JP5063360B2 - エンボス加工された不織繊維 - Google Patents
エンボス加工された不織繊維 Download PDFInfo
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- D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
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- D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
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Description
ここで使用されている「機械方向」とは、不織布を形成する間に、繊維が堆積された成形表面が移動する方向を指す。
B. A. Wendt, E. L. Boone, D. D. Fluharty著「Manufacture of Super-Fine Organic Fibers」NRL Report 4364 K.D. Lawrence, R. T. Lukas, J. A. Young著「An Improved Device For The Formation of Super-Fine Thermoplastic Fibers」NRL Report 5265
高パルプ含有水圧交絡不織複合繊維は、特許文献1に記載のプロセスに従って製造された。材料は、ポリプロピレンのスパンボンド繊維の0.75osyのウエブ上にパルプ層を重ねることによって製造した。スパンボンド材料は、図3に示されるような「ワイヤー模様」パターンとして技術的に一般に知られているパターンを有した。パターンの接着面積は約15%乃至約21%であり、1平方インチ当たり約308個所の接着点を有した。パルプ層は、約50重量%の北部針葉樹クラフトパルプと、約50重量%の南部針葉樹クラフトパルプとの混合物であった。材料は、ヤンキークレープ加工されていた。結果生成された水圧交絡複合繊維の坪量は116gsmであった。
例1の材料を、エンボス加工プロセスのパイロットラインに設けられたエンボス加工ギャップを通過させた。エンボス加工プロセスは、鋼鉄製かつ呼び径8インチ(203mm)の一組の一致したエンボスロールによって行われた。エンボスロールは、内部で195°F(90.6℃)に加熱された循環オイルによって加熱されていた。エンボスロールのエンボス加工パターンは、図7に示すものと同様であって、ピン高さは0.072インチ(1.8mm)であり、ポケット深さは0.072インチ(1.8mm)であった。例1の材料は、エンボスロールの前であって隣接した位置に設けられた赤外線加熱装置に材料を通過させることによって加熱された。材料がエンボス加工ギャップに入る前に加熱するべく、循環エアと、ウエブから約3インチ(76mm)の所に配置された中赤外線を発する2つのプラテンとが加熱装置で使用された。
例1の材料を、例2について記載したものと同様のパイロットプロセスを通過させた。エンボスロールのエンボス加工パターンは、図7に示すものと同様であって、ピン高さは0.072インチ(1.8mm)であり、ポケット深さは0.072インチ(1.8mm)であった。エンボス加工ギャップに入る材料は、表面温度が183°F(83.4℃)に加熱された。温度はエンボス加工ギャップに入る直前の材料表面に向けられたガンタイプの赤外放射計に測定された。一致したエンボスロールのギャップは0.030インチ(0.76mm)に設定された。材料は、135fpm(41m/分)の速度でエンボス加工ギャップに送られた。
例1の材料を、例2について記載したものと同様のパイロットプロセスを通過させた。エンボスロールのエンボス加工パターンは、図7に示すものと同様であって、ピン高さは0.072インチ(1.8mm)であり、ポケット深さは0.072インチ(1.8mm)であった。エンボス加工ギャップに入る材料は、表面温度が182°F(83.3℃)に加熱された。温度はエンボス加工ギャップに入る直前の材料表面に向けられたガンタイプの赤外放射計に測定された。一致したエンボスロールのギャップは0.025インチ(0.64mm)に設定された。材料は、110fpm(34m/分)の速度でエンボス加工ギャップに送られた。
例1のものと同様の材料を、例2について記載したものと同様のエンボス加工プロセスを通過させた。エンボスロールのエンボス加工パターンは、図7に示すものと同様であって、ピン高さは0.072インチ(1.8mm)であり、ポケット深さは0.072インチ(1.8mm)であった。エンボス加工ギャップに入る材料は、表面温度が175°F(79.4℃)に加熱された。温度はエンボス加工ギャップに入る直前の材料表面に向けられたガンタイプの赤外放射計に測定された。一致したエンボスロールのギャップは0.035インチ(0.89mm)に設定された。材料は、450fpm(140m/分)の速度でエンボス加工ギャップに送られた。
材料は、クレープ加工されていないことを除いて例1のものと同様に製造された。材料の坪量は、115gsmであった。結果生成した材料の湿潤パターン明瞭度を評価し、質的湿潤パターン明瞭度は0であることを確認した。更に、WCRR試験を材料について実施し、WCRRは0.070であることを確認した。図13は、例6の材料に対するWCRR試験についてのプロットを示している。
材料は、ヤンキークレープ加工されていることを除いて例6のものと同様に製造された。材料の坪量は、116gsmであった。結果生成した材料の湿潤パターン明瞭度を評価し、質的湿潤パターン明瞭度は0であることを確認した。
例7の材料を、例2で記載したものと同様のエンボス加工プロセスを通過させた。エンボスロールのエンボス加工パターンは、図7に示すものと同様であって、ピン高さは0.072インチ(1.8mm)であり、ポケット深さは0.072インチ(1.8mm)であった。エンボス加工ギャップに入る材料は、表面温度が166°F(74.4℃)に加熱された。温度はエンボス加工ギャップに入る直前の材料表面に向けられたガンタイプの赤外放射計に測定された。一致したエンボスロールのギャップは0.021インチ(0.53mm)に設定された。材料は、200fpm(61m/分)の速度でエンボス加工ギャップに送られた。
例6の材料を、例2で記載したものと同様のエンボス加工プロセスを通過させた。エンボスロールのエンボス加工パターンは、図7に示すものと同様であって、ピン高さは0.060インチ(1.5mm)であり、ポケット深さは0.072インチ(1.8mm)であった。
例6の材料を、例9で記載したものと同様のエンボス加工プロセスを通過させた。エンボスロールのエンボス加工パターンは、図7に示すものと同様であって、ピン高さは0.060インチ(1.5mm)であり、ポケット深さは0.072インチ(1.8mm)であった。エンボス加工ギャップに入る材料は、表面温度が177°F(80.6℃)に加熱された。温度はエンボス加工ギャップに入る直前の材料表面に向けられたガンタイプの赤外放射計に測定された。一致したエンボスロールのギャップは0.034インチ(0.86mm)に設定された。材料は、140fpm(43m/分)の速度でエンボス加工ギャップに送られた。
例6の材料を、例9で記載したものと同様のエンボス加工プロセスを通過させた。エンボスロールのエンボス加工パターンは、図7に示すものと同様であって、ピン高さは0.060インチ(1.5mm)であり、ポケット深さは0.072インチ(1.8mm)であった。エンボス加工ギャップに入る材料は、表面温度が185°F(85℃)に加熱された。温度はエンボス加工ギャップに入る直前の材料表面に向けられたガンタイプの赤外放射計に測定された。一致したエンボスロールのギャップは0.028インチ(0.71mm)に設定された。材料は、110fpm(34m/分)の速度でエンボス加工ギャップに送られた。
比較例12乃至19は、WCRRに対する試験であり、結果を表1に示す。
より軽量な高パルプ含有の水圧交絡不織複合繊維が、特許文献1に記載のプロセスによって製造された。材料は、ポリプロピレンスパンボンド繊維の0.35osyのウエブ上にパルプ層を重ねることによって製造した。スパンボンド材料は、図3に示されるような「ワイヤー模様」パターンとして技術的に一般に知られているパターンを有した。パターンの接着面積は約15%乃至約21%であり、1平方インチ当たり約308個所の接着点を有した。パルプ層は、約50重量%の北部針葉樹クラフトパルプと、約50重量%の南部針葉樹クラフトパルプとの混合物であった。材料は、ヤンキークレープ加工されていた。結果生成された水圧交絡複合繊維の坪量は45gsmであった。
より軽量な高パルプ含有の水圧交絡不織複合繊維は、例20の材料と同様に製造されたが、結果生成された水圧交絡複合繊維の坪量は54gsmであった。
エンボス加工されていない、例21の基となる材料を、異なるエンボス加工条件の下で、エンボス加工プロセスを通過させた。エンボスロールのエンボス加工パターンは、図7に示すものと同様であって、ピン高さは0.072インチ(1.8mm)であり、ポケット深さは0.072インチ(1.8mm)であった。エンボス加工ギャップに入る材料は、表面温度が167°F(75℃)に加熱された。温度はエンボス加工ギャップに入る直前の材料表面に向けられたガンタイプの赤外放射計に測定された。一致したエンボスロールのギャップは0.024インチ(0.61mm)に設定された。材料は、200fpm(61m/分)の速度でエンボス加工ギャップに送られた。
より軽量な高パルプ含有の水圧交絡不織複合繊維を例20の材料と同様に製造したが、結果生成された水圧交絡複合繊維の坪量は64gsmであった。
エンボス加工されていない、例23の基となる材料を、異なるエンボス加工条件の下で、エンボス加工プロセスを通過させた。エンボスロールのエンボス加工パターンは、図7に示すものと同様であって、ピン高さは0.072インチ(1.8mm)であり、ポケット深さは0.072インチ(1.8mm)であった。エンボス加工ギャップに入る材料は、表面温度が150°F(65.6℃)に加熱された。温度はエンボス加工ギャップに入る直前の材料表面に向けられたガンタイプの赤外放射計に測定された。一致したエンボスロールのギャップは0.022インチ(0.56mm)に設定された。材料は、150fpm(46m/分)の速度でエンボス加工ギャップに送られた。
Claims (11)
- 不織要素と、繊維を含む繊維性要素とを有し、エンボス加工がなされ、水圧によって交絡された不織複合繊維を製造する方法であって、
繊維性材料層を不織繊維ウエブ層の上に重ね合わせるステップと、
複合材料を形成するために前記両層を水圧によって交絡するステップと、
前記複合材料を乾燥するステップと、
前記複合材料の表面を60℃以上の第1の温度に加熱して、加熱された複合材料を形成するステップと、
前記複合材料を一組の第2の温度に加熱されたエンボスロールによって形成されたエンボス加工ギャップにおいてエンボス加工するステップとを含み、
前記第2の温度は、前記不織複合繊維の湿潤圧縮反発率が0.13以上となるように、前記第1の温度に近づけられ、
前記複合材料を前記第1の温度に加熱するために前記エンボスロールと別個の装置が設けられていることを特徴とする製造方法。 - 前記複合材料を前記エンボス加工ギャップにおいてエンボス加工する前に、前記複合材料の表面は93℃以上に加熱されることを特徴とする請求項1に記載の製造方法。
- 前記複合材料を前記エンボス加工ギャップにおいてエンボス加工する前に、前記複合材料の表面は149℃以上に加熱されることを特徴とする請求項2に記載の製造方法。
- 前記両層は、乾式成形または湿式成形により、繊維の懸濁液を含む繊維性材料層を連続フィラメントの不織繊維ウエブ層の上に堆積させることにより重ね合わされることを特徴とする請求項1に記載の製造方法。
- 前記繊維性材料層は、連続スパンボンドフィラメントの不織繊維ウエブ層の上に重ね合わされることを特徴とする請求項1に記載の製造方法。
- 水圧によって交絡する前の前記両層に、クレー、活性炭、でんぷん、粒状物質及び超吸収粒状物質からなる群から選ばれる物質を加えるステップを更に有することを特徴とする請求項1に記載の製造方法。
- 重ね合わされ、水圧によって交絡された前記複合材料にクレー、活性炭、でんぷん、粒状物質及び超吸収粒状物質からなる群から選ばれる物質を加えるステップを更に有することを特徴とする請求項1に記載の製造方法。
- 前記繊維性材料層を前記連続スパンボンドフィラメントの前記不織繊維ウエブ層の上に形成するべく使用された前記繊維の懸濁液にクレー、活性炭、でんぷん、粒状物質及び超吸収粒状物質からなる群から選ばれる物質を加えるステップを更に有することを特徴とする請求項5に記載の製造方法。
- 前記水圧によって交絡された不織複合繊維は、機械的な軟化処理、圧縮処理、クレープ加工処理及びブラッシング処理からなる群から選ばれる最終ステップの処理を受けることを特徴とする請求項1に記載の製造方法。
- 前記水圧によって交絡された不織複合繊維は、染色及び接着から選択される化学的な後処理を受けることを特徴とする請求項1に記載の製造方法。
- 前記複合材料の加熱が該複合材料の乾燥後に行われ、前記加熱は、付加的な熱源により行われることを特徴とする請求項1に記載の製造方法。
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BRPI0516613B8 (pt) | 2020-09-01 |
BRPI0516613A (pt) | 2008-09-16 |
AU2005317061A1 (en) | 2006-06-22 |
KR20070086120A (ko) | 2007-08-27 |
ZA200702689B (en) | 2008-08-27 |
WO2006065315A1 (en) | 2006-06-22 |
JP2008523263A (ja) | 2008-07-03 |
MX2007007126A (es) | 2007-07-13 |
RU2007121926A (ru) | 2009-01-27 |
KR101262398B1 (ko) | 2013-05-09 |
BRPI0516613B1 (pt) | 2020-08-11 |
IL182217A0 (en) | 2007-09-20 |
AU2005317061B2 (en) | 2011-08-11 |
CN101076630B (zh) | 2010-05-05 |
CA2583814A1 (en) | 2006-06-22 |
EP1825048B1 (en) | 2012-09-19 |
CN101076630A (zh) | 2007-11-21 |
US20060128247A1 (en) | 2006-06-15 |
RU2392363C2 (ru) | 2010-06-20 |
EP1825048A1 (en) | 2007-08-29 |
US8425729B2 (en) | 2013-04-23 |
CA2583814C (en) | 2014-02-11 |
CR9061A (es) | 2007-12-04 |
US20090123707A1 (en) | 2009-05-14 |
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