduce the uneven lines on the front side, it is preferable to perform the treatment twice or more with a water flow having a work rate of 4 to 35 W, and it is more preferable to perform the treatment twice or more at 4 to 20 W. In addition, the power of the fluid per hole of the nozzle from the nonwoven fabric back side can be calculated by the above-described Expression 3. The above-described work rate hardly varies in the formation of uneven stripes due to a change in the relative speed (so-called processing speed) between the nozzle head and the nonwoven fabric A when performing high-speed fluid treatment.

  Moreover, since the high-speed fluid treatment from the back side of the non-woven fabric A does not sufficiently reduce the uneven stripes on the front side of the non-woven fabric, it is important to pass the column-like fluid flow at least twice from the back side of the non-woven fabric. In this invention, the frequency | count of the high-speed fluid process from the back side of the nonwoven fabric A is 2 times or more, Preferably it is 3 times or more. In addition, although the upper limit of the frequency | count of a process is not specifically limited, From the surface of the energy used for manufacture, it is preferable that it is 6 times or less.

  In addition, when the nozzle diameter, the cover factor, and the fluid power per nozzle hole used in the high-speed fluid treatment from the back side of the nonwoven fabric A are processed under the conditions out of the above range, the surface of the nonwoven fabric A is uneven. Since streaks cannot be reduced, it is necessary to process within the above-mentioned range. In addition, as long as it falls in said range, you may use the nozzle from which a hole diameter and a cover factor differ by each nozzle head.

When performing the high-speed fluid treatment from the back side of the nonwoven fabric A three times or more, by treating with a fluid having a work rate of 70 to 90% of the work rate of the fluid per hole of the nozzle performed immediately before, It is more preferable because the effect of reducing uneven lines is increased. In order to perform the fluid treatment from the back side of the nonwoven fabric A under the above-described conditions, for example, using a nozzle having a hole diameter of 0.08 mm, a pitch of 0.48 mm, and three rows of injection holes arranged in a staggered manner, What is necessary is just to process 3 times with the water pressure of 140 kgf / cm < ² >.
In addition, if the last high-speed fluid processing surface becomes the back side of the nonwoven fabric A and is within the range of the above-described conditions, the fluid processing from the back side of the nonwoven fabric A is performed before or during the high-speed fluid processing from the front side of the nonwoven fabric A. May be.

  Moreover, in the high-speed fluid treatment of the fluid entangled nonwoven fabric in the present invention, the total energy applied by the fluid from the front side of the nonwoven fabric A is treated to be 1.5 kWh / kg / m or more from the viewpoint of improving the wear resistance. preferable. The energy applied by the fluid here is a value obtained by dividing the energy of the fluid discharged from the nozzle by the basis weight of the processing target and the processing speed. The processing speed is not particularly limited, but considering the production speed and cost, the processing speed is usually preferably 4 m or more, and more preferably 6 to 10 m.

  The energy applied by the fluid can be calculated from the following Equation 5.

E = W × N × T / (M / 1000 × U × 60) (Formula 5)
Here, E: energy (kWh / kg / m) applied in 1 hour per 1 m width to the nonwoven fabric per 1 kg
W: Work rate of fluid per nozzle hole (W)
N: Number of holes opened in the nozzle per 1 m width
T: Number of processes
M: basis weight for high-speed fluid treatment (g / m ² )
U: Processing speed (m / min).

  Since the front side of the nonwoven fabric A is the outer surface of the product, it is preferable that the energy application is 1.5 kWh / kg / m or more because the fibers on the front side of the nonwoven fabric are highly entangled and high wear resistance is obtained. Although the upper limit of the energy application from this nonwoven fabric A is not specifically limited, When considering the usage-amount and cost of a fluid, it becomes a preferable range to set it as 1.5-10 kWh / kg or less, and 2.0-5 kWh / Kg is more preferable.

  Moreover, in the process from the back side of the nonwoven fabric A, if the total energy applied by the fluid is 0.8 to 3.5 kWh / kg / m, the uneven stripes can be formed without forming new uneven stripes on the nonwoven fabric front side. It is preferable in that it can be effectively broken down and uneven stripes can be efficiently reduced, and is more preferably 1.0 to 3.0 kWh / kg / m. When the energy applied from the back side of the nonwoven fabric A is less than 0.8 kWh / kg / m, there is no energy to destroy the uneven lines on the front side, and it is difficult to obtain a sufficient obscuring effect, and uneven lines remain. In addition, if it exceeds 3.5 kWh / kg / m, the fluid treatment trace from the back side reaches the front side, and new uneven stripes tend to be formed, which is not preferable.

For example, when a non-woven fabric having a basis weight of 150 g / m ² is processed at a processing speed of 7 m, the front side of the non-woven fabric has a hole diameter of 0.12 mm, a pitch of 0.6 mm, and injection holes arranged in a row. Nozzle with a water pressure of 170 kgf / cm ² and three times using a nozzle, and a hole diameter of 0.08 mm and a pitch of 0.48 mm from the back side of the nonwoven fabric. Can be achieved by treating three times with a fluid water pressure of 140 kgf / cm ² .

  The fluid entangled nonwoven fabric of the present invention produced by the high-speed fluid treatment described above is a woven fabric or a knitted fabric between the front and back nonwoven fabrics (they can be used) It is preferably a non-woven fabric having a multi-layer structure in which a general knitted fabric) is inserted.

  Therefore, it is preferable that the nonwoven fabric A which can be used for the fluid entangled nonwoven fabric of the present invention is a nonwoven fabric having a multi-layer structure. In particular, compared to paper-made nonwoven fabrics, it is easier to obtain non-woven fabrics with a high weight, and a non-woven fabric with a multi-layer structure in which dry nonwoven fabrics that are easily changed in bristles length by buffing are arranged on the front side of the product has a high-quality appearance that is rich in variety. It is preferable in that it can be easily obtained. In this case, it is preferable to use a paper-made non-woven fabric on the opposite surface of the dry non-woven fabric in that a low-weight non-woven fabric can be easily obtained and water drainability during high-speed fluid treatment is excellent.

  For the reasons described above, the nonwoven fabric A preferably has a three-layer structure in which a dry nonwoven fabric is provided on the front side, a papermaking nonwoven fabric is provided on the back side, and a woven or knitted fabric is disposed between the dry nonwoven fabric and the papermaking nonwoven fabric.

  The dry nonwoven fabric that can be preferably used in the present invention is not particularly limited, but that the dry nonwoven fabric is composed of ultrafine fibers having an average single fiber fineness of 0.001 to 0.5 dtex is like natural leather. It is preferable in that a good texture and surface feeling can be obtained and good wiping properties can be obtained, more preferably 0.001 dtex or more, and even more preferably 0.005 dtex. Further, it is more preferably 0.3 dtex or less, and further preferably 0.15 dtex or less. On the other hand, if the average fiber fineness is less than 0.001 dtex, the strength of the final product becomes low, and it becomes difficult to obtain a dark color when dyeing is performed, and the average single fiber fineness exceeds 0.5 dtex. The high-speed fluid treatment is not preferable because the fibers are less likely to be entangled and wear resistance tends to be reduced, and it is difficult to obtain a high-grade appearance. However, as long as the object of the present invention is not impaired, fibers having an average single fiber fineness of less than 0.001 dtex or fibers having a single fiber fineness of more than 0.5 dtex may be included. The content of fibers having an average single fiber fineness of less than 0.001 dtex and fibers of more than 0.5 dtex is preferably 30% or less, more preferably 10% or less of the fibers constituting the nonwoven fabric in number. Most preferably not.

  The polymer used for the ultrafine fibers constituting the dry nonwoven fabric is not particularly limited. For example, polyester, polyamide, polypropylene, polyethylene, and the like can be used according to the intended use. It is preferable that

  The polyester is not particularly limited as long as it is a polymer synthesized from a dicarboxylic acid or an ester-forming derivative thereof and a diol or an ester-forming derivative thereof, and can be used as an ultrafine fiber generating fiber. It is not a thing.

  Specifically, for example, polyethylene terephthalate (hereinafter abbreviated as PET), polytrimethylene terephthalate (hereinafter abbreviated as PTT), polybutylene terephthalate (hereinafter abbreviated as PBT), polycyclohexylenedimethylene terephthalate, Examples include polyethylene-2,6-naphthalenedicarboxylate, polyethylene-1,2-bis (2-chlorophenoxy) ethane-4,4′-dicarboxylate, and the like. In the present invention, the most commonly used PET or a polyester copolymer mainly containing ethylene terephthalate units can be preferably used.

  As the polyamide, for example, a polymer having an amide bond such as nylon 6, nylon 66, nylon 610, and nylon 12 can be used.

The method for producing a dry nonwoven fabric composed of ultrafine fibers having an average single fiber fineness of 0.001 to 0.3 dtex in the present invention is not particularly limited. For example, a method of directly spinning ultrafine fibers, or a fiber having a normal fineness. There is a method of spinning a fiber capable of generating ultrafine fibers (ultrafine fiber generating fiber) and then generating ultrafine fibers. Examples of the method using the ultrafine fiber generation type fiber include means such as a method of removing sea components after spinning the sea-island type fiber, a method of spinning and splitting the split type fiber, and ultrafinening. it can. As the sea-island fiber here, a fiber in which two or more components are combined and mixed at any stage to form a sea-island state can be used. The method for obtaining this fiber is not particularly limited. For example,
(A) A method of blending and spinning different types of polymers of two or more components in a chip state,
(B) A method in which different types of polymers of two or more components are kneaded in advance to form chips, and then spun.
(C) A method of mixing different polymers of two or more components in a molten state in a spinning machine pack using a static kneader or the like,
(D) A method for producing using a die such as Japanese Patent Publication No. 44-18369 and Japanese Patent Application Laid-Open No. 54-116417.

  In the present invention, any method can be used for satisfactory production, but the method (D) is preferably employed because the selection of the polymer is easy. In the method (D), the cross-sectional shape of the island fiber obtained by removing the sea-island fiber and the sea component is not particularly limited. For example, a circle, a polygon, Y, H, X, W, C, π-type, etc. Is mentioned. Further, the number of polymer species to be used is not particularly limited, but it is preferably 2 to 3 components in consideration of spinning stability, and particularly composed of 2 components of sea 1 component and island 1 component. preferable. In addition, the component ratio at this time is preferably 0.3 or more by weight ratio of island fibers to sea-island fibers, more preferably 0.4 or more, and still more preferably 0.5 or more. Moreover, it is preferable that it is 0.99 or less, 0.97 or less is more preferable, and 0.8 or less is further more preferable. If it is less than 0.3, the removal rate of sea components increases, which is not preferable in terms of cost. On the other hand, if it exceeds 0.99, the island components are likely to merge with each other, which is not preferable in terms of spinning stability.

  When ultrafine fibers are obtained from sea-island type fibers, the island components become the intended ultrafine fibers. The polymer used for the island component is not particularly limited, and those that can be fiberized can be appropriately selected and used. However, the polyesters and polyamides described above are preferably used in the present invention. In addition, the polymer used as the sea component is not particularly limited as long as it is incompatible with the island component, but it is a chemical that is more soluble and degradable with respect to the solvent and chemicals used than the polymer of the island component. It is preferable that it has a property. Depending on the selection of the polymer constituting the island component, for example, polyolefins such as polyethylene and polystyrene, polyvinyl alcohol, polyethylene glycol or copolymers thereof, JP-A 61-29120, JP-A 63-165516, Hot water-soluble polymers such as hot water-soluble polyesters described in JP-A-63-159520, JP-A-1-272820, etc., 5-sodium sulfoisophthalic acid, sodium dodecylbenzenesulfonate, bisphenol A compound, Polyester obtained by copolymerization of isophthalic acid, adipic acid, dodecadioic acid, cyclohexyl carboxylic acid, or the like can be used. Polystyrene is preferable from the viewpoint of spinning stability, but a hot water-soluble polymer and a copolyester having a sulfone group are preferable because they can be easily removed without using an organic solvent. The copolymerization ratio is preferably 5 mol% or more from the viewpoint of processing speed and stability, and 20 mol% or less from the viewpoint of ease of polymerization, spinning and stretching.

  When obtaining a dry nonwoven fabric using sea-island fibers, a preferred combination of the island component and the sea component is to use a polyethylene terephthalate as the island component and a copolyester having a polystyrene or sulfone group as the sea component. To these polymers, inorganic particles such as titanium oxide particles may be added to the polymer in order to improve the concealing property. In addition, lubricants, pigments, heat stabilizers, ultraviolet absorbers, conductive agents, heat storages, etc. Materials, antibacterial agents, etc. can be added according to various purposes.

  The polymer spun in this way can be stretched and crystallized. For example, after drawing an unstretched yarn, it can be stretched 1 to 3 stages by wet heat or dry heat, or both. In addition, when using split type | mold fiber, it can mainly carry out according to the manufacturing method of the above-mentioned sea-island type | mold fiber, compounding 2 or more components within a nozzle | cap | die.

The ultrafine fiber generation type fibers and split type fibers obtained in this way are collected directly on the net, and a dry nonwoven fabric is obtained by the spunbond method, melt blow method, etc., and the ultrafine fiber generation type fibers are crimped by a conventional method. After giving and cutting to make short fibers, cards and cloth wrappers, webs made using random webbers were obtained by dry punching by the needle punch method, then the sea components of the sea-island fibers were swollen with hot water or chemicals, Remove by decomposition, dissolution, etc. At that time, in order to suppress elongation due to process tension and fluffing of fibers on the surface, it is preferable to provide a resin such as polyvinyl alcohol in advance. Moreover, you may perform a slice process to the thickness direction as needed after sea component removal. By such a method, the dry nonwoven fabric comprised from the average fiber fineness 0.001-0.3 decitex ultrafine fiber used for this invention can be obtained. Note that a dry nonwoven fabric to which a resin such as polyvinyl alcohol is attached may be used as long as it can be easily removed during high-speed fluid treatment. The dry nonwoven fabric produced by such a method preferably has a basis weight of 30 to 200 g / m ² .

Next, the woven or knitted fabric disposed between the dry nonwoven fabric and the papermaking nonwoven fabric will be described. The woven or knitted fabric that can be used in the present invention is not particularly limited, but the basis weight is preferably 30 g / m ² or more, more preferably 50 g / m ² or more, and preferably 150 g / m ² or less. Preferably it is 120 g / m ² or less. Further, the air flow rate is preferably 150 cc / cm ² / sec or more, more preferably 250 cc / cm ² / sec or more. When the basis weight of the woven or knitted fabric is less than 30 g / m ² , the effect of suppressing the occurrence of elbow slipping or kneeling is low, the basis weight exceeds 150 g / m ² , or the air flow rate is less than 150 cc / cm ² / sec. Water permeability during high-speed fluid treatment decreases, water tends to accumulate on the treated surface, and when fluid treatment is further performed in a state where water has accumulated, it is preferable because the fiber entanglement efficiency decreases and wear resistance decreases. Absent. The upper limit of the air flow rate of the knitted or knitted fabric is not particularly limited. However, if the air flow rate exceeds 1500 cc / cm ² / sec, the woven or knitted fabric is easily misaligned, the handling property is lowered, and the kneading and kneeling are suppressed. Since the effect tends to decrease, it is preferable to use a woven or knitted fabric having an air flow rate of 1500 cc / cm ² / sec or less, and it is more preferable to use a woven or knitted fabric having 700 cc / cm ² / sec or less.

  In addition, the structure and manufacturing method of the woven or knitted fabric are not particularly limited. In the case of a woven fabric, a plain woven fabric, a twill woven fabric, a satin weaving fabric, etc. A suitable loom or knitting machine can be used depending on the tissue to be used. As a loom, for example, an air jet loom, a water jet loom, a fly shuttle loom, and a knitting machine can be prepared by, for example, a flat knitting machine, a circular knitting machine, a tricot machine, a Russell machine, or the like.

  Next, the papermaking nonwoven fabric which is arranged on the surface opposite to the dry nonwoven fabric and constitutes the back surface of the fluid entangled nonwoven fabric of the present invention will be described.

  Although the papermaking nonwoven fabric used for this invention is not specifically limited, The average single fiber fineness is 0.01-0.5 decitex in the point which can obtain the fluid entanglement nonwoven fabric which is excellent in the surface quality and touch of a back side. It is preferable to use a paper-made non-woven fabric composed of these fibers. If the average single fiber fineness is less than 0.01 decitex, the number of fibers constituting the papermaking nonwoven fabric increases, which is not preferable because the water permeability decreases during high-speed fluid treatment, and the average single fiber fineness exceeds 0.5 decitex. Then, the back side of the obtained fluid entangled nonwoven fabric has a rough touch, and the quality tends to decrease.

The basis weight of the papermaking nonwoven fabric is preferably 20 g / m ² or more, and more preferably 40 g / m ² or more. It is preferable to use a material of 50 g / m ² or less, and more preferably 40 g / m ² or less. If the basis weight is less than 20 g / m ² , the layer of the nonwoven fabric may be thin and the woven or knitted fabric may be exposed. If the basis weight exceeds 50 g / m ² , the dry nonwoven fabric, the woven or knitted fabric, and the nonwoven fabric are layered. Therefore, it is not preferable because the water permeability deteriorates during high-speed fluid treatment.

  Although the manufacturing method of the papermaking nonwoven fabric used for this invention is not specifically limited, For example, the fiber of average fiber length 0.1-1cm and average single fiber fineness 0.01-0.5 dtex is water-soluble resin etc. Can be produced by making a dispersion on a wire mesh or the like by beating in water containing water and dispersing at a concentration of about 0.0001 to 0.1%. In addition, when forming a papermaking web on a woven or knitted fabric at once, it can be manufactured by a method of placing a woven or knitted fabric on a wire mesh and performing papermaking from there.

  The polymer used for the above-mentioned woven or knitted fabric or paper-making nonwoven fabric is not particularly limited, and can be used as appropriate according to the intended use, such as polyester, polyamide, polypropylene, polyethylene, etc. The same polymer as the dry nonwoven fabric to be used is preferable because dyeing with the same dye is possible at the time of dyeing.

  In addition, the woven and knitted fabrics and the paper-woven nonwoven fabrics constituting the nonwoven fabric A may be one in which only the woven and knitted fabrics and the paper-woven fabrics are overlapped and subjected to high-speed fluid treatment and intertwined. In this case, the papermaking nonwoven fabric is first overlapped on the woven or knitted fabric, and the application of energy is 0.05 to 2.0 kWh / kg / kg using a nozzle having a pore diameter of 0.05 to 0.14 mm from the surface of the papermaking nonwoven fabric. It is preferable to perform the fluid treatment under conditions such that m. At this time, if the nozzle hole diameter is less than 0.05 mm, nozzle clogging tends to occur, and if it exceeds 0.14 mm, uneven streaks are likely to remain in the paper-made nonwoven fabric, which is not preferable. Further, when the energy applied when the woven and knitted fabric and the woven fabric are entangled and integrated is less than 0.05 kWh / kg / m, the woven and woven fabric may peel off without being sufficiently entangled with the woven or knitted fabric. Therefore, it is not preferable. On the other hand, if it exceeds 2.0 kWh / kg / m, there is a tendency that the papermaking nonwoven fabric is torn or the uneven streaks tend to remain strong, which is not preferable.

For example, when using a plain woven fabric with a basis weight of 60 g / m ² and a paper-made nonwoven fabric with a basis weight of 30 g / m ² , the paper-woven fabric is layered on the fabric, and the pore diameter is 0.12 mm from the surface of the paper-woven fabric. Using a nozzle with 0.6 mm jet nozzles arranged in a row, the woven fabric and the nonwoven fabric are intertwined and dried by treating twice with a water pressure of 50 kgf / cm ² of the fluid. A non-woven fabric A can be formed by placing the non-woven fabric side down and overlaying a dry non-woven fabric thereon.

  In addition, when the dry nonwoven fabric constituting the fluid entangled nonwoven fabric is a needle punched nonwoven fabric, the fibers are entangled three-dimensionally in advance, so that the fibers are not entangled by further high-speed fluid treatment. It is preferable in that high abrasion resistance can be obtained as compared with a dry nonwoven fabric produced by a bond method, a melt blow method, or the like, or a papermaking nonwoven fabric having a short fiber length.

  The average fiber length of the fibers constituting the needle punched nonwoven fabric is not particularly limited, but the average fiber length is preferably 30 to 80 mm. Nonwoven fabrics composed of ultrafine fibers with an average fiber length of less than 30 mm tend to drop off due to friction and tend to reduce wear resistance. When the average fiber length exceeds 80 mm, the fibers are entangled by high-speed fluid treatment. It tends to be difficult to cause pilling due to friction.

  Moreover, it is preferable that the aspect ratio of the average fiber length and the average fiber diameter of the fibers constituting the needle punched nonwoven fabric is 6500 to 220,000 because the fibers are easily entangled by high-speed fluid treatment, and the fibers are not dropped due to friction. The aspect ratio here can be calculated by the following equation (6).

A = 1 / w (Formula 6)
Where A: aspect ratio l: average fiber length (μm)
w: Mean fiber diameter (μm).

Considering the water permeability during high-speed fluid treatment, the basis weight of the needle punched nonwoven fabric is preferably 50 to 200 g / m ² and the density is preferably 0.2 to 0.3 g / cm ³ . If the basis weight of the needle punched nonwoven fabric is less than 30 g / m ² , the water permeability is good, but the nonwoven fabric layer is thin and it is difficult to control the napping length by buffing, and if the basis weight exceeds 200 g / m ² , the water permeability becomes poor. When the high-speed fluid treatment is performed on the surface, the fluid tends to accumulate, and when the high-speed fluid treatment is further performed in a state where the fluid is accumulated, the fiber entanglement efficiency is lowered and the wear resistance is lowered, which is not preferable. In addition, if the density is less than 0.2 g / cm ³ , the fiber entanglement by the needle punch is not sufficient, and thus wear resistance tends to decrease. If the density exceeds 0.3 g / cm ³ , water permeability Is unfavorable because of lowering. Here, the basis weight and density are only the fibers constituting the needle punched nonwoven fabric, and for example, the basis weight and density of the resin to which the resin is adhered in addition to the fibers are not included in this. .

  In addition, it is preferable that the elongation rate of the needle punched nonwoven fabric is 3% or more in both the vertical direction and the horizontal direction in that the obtained fluid-entangled nonwoven fabric can easily follow the movement. If the elongation rate is less than 3%, the elongation of the fluid entangled nonwoven fabric deteriorates, and when used as a garment material, the followability to movement decreases and the wearing feeling of the sheet deteriorates. This is not preferable because the formability deteriorates when the sheet is bonded along the shape of the sheet. Although the upper limit of the elongation rate is not particularly limited, it is usually preferable to use a needle punched nonwoven fabric having an elongation rate of 40% or less because the nonwoven fabric is easily stretched by process tension as the elongation rate increases.

  Although the manufacturing method of the above-mentioned needle punch nonwoven fabric is not specifically limited, For example, it can obtain by the following methods.

As the fibers constituting the needle punched nonwoven fabric, the ultra-fine fiber generation type sea-island fiber described in the dry nonwoven fabric manufacturing method is used, and after stretching, 12 to 16 pieces / 25 mm are crimped, and 30 to 80 mm. Cut to obtain short fibers. Then, a web is produced using a card | curd, a cross wrapper, and a random webber, and a web is piled up so that it may become a required fabric weight. When stacking webs, the basis weight of the web is adjusted as appropriate so that the basis weight is 30 to 200 g / m ² , based on the island component ratio of the sea-island fibers and the hot water shrinkage of the fibers. To do. Subsequently, the overlapped web is needle punched so that the number of needles is 500 to 5000 / cm ² to obtain a nonwoven fabric made of sea-island fibers.

  Next, the nonwoven fabric is shrunk by wet heat through a hot water bath or the like and pressed by a calendar roll or the like. By performing such treatment, a dense nonwoven fabric having a smooth surface can be obtained, and the quality of the finally obtained fluid-entangled nonwoven fabric can be improved.

Further, it is preferable to shrink the nonwoven fabric in a polyvinyl alcohol aqueous solution instead of a hot water bath, so that polyvinyl alcohol can be imparted simultaneously with the shrinkage, and it can be used as a strength retaining material that suppresses elongation during sea component removal. To finally density obtain 0.2 to 0.3 g / cm ³ of the needle punched nonwoven fabric, at this point, the density of the nonwoven fabric is in 0.22~0.41g / cm ³ comprising a strength retention member It is preferable. Subsequently, sea components are removed by swelling, decomposition, dissolution, etc. with hot water or chemicals to generate ultrafine fibers. The agent used at this time can be appropriately selected depending on the polymer of the sea component. For example, when the sea component is polystyrene, trichloroethylene, when it is polyethylene, toluene, when it is a copolymerized polyester having a sulfone group, sodium hydroxide is used. Can be used. Moreover, since voids are generated in the nonwoven fabric by removing the sea component, it becomes easy to stretch due to process tension. Therefore, a resin that can be easily removed such as polyvinyl alcohol is provided in advance to maintain the strength, and the elongation is increased when the sea component is removed. % Or less is preferable. If the elongation at the time of removal of the sea component exceeds 20%, the elongation rate of the needle punched nonwoven fabric may eventually be less than 3%, which is not preferable.

  After removing the sea component, slice processing may be performed in the thickness direction as necessary. If the resin applied when removing the sea component can be easily removed by high-speed fluid treatment, it may remain in the needle punched nonwoven fabric made of ultrafine fibers, but there are resins that are not easy to remove by high-speed fluid treatment. Any remaining material is removed prior to high speed fluid treatment to inhibit fiber entanglement. By such a method, the target needle punched nonwoven fabric can be obtained.

  Moreover, when using the fluid entangled nonwoven fabric obtained by this invention for the skin material of clothing materials and sheets, the woven or knitted fabric to be inserted into the nonwoven fabric A has a stretch property and can obtain an excellent fluid entangled nonwoven fabric. Is a composite fiber in which two or more different polyester polymers are bonded side-by-side along the fiber length direction, or a composite fiber in which two or more different polyester polymers are arranged in an eccentric core-sheath type It is comprised and it is preferable that the elongation rate of a length direction and a horizontal direction is 15 to 40%.

  Examples of the polyester polymer used herein include polymers such as polyethylene terephthalate, polytrimethylene terephthalate, and polybutylene terephthalate. Further, as the two or more different kinds of polyesters, it means that two or more kinds of polyesters having different physical and / or chemical properties are used. That is, two or more different types of polyesters joined to the side-by-side type or the eccentric core-sheath type means that two or more polyesters having different physical and / or chemical properties are side-by-side type or eccentric core along the fiber length direction. It means that it is joined to the sheath type. Thereby, the crimp of a coil shape can be expressed in a composite fiber by a physical or chemical factor. It is preferable to use two or more polyesters having different heat shrinkability in terms of easy crimp expression. Thereby, crimping can be easily expressed by relaxing the composite fiber in a hot water bath or the like. By developing crimps in the composite fiber, a high elongation rate can be obtained.

  Examples of polyesters having different heat shrinkability include those having different degrees of polymerization of polymers and blends of different polymers. In the present invention, in particular, a low-viscosity polyester having an intrinsic viscosity of 0.35 to 0.45 and a high-viscosity polyester having an intrinsic viscosity of 0.65 to 0.85 are obtained in that a leather-like sheet having excellent resilience is obtained. A composite fiber is preferable. In this case, in general, the high-viscosity polyester has higher heat shrinkability than the low-viscosity polyester. If the intrinsic viscosity of the low-viscosity polyester is less than 0.35, the spinning stability is lowered, which is not preferable. On the other hand, if the intrinsic viscosity of the low-viscosity polyester exceeds 0.45, the resilience of the leather-like sheet is lowered, which is not preferable. Further, if the intrinsic viscosity of the high-viscosity polyester exceeds 0.85, the spinning stability is lowered, which is not preferable. If the intrinsic viscosity of the high-viscosity polyester is less than 0.65, the heat shrinkability becomes close, so that the crimp expression of the composite fiber is weak and the stretchability and rebound of the leather-like sheet are lowered, which is not preferable.

  In order to obtain a leather-like sheet excellent in stretchability and resilience, the intrinsic viscosity difference between the low-viscosity polyester and the high-viscosity polyester is preferably in the range of 0.20 to 0.40.

  As the intrinsic viscosity [η], a value measured as an orthochlorophenol solution at a temperature of 25 ° C. was used.

  The composite ratio of two or more polyester polymers is high shrinkage component: low shrinkage component = 75 in terms of yarn uniformity and dimensional homogeneity of the coil in the fiber length direction when crimping is manifested. The range of 25-35: 65 (weight%) is preferable, and the range of 65: 35-45: 55 is more preferable.

  The composite form of the composite fiber may be either a side-by-side type or an eccentric core-sheath type, but the side-by-side type is preferable in that when the knitted or knitted fabric is crimped, a resilience is obtained in addition to the elongation rate.

  The average single fiber fineness of the composite fiber is not particularly limited, but is preferably 1 to 15 dtex. If it is less than 1 dtex, the fiber tends to break, and if it exceeds 15 dtex, it is not preferable because the texture tends to be hard when a fluid entangled nonwoven fabric is obtained.

  Moreover, in order to give a preferable feeling of wear and formability to the fluid entangled nonwoven fabric of the present invention, in the warp direction and the horizontal direction of the woven or knitted fabric using the above-described composite fiber, JIS L 1096 (1999) 8.14. It is preferable that the elongation rate prescribed | regulated by 1A method is 15 to 40%. When the elongation rate is less than 15%, the followability to the movement of the fluid entangled nonwoven fabric is insufficient. On the other hand, when the elongation rate exceeds 40%, the elongation is caused by process tension, and wrinkles are likely to occur.

  In order to obtain a woven or knitted fabric having an elongation ratio in the above-mentioned range, for example, a woven or knitted fabric is produced using a composite yarn that is twisted so that the twist coefficient K represented by the following formula 7 is 3500 to 15000. This can be achieved by relaxing the woven or knitted fabric in hot water and contracting it by about 30% in the vertical and horizontal directions to develop a crimped structure.

K = t × d ^0.5 (Expression 7)
Where K: twist coefficient
t: Number of twists per meter of yarn length (times)
d: Yarn fineness (decitex).

Further, the basis weight of such a woven or knitted fabric can be appropriately adjusted according to the use of the fluid entangled nonwoven fabric, but the basis weight of the woven or knitted fabric is preferably 30 g / m ² or more, and more preferably 50 g / m ² or more. It is more preferable. It is preferably 150 g / m ² or less, and more preferably 120 g / m ² or less. If the basis weight of the woven or knitted fabric is less than 30 g / m ² , it is difficult to sufficiently suppress the occurrence of elbow slipping or kneeling, and if the basis weight exceeds 150 g / m ² , the water permeability during high-speed fluid treatment decreases. This is not preferable because water tends to accumulate on the nonwoven fabric surface and wear resistance decreases.

  The weight ratio of the woven or knitted fabric is preferably 15% or more of the entire fluid entangled nonwoven fabric, and more preferably 20% or more. It is preferably 50% or less, and more preferably 40% or less. If the weight ratio is less than 15%, it is not preferable because it is difficult to obtain an effect of suppressing elbow slipping or kneeling. If the weight ratio exceeds 50%, the resulting fluid-entangled nonwoven fabric has a texture like a woven or knitted fabric. This is not preferable because it is difficult to obtain a feeling.

  Raising the fluid entangled nonwoven fabric obtained by performing the high-speed fluid treatment with the above-described configuration and conditions is preferable in that it can further reduce uneven streaks and provide a sheet having a raised feel. .

  The raising treatment is not particularly limited, but the surface of the dry nonwoven fabric is ground by sandpaper having a particle size of 400 to 1500 to raise the irregularities, thereby obtaining a more uniform surface. In addition, a suede-like or nubuck-like leather-like appearance and an excellent lighting effect can be obtained. When the particle size of the sandpaper used for the raising treatment is less than 400, the fibers are easily cut, and therefore, the length of the napping is long, the appearance is rough, and it is difficult to obtain a high-quality surface quality. The treatment with sandpaper having a particle size exceeding 1500 is not preferable because the fibers are hardly cut and the treatment efficiency is lowered. However, in the fluid entangled nonwoven fabric that deviates from the conditions of the present invention, uneven lines cannot be reduced even after grinding, and it becomes rough raised with a long raised length, and such an effect is obtained. Can not. That is, by using the fluid entangled nonwoven fabric of the present invention and raising the hair with sandpaper, an excellent effect of suppressing uneven stripes is exhibited.

  In addition, when raising the papermaking nonwoven fabric of the back side of a product surface, it is preferable to process by the grade which lightly rubs. It is not preferred that the surface of the nonwoven fabric is strongly raised because the fibers tend to fluff due to dyeing described later.

  Further, in the present invention, the uneven lines can be reduced by treating the fluid entangled nonwoven fabric with a liquid dyeing machine, that is, by sandwiching the fluid entangled nonwoven fabric with the liquid dyeing machine. By carrying out the stagnation treatment at 90 to 130 ° C. for 30 minutes or more with a liquid dyeing machine, it is possible to preferably reduce uneven stripes, and this effect can be usually obtained by treatment for 30 to 40 minutes. It is more preferable to perform a scouring process with a liquid dyeing machine after performing a raising process with sandpaper, because the effect of reducing uneven lines is obtained as compared with a single process.

  In addition, it is preferable to use the fluid-entangled nonwoven fabric obtained in the present invention as a leather-like sheet-like base fabric because it can obtain a nap-like or nubuck-like high-priced nap.

  The leather-like sheet-like material can be obtained by subjecting the above-described fluid entangled nonwoven fabric to napping with sandpaper and dyeing. The dyeing method is not particularly limited, and it can be dyed by a general method used for dyeing conventional artificial leather. However, the liquid dyeing machine is advantageous in that uneven lines are reduced and the texture is softened by the itch effect. It is preferable to dye with.

  The fluid entangled nonwoven fabric and leather-like sheet-like material of the present invention can be provided with functional agents such as a softening agent, an anti-pilling agent, an antistatic agent, a water absorbing agent, a water repellent, and an SR agent. This is preferable because it can improve the performance and wear resistance and can add functionality. The method for applying the drug is not particularly limited. For example, the drug can be applied by application in a bath of a liquid dyeing machine or by a pad / dry method.

  Hereinafter, the present invention will be described in more detail with reference to examples. In addition, the physical-property value in an Example was measured by the method described below.

(1) Measurement of average single fiber fineness and average fiber diameter The cross section of the fiber used for preparation of a nonwoven fabric and a woven / knitted fabric was observed with an optical microscope. 100 cross-sections of fibers were selected at random, and the cross-section was measured. The cross-sectional area of 100 fibers and the number average of fiber diameters were obtained. From the average value of the obtained fiber cross-sectional area and the specific gravity of the fiber, the average single fiber fineness was obtained by calculation. The specific gravity of the fibers was measured based on JIS L 1015 8.14.1 (1999). The obtained fiber diameter was defined as the average fiber diameter. In addition, for the fiber having an atypical cross section, the diameter of the fiber having a circular cross section having the same cross sectional area as the obtained cross sectional area was defined as the average fiber diameter of the atypical cross section.

(2) Fabric weight, density Fabric weight of nonwoven fabric and woven / knitted fabric was measured by the method described in JIS L 1096 8.4.2 (1999) and rounded off to one decimal place. The thickness was measured with a dial thickness gauge (manufactured by Ozaki Seisakusho, trade name “Peacock H”), and the density was determined by dividing the basis weight value by the thickness value.

(3) Aeration rate The aeration rate of the woven or knitted fabric was measured based on JIS L 1096 8.27.1 A method (1999) and rounded off to one decimal place.

(4) Measurement of average fiber length The sea-island type composite fiber used for the production of the dry nonwoven fabric was measured based on JIS L 1015 8.4.1 C method (1999), and the average fiber was calculated by rounding off the first decimal place. It was long.

(5) Elongation rate Measured based on JIS L 1096 (1999) 8.14.1 A method (grab interval 20 cm), rounded off to one decimal place.

(6) Concavity and convexity lines After raising and dyeing the product surface of the fluid entangled nonwoven fabric, the appearance of the product surface was visually evaluated in three stages of ◯ to ×. In addition, (circle)-* was determined by the following content.
◎: No uneven stripes and excellent surface uniformity ○: No uneven stripes △: Slightly uneven stripes ×: Strong uneven stripes (7) Abrasion resistance Dyeing by raising the product surface of fluid-entangled nonwoven fabric After the test, test specimens were collected according to JIS L 1096 (1999) 8.17.5 E method (Martindale method), and the product surface was rubbed with a load for clothing (9 kPa). The position of the Martindale abrasion tester was set at C (THREE DRIVE ROLLERS = POSITION C).

The abrasion resistance was evaluated by stopping the test machine after rubbing 20000 times, and evaluating the appearance of the product surface after the test in three stages of ○ to ×. O to X were determined based on the following contents.
○: “Excellent wear resistance”
No napped state change, 1 pilling or less, no knitted or knitted fabric exposed Δ: “Abrasion resistance is slightly inferior”
2 to 4 small pillings, no knitted or knitted fabric exposed x: "Wear resistance is poor"
With 5 or more pillings or woven / knitted fabric exposed.

(8) Followability After raising and dyeing the product surface of the fluid entangled nonwoven fabric, the elongation rate in the vertical and horizontal directions of the fluid entangled nonwoven fabric is measured based on JIS L 1096 (1999) 8.14.1 A method. (The distance between grips is 20 cm), and the first decimal place is rounded off.
The followability was evaluated from O to X based on the vertical and horizontal elongation rates of the fluid entangled nonwoven fabric. O to X were determined based on the following contents.
○: “Good trackability”
Those whose vertical and horizontal elongations are both 10% or more.
Δ: “Followability is normal”
Elongation rate in the vertical and horizontal directions is 5-9%. Or, one of the vertical and horizontal elongations is 10% or more and the other is 5 to 9%.
X: “Following ability”
Any one of the vertical and horizontal elongation rates is 4% or less.

Reference Example 1 (Production of papermaking nonwoven fabric)
A 0.3 decitex polyethylene terephthalate fiber was cut to a length of 0.5 cm (the aspect ratio was 962), and a papermaking nonwoven fabric of 30 g / m ² was obtained by a papermaking method.

Reference example 2 (production of knitted fabric 1)
A polymer component composed of polyethylene terephthalate having an intrinsic viscosity of 0.66 was spun and drawn to obtain a multifilament fiber yarn of 56 dtex 12 filaments. A plain tricot was produced from this fiber yarn with a 28-gauge tricot knitting machine to obtain a knitted fabric 1 having a basis weight of 70 g / m ² and an air flow rate of 400 cc / cm ² / sec or more.

Reference Example 3 (Production of woven fabric 1)
A polymer component composed of polyethylene terephthalate having an intrinsic viscosity of 0.66 was spun and drawn to obtain a multifilament fiber yarn of 60 dtex 12 filaments. This was additionally twisted at 600 T / m (twisting coefficient 4648) and steam set at 65 ° C. This yarn was used as warp yarn and weft yarn, and the woven structure was made into a plain weave and woven at a density of 94 × 64 / 2.54 cm. This fabric is scoured at 98 ° C. and then subjected to a relaxation treatment at 110 ° C. using a liquid dyeing machine. The weave density is 115 × 71 / 2.54 cm, the basis weight is 57 g / m ² , the air flow rate is 368 cc / cm ² / A sec woven fabric 1 was obtained.

Reference Example 4 (Production of Woven Fabric 2)
A low-viscosity component composed of polyethylene terephthalate having an intrinsic viscosity of 0.40 and a high-viscosity component composed of polyethylene terephthalate having an intrinsic viscosity of 0.75 are bonded side by side at a weight composite ratio of 50:50, and spun and stretched. A composite multifilament fiber yarn of decitex 12 filaments was obtained. This was additionally twisted at 1500 T / m (twisting coefficient 11225) and steam set at 65 ° C. This yarn was used as warp yarn and weft yarn, and the woven structure was made into a plain weave and woven at a density of 94 × 64 / 2.54 cm. This fabric is scoured at 98 ° C. and then subjected to a relaxation treatment at 110 ° C. using a liquid dyeing machine. The weave density is 122 × 87 pieces / 2.54 cm, the basis weight is 64 g / m ² , and the air flow rate is 330 cc / cm ^2. A fabric 2 of / sec was obtained.

Reference Example 5 (Production of woven fabric 3)
A polymer component composed of polyethylene terephthalate having an intrinsic viscosity of 0.66 was spun and drawn to obtain a multifilament fiber yarn of 165 dtex 36 filaments. This was additionally twisted at 600 T / m (twisting coefficient 7707) and steam set at 65 ° C. This yarn was used as warp yarn and weft yarn, and the woven structure was made into a plain weave and woven at a density of 94 × 64 / 2.54 cm. This fabric is scoured at 98 ° C. and then subjected to a relaxation treatment at 110 ° C. using a liquid dyeing machine. The weave density is 125 × 76 / 2.54 cm, the basis weight is 170 g / m ² , the air flow rate is 70 cc / cm ² / A sec woven fabric 3 was obtained.

Example 1
A web was prepared by passing sea island type composite short fibers having an average single fiber fineness of 3 dtex, 36 islands, and an average fiber length of 51 mm consisting of 45 parts of polystyrene as a sea component and 55 parts of polyethylene terephthalate as an island component through a card machine and a cross wrapper. . The obtained web was subjected to needle punching using a 1 barb type needle at a driving density of 3000 / cm ² to obtain a composite short fiber nonwoven fabric having an apparent fiber density of 0.199 g / cm ³ . The composite single fiber nonwoven fabric is immersed in an aqueous solution of polyvinyl alcohol (PVA) 12% with a polymerization degree of 500 and a saponification degree of 88% heated to 95 ° C. for 2 minutes. At the same time, the shrinkage treatment was performed. Thereafter, the nonwoven fabric was dried at 100 ° C. to remove moisture. Next, this composite short fiber nonwoven fabric was treated with trichlorethylene until the polystyrene was completely removed, thereby expressing ultrafine fibers (aspect ratio: 25198) having an average single fiber fineness of 0.046 dtex from the composite short fibers. The ultra-fine short fiber nonwoven fabric obtained in this manner was split into two pieces perpendicular to the thickness direction using a standard splitting machine manufactured by Murota Manufacturing Co., Ltd., and the basis weight was 105 g / m ² and the density was 0. An ultrafine fiber nonwoven fabric having a weight of only 260 g / cm ³ (medium weight of only ultrafine fibers 90 g / m ² , density 0.227 g / cm ³ ) was obtained. In addition, when polyvinyl alcohol adhering to this ultrafine fiber nonwoven fabric was removed and the elongation rate was measured, the vertical direction was 6% and the horizontal direction was 28%.

  The knitted fabric 1 produced in Reference Example 2 is stacked between the ultrafine fiber nonwoven fabric and the paper-made nonwoven fabric produced in Reference Example 1, and water flow is sprayed from the head arrangement equipped with the nozzles shown in Table 1 at a processing speed of 7 m / min. Water jet punching was performed from the fiber nonwoven fabric surface (in this case, the number of heads corresponds to the number of high-speed fluid treatments, and the head number represents the number of high-speed fluid treatments, the same applies hereinafter). In the treatment from the surface of the ultrafine fiber nonwoven fabric, the power of water flow per nozzle hole was 34.2 W and 11.4 W, and a total of 2.15 kWh / kg / m of energy was applied.

  Next, the film was turned over, and a water flow was jetted from a head arrangement equipped with the nozzles shown in Table 2, and water jet punching was performed from the surface of the paper-made nonwoven fabric at a processing speed of 7 m / min. In the treatment from the surface of the paper-made nonwoven fabric, the water flow power per nozzle hole was 11.4 W, and a total energy of 2.47 kWh / kg / m was applied.

  When the ultrafine fiber nonwoven fabric surface of the fluid entangled nonwoven fabric obtained in this way was observed, there were no uneven stripes. Moreover, it was excellent in wear resistance and poor in followability.

Example 2
The ultra-fine nonwoven fabric surface of the fluid entangled nonwoven fabric obtained in Example 1 was polished with sandpaper having a particle size of 600, and the paper-made nonwoven fabric surface was applied to the sandpaper having a particle size of 600 and rubbed to perform raising treatment. After brushing treatment, it was dyed with a liquid dyeing machine at 120 ° C for 45 minutes at a concentration of 20% owf using "Sumikaron Blue S-BBL200" (manufactured by Sumika Chemtex Co., Ltd.). A high-quality leather-like sheet having a uniform surface and short-napped nubuck-like appearance was obtained.

  The surface of the ultrafine nonwoven fabric of the sheet had no uneven stripes, and the surface was excellent in uniformity compared to the fluid entangled nonwoven fabric obtained in Example 1. Further, the sheet was squeezed by dyeing, so that the texture became soft, the followability had ordinary performance, and was excellent in wear resistance.

Example 3
Using the dyed leather-like sheet-like material of Example 2, a softening agent ("ELSOFT N-500 Conch" manufactured by One Company Ltd.), an anti-pilling agent (New Size CM-480, manufactured by One Company Ltd.) Then, it was immersed in an aqueous solution containing an antistatic agent (“Nicepol FL”, manufactured by Nikka Chemical Co., Ltd.), squeezed, and dried at 100 ° C. to give a functional agent. The leather-like sheet material thus obtained had a softer texture than that of Example 2 and had the same performance in terms of wear resistance and follow-up performance.

Example 4
The papermaking nonwoven fabric produced in Reference Example 1 was layered on the knitted fabric 1 produced in Reference Example 2, and water flow was jetted from the head arrangement equipped with the nozzles shown in Table 3, and the waterjet was applied from the surface of the papermaking nonwoven fabric at a processing speed of 7 m / min. Punched. In this treatment, a total energy of 0.43 kWh / kg / m was applied.

  Subsequently, drying was performed to prepare a sheet in which the knitted fabric and the papermaking nonwoven fabric were intertwined and integrated. The sheet was placed on the side on which the papermaking nonwoven fabric was placed and the ultrafine fiber nonwoven fabric produced in Example 1 was stacked thereon to obtain a fluid entangled nonwoven fabric. In that case, there was no problem in the process by using the sheet | seat with which the papermaking nonwoven fabric and the knitted fabric were integrated. This was processed in the same manner as in Example 2 to obtain a leather-like sheet. When this sheet was evaluated, it had the same appearance, wear resistance and follow-up properties as those of Example 2.

Example 5
Superfine fiber nonwoven fabric is laminated on a sheet in which knitted fabric and papermaking nonwoven fabric are integrated in the same manner as in Example 4, and water flow is sprayed from the head arrangement equipped with the nozzles shown in Table 4 at a processing speed of 7 m / min. Were subjected to water jet punching. By the treatment from the surface of the ultrafine fiber nonwoven fabric, the work rate of water flow per nozzle hole is 23.8 W for a nozzle having a hole diameter of 0.1 mm, and 11.4 W for a nozzle having a 0.08 mm, a total of 2.26 kWh / kg / An energy of m was applied. Next, the film was turned upside down, and a water flow was sprayed from a head arrangement equipped with the nozzles shown in Table 5, and water jet punching was performed once from the surface of the paper-made nonwoven fabric at a processing speed of 7 m / min. In the treatment from the surface of the paper-made nonwoven fabric, the power of the water flow per nozzle hole was 11.4 W and 4.9 W, and a total energy of 2.01 kWh / kg / m was applied.

After the obtained fluid entangled nonwoven fabric was dried, the same brushing treatment and dyeing as in Example 2 were performed, and then the same functional drug as in Example 3 was applied.
As a result, a high-quality leather-like sheet-like material having no uneven stripes on the surface of the ultrafine nonwoven fabric, a uniform surface, and a short-napped nubuck-like appearance was obtained. Further, the texture was soft and excellent in wear resistance, and the followability had ordinary performance.

Example 6
A leather-like sheet was obtained in the same manner as in Examples 1 and 2, except that the woven or knitted fabric used was changed to the woven fabric 1 produced in Reference Example 3. The energy applied by the water jet punch was 2.12 kWh / kg / m and 2.64 kWh / kg / m from the non-woven fabric surface in the treatment from the ultrafine fiber nonwoven fabric surface. The leather-like sheet-like material thus obtained had normal followability, and was excellent in wear resistance and appearance as well as the fluid-entangled nonwoven fabric obtained in Example 2.

Example 7
A leather-like sheet was obtained in the same manner as in Examples 1 and 2 except that the woven or knitted fabric used was changed to the woven fabric 2 produced in Reference Example 4. The energy applied by the water jet punch was 2.05 kWh / kg / m in the treatment from the ultrafine fiber nonwoven fabric surface and 2.55 kWh / kg / m from the papermaking nonwoven fabric surface. The leather-like sheet material thus obtained was excellent in followability, and the wear resistance and appearance were as excellent as the fluid-entangled nonwoven fabric obtained in Example 2.

Comparative Example 1
The papermaking nonwoven fabric prepared in Reference Example 1 was layered on both sides of the knitted fabric 1 prepared in Reference Example 2, and water flow was sprayed from the head arrangement equipped with the nozzles shown in Table 6 from the front side of the papermaking nonwoven fabric, and extremely fine at a processing speed of 7 m / min. Water jet punching was performed from the fiber nonwoven fabric surface. In this treatment, the work rate of the water flow per nozzle hole was 7.7 W, and a total energy of 0.7 kWh / kg / m was applied.

  Next, the film was turned over, and a water flow was jetted from a head arrangement equipped with nozzles shown in Table 7, and water jet punching was performed from the surface of the paper-made nonwoven fabric at a processing speed of 7 m / min. In this treatment, the energy of the water flow per nozzle hole was 6.9 W, and a total of 1.88 kWh / kg / m of energy was applied.

  After the fluid entangled nonwoven fabric obtained in this manner was dried, the papermaking nonwoven fabric on both the front and back surfaces was applied to sandpaper having a particle size of 600 and rubbed to perform a raising treatment. After the brushing treatment, it was dyed with a liquid dyeing machine at 120 ° C. for 45 minutes at a concentration of 20% owf using “Sumikaron Blue S-BBL200” (manufactured by Sumika Chemtex Co., Ltd.). Thereby, although the fluid entangled nonwoven fabric without an uneven | corrugated streak on the surface of a papermaking nonwoven fabric was obtained, it was inferior to abrasion resistance.

Comparative Example 2
When water jet punching was performed from the surface of the ultrafine fiber nonwoven fabric, processing was performed in the same manner as in Example 1 and Example 2 except that the head arrangement was changed to the nozzle shown in Table 8. In the water jet punch treatment from the surface of the ultrafine fiber nonwoven fabric, the work flow rate of the water flow per nozzle hole was 6.9 W, and a total energy of 1.19 kWh / kg / m was applied. The leather-like sheet thus obtained did not have uneven stripes on the surface of the ultra-thin nonwoven fabric, but was inferior in wear resistance, and the same wear resistance as in Example 2 was not obtained.

Comparative Example 3
When the same functional chemical as in Example 3 was applied to the leather-like sheet obtained in Comparative Example 2, the abrasion resistance was improved as compared with Comparative Example 1, but the abrasion resistance was inferior.

Comparative Example 4
When water jet punching was performed from the surface of the papermaking nonwoven fabric, processing was performed in the same manner as in Example 1 and Example 2 except that a water flow was ejected from the head arrangement equipped with the nozzles shown in Table 9. In the water jet punch treatment from the paper-made nonwoven fabric surface, the water flow work per nozzle hole was 34.2 W and 23.8 W, respectively, and energy of 1.6 kWh / kg / m in total was applied. The leather-like sheet-like material thus obtained had strong irregularities on the surface of the ultra-fine nonwoven fabric, and the surface quality was extremely inferior.

Comparative Example 5
When water jet punching was performed from the surface of the paper-made nonwoven fabric, processing was performed in the same manner as in Example 1 and Example 2 except that a water flow was ejected from the head arrangement equipped with the nozzles shown in Table 10. In the water jet punch treatment from the paper-made nonwoven fabric surface, the work rate of the water flow per nozzle hole was 2.4 W, and a total energy of 0.4 kWh / kg / m was applied. The leather-like sheet-like material obtained in this way was strong on the surface of the ultra-thin nonwoven fabric and had poor surface quality.

Comparative Example 6
When water jet punching was performed from the surface of the papermaking nonwoven fabric, processing was performed in the same manner as in Example 1 and Example 2 except that a water flow was ejected from the head arrangement equipped with the nozzles shown in Table 11. In the water jet punch treatment from the surface of the paper-made nonwoven fabric, the work rate of the water flow per nozzle hole was 39.6 W, and a total energy of 1.15 kWh / kg / m was applied. The leather-like sheet-like material obtained in this way has strong irregularities on the surface of the ultra-fine nonwoven fabric and has poor surface quality.

The physical properties of Examples 1 to 6 and Comparative Examples 1 to 6 are shown in Table 12 and Table 13.

  ADVANTAGE OF THE INVENTION According to this invention, the fluid entangled nonwoven fabric which has a uniform surface which can be used suitably for the base fabric of artificial leather can be provided, and uses, such as a clothing material, the skin material of a car seat, furniture, miscellaneous goods, etc. Can be suitably used.

It is a figure which shows the nozzle pitch in case a nozzle head is arrange | positioned in parallel with a sheet | seat, (A) is the figure seen from the advancing direction of a sheet | seat, (B) is the figure seen from right above. It is a figure which shows the nozzle pitch in case a nozzle head is arrange | positioned with an angle to a sheet | seat, (A) is the figure seen from the advancing direction of a sheet | seat, (B) is the figure seen from right above.

Explanation of symbols

1: Sheet 2: Nozzle 3: Nozzle hole 4: Nozzle head 5: Water column R: Nozzle pitch

Claims (9)

In the high-speed fluid treatment of the fluid entangled nonwoven fabric, from the front side of the nonwoven fabric A, the fluid power per hole of the nozzle is 10 W or more and high-speed fluid treatment is performed at least twice, and the pore diameter is 0.05 from the back side of the nonwoven fabric A. A fluid entangled nonwoven fabric characterized in that high-speed fluid treatment is performed at least twice at a work rate of fluid per hole of the nozzle of 4 to 35 W using a nozzle having a cover factor of 25 or more with a 0.1 to 0.14 mm Production method. The total energy applied by the high-speed fluid treatment from the front side of the nonwoven fabric A is 1.5 kWh / kg / m or more, and the total energy applied by the high-speed fluid treatment from the back side of the nonwoven fabric A is 0.8-3. It is 0.5 kWh / kg / m, The manufacturing method of the fluid entangled nonwoven fabric of Claim 1 characterized by the above-mentioned. The nonwoven fabric A is a dry nonwoven fabric composed of ultrafine fibers having an average single fiber fineness of 0.001 to 0.5 dtex on the front side, and a basis weight of 30 to 150 g / m ² and an air flow rate of 150 cc / cm ² / sec. The fluid entangled nonwoven fabric according to claim 1 or 2, wherein the woven or knitted fabric is a nonwoven fabric having a paper-made nonwoven fabric composed of ultrafine fibers having an average single fiber fineness of 0.1 to 0.5 dtex on the back side. Manufacturing method. The nonwoven fabric A has a papermaking nonwoven fabric disposed on one side of a woven or knitted fabric, and the total energy applied is 0.05 to 2.0 kWh / kg / m using a nozzle having a pore diameter of 0.05 to 0.14 mm. The hydroentangled nonwoven fabric according to any one of claims 1 to 3, wherein the fluid-entangled nonwoven fabric according to any one of claims 1 to 3 is obtained by superimposing a dry nonwoven fabric on the opposite surface of the woven or knitted fabric after high-speed fluid treatment from the surface of the paper-woven nonwoven fabric. Production method. The method for producing a fluid-entangled nonwoven fabric according to claim 3 or 4, wherein the dry nonwoven fabric is a dry nonwoven fabric that satisfies the following conditions (1) to (5).
(1) It is produced by the needle punch method.
(2) It is an ultrafine fiber having an average fiber length to average fiber diameter ratio (aspect ratio) of 6500 to 220,000.
(3) The basis weight is 30 to 200 g / m ² .
(4) The density is 0.2 to 0.3 g / cm ³ .
(5) The elongation rate is 3% or more. The method for producing a fluid entangled nonwoven fabric according to any one of claims 3 to 5, wherein the woven or knitted fabric is a woven or knitted fabric satisfying the following conditions (i) and (ii).
(I) The different type polyester polymer is constituted by a composite fiber arranged in a side-by-side type or an eccentric core-sheath type.
(Ii) The elongation in the vertical direction and the horizontal direction is 15 to 40%. The method for producing a fluid entangled nonwoven fabric according to any one of claims 1 to 6, wherein the fluid entangled nonwoven fabric is brushed with sandpaper having a particle size of 400 to 1500. Furthermore, the fluid entangled nonwoven fabric is processed by a liquid dyeing machine, The method for producing a fluid entangled nonwoven fabric according to any one of claims 1 to 7. Method for producing a leather-like sheet, which comprises using a fluid entangling the nonwoven fabric obtained by the method of any of the fluid entangling the nonwoven fabric of claims 1 to 8 as a base fabric.

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