JP6375781B2 - Cushioned fiber molded body and product obtained using the same - Google Patents
Cushioned fiber molded body and product obtained using the same Download PDFInfo
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- JP6375781B2 JP6375781B2 JP2014174719A JP2014174719A JP6375781B2 JP 6375781 B2 JP6375781 B2 JP 6375781B2 JP 2014174719 A JP2014174719 A JP 2014174719A JP 2014174719 A JP2014174719 A JP 2014174719A JP 6375781 B2 JP6375781 B2 JP 6375781B2
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- 239000000835 fiber Substances 0.000 title claims description 278
- 238000000034 method Methods 0.000 claims description 27
- 239000002131 composite material Substances 0.000 claims description 24
- -1 polyethylene Polymers 0.000 claims description 16
- 230000037303 wrinkles Effects 0.000 claims description 15
- 238000004519 manufacturing process Methods 0.000 claims description 13
- 239000004698 Polyethylene Substances 0.000 claims description 6
- 229920000573 polyethylene Polymers 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 5
- 229920000728 polyester Polymers 0.000 claims description 3
- 238000007789 sealing Methods 0.000 claims description 3
- 238000002844 melting Methods 0.000 description 32
- 230000008018 melting Effects 0.000 description 30
- 238000011156 evaluation Methods 0.000 description 11
- 230000006835 compression Effects 0.000 description 10
- 238000007906 compression Methods 0.000 description 10
- 229920000139 polyethylene terephthalate Polymers 0.000 description 10
- 239000005020 polyethylene terephthalate Substances 0.000 description 10
- 229920001903 high density polyethylene Polymers 0.000 description 8
- 239000004700 high-density polyethylene Substances 0.000 description 8
- 239000004745 nonwoven fabric Substances 0.000 description 8
- 229920001577 copolymer Polymers 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 3
- 239000005977 Ethylene Substances 0.000 description 3
- 239000004743 Polypropylene Substances 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- 230000004927 fusion Effects 0.000 description 3
- 238000009413 insulation Methods 0.000 description 3
- 229920005606 polypropylene copolymer Polymers 0.000 description 3
- 229920005629 polypropylene homopolymer Polymers 0.000 description 3
- 150000001336 alkenes Chemical class 0.000 description 2
- 239000011810 insulating material Substances 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 240000007594 Oryza sativa Species 0.000 description 1
- 235000007164 Oryza sativa Nutrition 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920005638 polyethylene monopolymer Polymers 0.000 description 1
- 238000003672 processing method Methods 0.000 description 1
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 1
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 235000009566 rice Nutrition 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
- D04H3/05—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in another pattern, e.g. zig-zag, sinusoidal
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/005—Synthetic yarns or filaments
- D04H3/007—Addition polymers
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/005—Synthetic yarns or filaments
- D04H3/009—Condensation or reaction polymers
- D04H3/011—Polyesters
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
- D04H3/04—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
- D04H3/147—Composite yarns or filaments
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
- D06C23/00—Making patterns or designs on fabrics
- D06C23/04—Making patterns or designs on fabrics by shrinking, embossing, moiréing, or crêping
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06J—PLEATING, KILTING OR GOFFERING TEXTILE FABRICS OR WEARING APPAREL
- D06J1/00—Pleating, kilting or goffering textile fabrics or wearing apparel
- D06J1/12—Forms of pleats or the like
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Nonwoven Fabrics (AREA)
Description
本発明は、クッション性を有する繊維成形体及びそれを用いた製品に関する。 The present invention relates to a fiber molded body having cushioning properties and a product using the same.
クッション材に用いられる繊維成形体は、通常、カードウェブをクロスレイヤー等で積層し、ニードルパンチ法にて得られるニードルパンチ不織布である。ニードルパンチ不繊布は、複数のニードルにて、ウェブ中の繊維同士を絡ませながら絞めつけることで得られる不織布である。この方法で得られるニードルパンチ不織布は、一般に不織布中の繊維の自由度が低く、空隙が少なく、さらに厚みが低くなる傾向があることから、どうしてもクッション性、保温性、遮音性が低くなってしまう。
他の製造方法で得られる繊維成形体としては、短繊維をカード法にてウェブとした後、折り畳み成形により得られる不繊布が挙げられる(例えば、特許文献1参照。)。ここでいう「折り畳み成形」とは、ウェブをプリーツ加工等によりウェブのMD方向に折り畳まれた状態にすることである。しかし、この方法で得られる不織布は、クッション性には優れるものの、短繊維から構成されるため、圧縮を繰り返した場合に毛羽立ちやリントが発生し、繰り返し圧縮の耐久性に劣ってしまうという問題がある。
The fiber molded body used for the cushion material is usually a needle punched nonwoven fabric obtained by laminating a card web with a cross layer or the like and obtained by a needle punch method. The needle punched non-woven fabric is a nonwoven fabric obtained by squeezing while entwining fibers in a web with a plurality of needles. Needle punched nonwoven fabrics obtained by this method generally have a low degree of freedom of fibers in the nonwoven fabric, less voids, and tend to have a lower thickness, which inevitably decreases cushioning, heat retention, and sound insulation. .
Examples of the fiber molded body obtained by other production methods include a non-woven fabric obtained by folding a short fiber into a web by a card method (see, for example, Patent Document 1). Here, “folding” means that the web is folded in the MD direction of the web by pleating or the like. However, although the nonwoven fabric obtained by this method is excellent in cushioning properties, it is composed of short fibers, so that when it is repeatedly compressed, fuzz and lint are generated, and the durability of repeated compression is inferior. is there.
そこで、本発明の課題は、繰り返し圧縮の耐久性に優れ、かつ、柔軟性、クッション性およびその耐久性(耐久クッション性)に優れる繊維成形体を提供することである。 Then, the subject of this invention is providing the fiber molded object which is excellent in durability of repeated compression, and is excellent in a softness | flexibility, cushioning property, and its durability (durable cushioning property).
本発明者らは、前記課題を解決するため鋭意検討を重ねた。その結果、捲縮を有し一方向に延びている連続繊維の束を開繊してなる繊維層を用いて、特定の構造の繊維成形体とすることにより、繰り返し圧縮の耐久性に優れ、さらにクッション性、柔軟性に優れる繊維成形体が得られることを見出し、この知見に基づいて本発明を完成するに至った。 The inventors of the present invention have made extensive studies in order to solve the above problems. As a result, by using a fiber layer formed by opening a bundle of continuous fibers having crimps and extending in one direction, it is excellent in durability of repeated compression by forming a fiber molded body of a specific structure, Furthermore, it discovered that the fiber molding excellent in cushioning property and a softness | flexibility was obtained, and came to complete this invention based on this knowledge.
本発明は、以下の構成を有する。
〔1〕捲縮を有し一方向に延びている連続繊維の束を開繊してなる繊維層3が、繊維層3の表面に畝2が繰り返し現れるように連続繊維の延びている方向に折り畳まれた構造を有してなる繊維成形体1であって、繊維成形体は、繊維成形体1の表面において、繊維成形体1の厚み方向4に圧縮扁平化された形状の畝2を形成しているか、または、繊維成形体は、畝2を形成し畝2の両側から繊維成形体1の厚み方向4に延びる繊維層3で連続した曲面を形成しており、畝を形成して繊維成形体1の厚み方向4に延びる互いに隣り合う畝の繊維層3が、繊維成形体1の厚み方向4において互いに密着している繊維成形体1。
〔2〕連続繊維が、熱融着性連続繊維であり、互いに隣り合う畝の繊維層が、繊維層3の熱融着性連続繊維の熱融着によって接合することで、繊維成形体1の厚み方向4において互いに密着している前記〔1〕記載の繊維成形体1。
〔3〕前記互いに密着している繊維層3を構成している熱融着性連続繊維の少なくとも一部が、少なくとも一方の畝の繊維層内に絡み込まれており、該畝の繊維層内部において、該繊維層3を構成する熱融着性連続繊維と、前記の絡み込まれた熱融着性連続繊維とが、熱融着によって接合されている前記〔2〕記載の繊維成形体1。
〔4〕前記〔1〕〜〔3〕のいずれか1項に記載の繊維成形体1の畝2を有する表面側に、さらに刻印紋様が賦形されてなる繊維成形体1。
〔5〕連続繊維が、ポリエステルを芯とし、ポリエチレンを鞘とする、鞘芯型複合連続繊維である前記〔1〕〜〔4〕のいずれか1に記載の繊維成形体1。
〔6〕前記〔1〕〜〔5〕のいずれか1に記載の繊維成形体1を用いて得られる製品。
The present invention has the following configuration.
[1] The fiber layer 3 formed by opening a bundle of continuous fibers having crimps and extending in one direction is in a direction in which the continuous fibers extend so that the wrinkles 2 repeatedly appear on the surface of the fiber layer 3. A fiber molded body 1 having a folded structure, and the fiber molded body forms, on the surface of the fiber molded body 1, a ridge 2 having a shape compressed and flattened in the thickness direction 4 of the fiber molded body 1. Or the fiber molded body forms a ridge 2 and forms a continuous curved surface with a fiber layer 3 extending from both sides of the ridge 2 in the thickness direction 4 of the fiber molded body 1, and forms a ridge to form a fiber. The fiber molded body 1 in which the adjacent fiber layers 3 extending in the thickness direction 4 of the molded body 1 are in close contact with each other in the thickness direction 4 of the fiber molded body 1.
[2] The continuous fiber is a heat-fusible continuous fiber, and the adjacent fiber layers are joined by heat-sealing of the heat-fusible continuous fiber of the fiber layer 3. The fiber molded body 1 according to [1], which is in close contact with each other in the thickness direction 4.
[3] At least a part of the heat-fusible continuous fibers constituting the fiber layer 3 in close contact with each other is entangled in at least one of the fiber layers of the cocoon, and the inside of the fiber layer of the cocoon The fiber molded body 1 according to the above [2], wherein the heat-fusible continuous fiber constituting the fiber layer 3 and the entangled heat-fusible continuous fiber are joined by heat-sealing. .
[4] A fiber molded body 1 in which a stamp pattern is further formed on the surface side of the fiber molded body 1 according to any one of [1] to [3] having the ridge 2.
[5] The fiber molded body 1 according to any one of [1] to [4], wherein the continuous fiber is a sheath-core type composite continuous fiber having polyester as a core and polyethylene as a sheath.
[6] A product obtained using the fiber molded body 1 according to any one of [1] to [5].
本発明の繊維成形体は、柔軟性、クッション性に優れている。また、繰り返し圧縮を行った場合であっても、リントの発生量が少なく、耐毛羽立ち性が良好である(毛羽立ちが生じにくい)ことから、良好な繰り返し圧縮の耐久性を有している。また、本発明の繊維成形体は、折り畳み構造を有することから、垂直反発性が高く、風合いが良好である。また、繊維成形体中に空隙が多いことから、保温性、遮音性に優れる。 The fiber molded body of the present invention is excellent in flexibility and cushioning properties. In addition, even when repeated compression is performed, the amount of lint generated is small and the fuzz resistance is good (the fuzz is less likely to occur). Moreover, since the fiber molded body of the present invention has a folded structure, it has high vertical resilience and good texture. Moreover, since there are many voids in the fiber molded body, it is excellent in heat retention and sound insulation.
<繊碓成形体>
本発明の繊碓成形体は、捲縮を有し一方向に延びている連続繊維の束を開繊してなる繊維層が、繊維層の表面に畝が繰り返し現れるように連続繊維の延びている方向に折り畳まれた構造を有している。
繊維成形体は、繊維成形体の表面において、繊維成形体の厚み方向に圧縮扁平化された形状の畝を形成しているか、または、繊維成形体は、畝を形成し畝の両側から繊維成形体の厚み方向に延びる繊維層で連続した曲面を形成しており、畝を形成して繊維成形体の厚み方向に延びる互いに隣り合う畝の繊維層が、繊維成形体の厚み方向において互いに密着している。
本発明でいう「畝」とは、繊維成形体の厚み方向に対して、垂直方向で、かつ、繊維層の密着状態と曲面の状態が観測できる方向から見た場合、畑などに見られる農作物を栽培するための畝のように高低のある状態が水平方向に続く構造をいう。
<Fabric molding>
The fiber molded body of the present invention has a fiber layer formed by opening a bundle of continuous fibers having crimps and extending in one direction, and the continuous fibers extend so that wrinkles repeatedly appear on the surface of the fiber layer. It has a structure folded in a certain direction.
The fiber molded body forms a ridge having a shape that is compressed and flattened in the thickness direction of the fiber molded body on the surface of the fiber molded body, or the fiber molded body forms a ridge and fiber molded from both sides of the ridge. A continuous curved surface is formed by fiber layers extending in the thickness direction of the body, and adjacent fiber layers of wrinkles that form wrinkles and extend in the thickness direction of the fiber molded body are in close contact with each other in the thickness direction of the fiber molded body. ing.
The term “発 明” as used in the present invention refers to a crop that can be seen in a field or the like when viewed from a direction perpendicular to the thickness direction of the fiber molded body and from the direction in which the adhesion state and curved surface of the fiber layer can be observed. A structure in which a certain state of height is continued in the horizontal direction, like a cocoon for cultivating rice.
<繊維層>
本発明に用いられる繊維層は、捲縮を有し一方向に延びている連続繊維の束を開繊してなる。連続繊維の束を用い、繊維層の表面に畝が繰り返し現れるように連続繊維の延びている方向に折り畳まれた構造を有していることで、得られる繊維成形体は、圧縮を繰り返して使用した場合であっても、毛羽立ちやリントが発生し難いなどの繰り返し圧縮の耐久性に優れることから、クッション材として好ましく用いることができる。
<Fiber layer>
The fiber layer used in the present invention is formed by opening a bundle of continuous fibers having crimps and extending in one direction. By using a bundle of continuous fibers and having a structure that is folded in the direction in which the continuous fibers extend so that wrinkles appear repeatedly on the surface of the fiber layer, the resulting fiber molded body is repeatedly used for compression. Even in such a case, it can be preferably used as a cushioning material because it is excellent in durability of repeated compression such that fuzz and lint hardly occur.
捲縮を有し一方向に延びている連続繊維の束を開繊してなる繊維層は、特に限定されないが、スパンボンド法で、連続繊維が一方向に配列するように調整され、製造された繊維層や、トウ開繊法で、連続繊維、特にトウを一方向に延びているように開繊し、製造された繊維層など、公知の方法で得られる繊維層を使用することができる。クッション性、嵩高性の点で、トウ開繊法で得られた繊維層を使用することが好ましい。 The fiber layer formed by opening a bundle of continuous fibers having crimps and extending in one direction is not particularly limited, but is manufactured by adjusting the continuous fibers to be aligned in one direction by a spunbond method. A fiber layer obtained by a known method, such as a fiber layer or a fiber layer produced by opening a continuous fiber, in particular, a tow extending in one direction, by a tow opening method can be used. . In view of cushioning properties and bulkiness, it is preferable to use a fiber layer obtained by a toe opening method.
<連続繊維>
本発明に用いられる連続繊維は、特に限定されないが、繰り返し圧縮の耐久性の点で、熱融着性を有することが好ましく、熱融着性複合連続繊維であることが特に好ましい。
<Continuous fiber>
Although the continuous fiber used for this invention is not specifically limited, From the point of durability of repeated compression, it is preferable to have heat-sealability, and it is especially preferable that it is a heat-sealable composite continuous fiber.
<熱融着性複合連続繊維>
熱融着性複合連続繊維としては、低融点成分と高融点成分とからなる複合連続繊維であることが好ましい。低融点成分/高融点成分の組み合わせとしては、ポリエチレン/ポリプロピレン、ポリプロピレンコポリマー/ポリプロピレンホモポリマー、ポリエチレン/ポリエチレンテレフタレートなどが例示できるが、これらに限定されない。本発明で用いられるポリエチレンは、ポリエチレンホモポリマー、エチレンとプロピレンもしくは他のオレフィンとのコポリマー、エチレンとその他の共重合成分とのコポリマーなどである。本発明で用いられるポリプロピレンは、ポリプロピレンホモポリマー、プロピレンとエチレンもしくは他のオレフィンとのコポリマー、プロピレンとその他の成分との共重合体などである。本発明で用いられるポリエステルは、ポリエチレンテレフタレート、ポリブチレンテレフタレート、それらの共重合体などである。特にポリエチレン/ポリエチレンテレフタレートの組み合わせで構成される熱融着性複合連続繊維は、ポリエチレンテレフタレートの樹脂特性である剛性を活かし、最終成形品はクッション性に優れるものとなるため好ましい。
<Heat-fusion composite continuous fiber>
The heat-fusible composite continuous fiber is preferably a composite continuous fiber composed of a low melting point component and a high melting point component. Examples of the combination of low melting point component / high melting point component include, but are not limited to, polyethylene / polypropylene, polypropylene copolymer / polypropylene homopolymer, polyethylene / polyethylene terephthalate and the like. The polyethylene used in the present invention is a polyethylene homopolymer, a copolymer of ethylene and propylene or another olefin, a copolymer of ethylene and another copolymer component, or the like. The polypropylene used in the present invention is a polypropylene homopolymer, a copolymer of propylene and ethylene or another olefin, a copolymer of propylene and other components, or the like. Examples of the polyester used in the present invention include polyethylene terephthalate, polybutylene terephthalate, and copolymers thereof. In particular, a heat-sealable composite continuous fiber composed of a combination of polyethylene / polyethylene terephthalate is preferable because it takes advantage of the rigidity that is the resin characteristic of polyethylene terephthalate and the final molded product has excellent cushioning properties.
熱融着性複合連続繊維の複合形態としては、鞘芯型や並列型が例示できる。鞘芯型複合連続繊維の場合、一般的には、熱接着性を発揮させるために低融点成分を鞘成分に配する構成とすることが好ましい。鞘芯型複合連続繊維としては、同心鞘芯型複合連続繊維、偏心鞘芯型複合連続繊維などが例示できる。本発明において、クッション性の観点から、立体捲縮を発現させやすい偏心鞘芯型複合連続繊維が好ましい。 Examples of the composite form of the heat-fusible composite continuous fiber include a sheath core type and a parallel type. In the case of a sheath-core type composite continuous fiber, it is generally preferable that a low melting point component is arranged in the sheath component in order to exhibit thermal adhesiveness. Examples of the sheath-core type composite continuous fiber include a concentric sheath-core type composite continuous fiber and an eccentric sheath-core type composite continuous fiber. In the present invention, from the viewpoint of cushioning properties, an eccentric sheath-core type composite continuous fiber that easily causes three-dimensional crimps is preferable.
連続繊維が、熱融着性複合連続繊維である場合、低融点成分と高融点成分との比率は、容量基準で30/70〜70/30の範囲が好ましく、40/60〜60/40の範囲がさらに好ましい。低融点成分の比率が30容量%以上であれば、マット等の繊維成形体を形成する場合、得られるマットは、接着が良好となるために、圧縮された場合であっても熱接着部が破断することなく、良好なクッション性を有する。高融点成分の比率が30容量%以上のとき、接着に寄与する低融点成分が少量となるため、熱接着後も比較的繊維の自由度が低下することがなく、得られた繊維成形体は、柔軟性に優れ(柔らかい)、クッション性が維持されるため、好ましい。 When the continuous fiber is a heat-fusible composite continuous fiber, the ratio of the low melting point component and the high melting point component is preferably in the range of 30/70 to 70/30 on a volume basis, and is 40/60 to 60/40. A range is further preferred. If the ratio of the low melting point component is 30% by volume or more, when forming a fiber molded body such as a mat, the resulting mat has good adhesion, so that even if it is compressed, the heat-bonding part is present. It has good cushioning properties without breaking. When the ratio of the high melting point component is 30% by volume or more, the low melting point component contributing to adhesion is small, so that the degree of freedom of the fiber is not relatively lowered even after heat bonding. It is preferable because it is excellent in softness (soft) and maintains cushioning properties.
連続繊維の束は、トウ開繊法によって開繊(「拡幅」ともいう。)され、繊維層となる。開繊とは、連続繊維の束(連続繊維同士が互いに収束して形成された束)において、連続繊維同士を引き離し、連続繊維を個々に存在させる操作である。これにより、連続繊維の束は、個々の繊維に解されて、束の幅が増すことで、繊維層となる。
連続繊維の束の開繊においては、ウインスロールによる繊維の開繊効果、ロールとロール間の速度比率、及び、Zバー(スイングするテンションバー)による緊張と緩和を繊維束に適度に与えることにより、均一に拡幅させることができる。繊維束へ緊張状態を与える場合、拡幅された繊維束の捲縮が伸びきるほどの過剰な緊張を与えないことが重要である。
A bundle of continuous fibers is opened (also referred to as “widening”) by a tow opening method to form a fiber layer. Opening is an operation in which continuous fibers are separated from each other in a bundle of continuous fibers (a bundle formed by converging continuous fibers), and the continuous fibers exist individually. Thereby, the bundle of continuous fibers is broken into individual fibers, and the width of the bundle increases to form a fiber layer.
In the opening of a bundle of continuous fibers, the fiber opening effect by the wins roll, the speed ratio between the rolls, and the tension and relaxation by the Z bar (swinging tension bar) are appropriately given to the fiber bundle. , Can be widened uniformly. When giving a tension state to a fiber bundle, it is important not to give an excessive tension to the extent that the crimp of the widened fiber bundle can be extended.
連続繊維の束が有する捲縮としては、顕在捲縮、潜在捲縮または顕在捲縮と潜在捲縮との組み合わせが利用できる。顕在捲縮としては、山/谷状のいわゆるジグザグ型などの二次元捲縮や、コイル型、スパイラル型などの三次元捲縮を利用することができるが、作業性の点で、二次元捲縮であることが好ましい。繊維成形体中の連続繊維の捲縮数は、開繊性と嵩高性の両特性の点で、5〜25山/2.54cmの範囲であるのが好ましく、さらに10〜20山/2.54cmであるのが好ましい。 As the crimp of the bundle of continuous fibers, an actual crimp, a latent crimp, or a combination of an actual crimp and a latent crimp can be used. As the actual crimp, two-dimensional crimps such as a so-called zigzag type of mountain / valley shape, and three-dimensional crimps such as a coil type and a spiral type can be used. It is preferable to be a contraction. The number of crimps of the continuous fibers in the fiber molded body is preferably in the range of 5-25 peaks / 2.54 cm, and more preferably 10-20 peaks / 2. It is preferably 54 cm.
連続繊維の束は、顕在捲縮を有することが好しく、その捲縮数は8〜70山/25mmであることが好ましく、9〜65山/25mmであることがより好ましく、10〜50山/25mmであることがさらに好ましい。捲縮数が8山/25mm以上であれば、トウの集束性が良好で、トウの引き上げ等のときに、繊維束が過度の縦割れ等を起こさず、高速開繊が容易となる。また70山/25mm以下であれば、連続繊維間の過度の絡み合いや高密度化が起こり難く、やはり高速開繊が容易となる。 The bundle of continuous fibers preferably has an actual crimp, and the number of crimps is preferably 8 to 70/25 mm, more preferably 9 to 65/25 mm, and 10 to 50 More preferably, it is / 25 mm. If the number of crimps is 8 peaks / 25 mm or more, the convergence of the tow is good, and when the tow is pulled up, the fiber bundle does not cause excessive vertical cracking, and high-speed fiber opening becomes easy. Moreover, if it is 70 ridges / 25 mm or less, excessive entanglement and densification between continuous fibers hardly occur, and high-speed fiber opening is also easy.
繊維成形体の製造に用いられる連続繊維の束が、顕在捲縮と共に、偏心鞘芯型の複合構造等であることに起因する潜在捲縮を有する場合には、開繊工程で加える張力によって、該複合構造と各複合成分間の受ける応力歪の差に起因して、潜在していた捲縮が発現(顕在化)する。繊維束を開繊して得られた繊維層を、その後の工程で加熱することによって、該繊維の複合構造と各複合成分間の熱収縮性の差を利用して、更なる潜在捲縮を発現(顕在化)させてもよい。 When the bundle of continuous fibers used for the production of the fiber molded body has a latent crimp due to an eccentric sheath core type composite structure, etc. along with the actual crimp, by the tension applied in the fiber opening process, Due to the difference in stress strain received between the composite structure and each composite component, latent crimps appear (appear). By heating the fiber layer obtained by opening the fiber bundle in a subsequent process, the latent shrinkage is further reduced by utilizing the difference in heat shrinkability between the composite structure of the fiber and each composite component. It may be expressed (emerged).
繊維成形体中の連続繊維が、潜在捲縮を有している場合、その顕在化によって、三次元捲縮であるスパイラル型などの捲縮形状を発現させることができることから、クッション性、嵩高性が良好となり好ましい。このとき、ジクザグ型等の二次元捲縮が、連続繊維の過半数を下回る割合で残存していてもよい。 When the continuous fiber in the fiber molded body has latent crimps, it is possible to express a crimped shape such as a spiral type that is a three-dimensional crimp by manifesting it, so that cushioning properties and bulkiness Is preferable. At this time, two-dimensional crimps such as a zigzag type may remain at a rate lower than the majority of continuous fibers.
連続繊維の単糸繊度は、0.5〜100dtexが好ましい。単糸繊度が0.5dtex以上であれば、開繊時の単糸切れや毛羽立等ができ難く、且つ高速で開繊することが可能になる。また100dtex以下であれば、トウの集束性がよく、開繊作業性が良好となるため、高速開繊が可能であり、種々用途への幅広い展開が可能となる。 The single yarn fineness of the continuous fiber is preferably 0.5 to 100 dtex. If the single yarn fineness is 0.5 dtex or more, it is difficult to break single yarn or fluff at the time of opening, and it is possible to open at high speed. Moreover, if it is 100 dtex or less, the convergence property of tow | toe is good and opening workability | operativity becomes favorable, Therefore High-speed opening is possible and the expansion | deployment to various uses is attained.
繊維束の全繊度(トータル繊度)は、1万〜50万dtexであることが好ましく、3万〜20万dtexであることがさらに好ましい。1万dtex以上であれば、繊維密度によるクッション性が維持でき、50万dtex以下であれば、拡幅性が良好となる。 The total fineness (total fineness) of the fiber bundle is preferably 10,000 to 500,000 dtex, and more preferably 30,000 to 200,000 dtex. If it is 10,000 dtex or more, the cushioning property by fiber density can be maintained, and if it is 500,000 dtex or less, the widening property is good.
繊維束を拡幅して得られた繊維層の目付けは、10〜150g/cm2が好ましく、さらに好ましくは20〜100g/cm2である。特に低い目付けの場合、折り畳み構造での折り返される距離が短くなり、高さの低い畝が、高密度で存在し、隣接する畝の壁面同士が互いに強く圧縮されて密着した構造となる。逆に高い目付けの繊維層を用いた場合は、折り畳み構造での折り返される距離が長くなり畝の幅が広がる構造となる。前者の構造を有する場合、繊維成形体は硬く強度のあるものとなる。後者の場合、繊維層内部には空隙が残存し、そのため、繊維成形体は柔らかく、また、その構造から、保温、遮音にも優れることが期待される。上記範囲内で目付けを変更することにより、用途に合ったクッション材を得ることが可能となる。 The basis weight of the fiber layer obtained by widening the fiber bundle is preferably 10 to 150 g / cm 2 , more preferably 20 to 100 g / cm 2 . In particular, in the case of a low basis weight, the folding distance in the folded structure is shortened, the ridges having a low height are present at a high density, and the wall surfaces of adjacent ridges are strongly compressed and closely adhered to each other. On the other hand, when a fiber layer having a high basis weight is used, the folded distance in the folding structure becomes long and the width of the folds widens. In the case of having the former structure, the fiber molded body is hard and strong. In the latter case, voids remain in the fiber layer, so that the fiber molded body is soft, and the structure is expected to be excellent in heat retention and sound insulation. By changing the basis weight within the above range, a cushioning material suitable for the application can be obtained.
本発明で使用する、捲縮を有し一方向に延びている連続繊維の束を開繊(拡幅)して得られた繊維層は、該繊維層を構成する連続繊維同士が互いに接合されていないことが好ましい。例えば、連続繊維の長さ方向と直交する方向の複数の融着線によって部分的に接合されて一体化(不織布化)されていないことが好ましい。
一方向に延びている連続繊維同士が互いに接合されていない繊維層を、繊維層の表面に畝が繰り返し現れるように連続繊維の延びている方向に折り畳み、隣り合う畝同士を構成する繊維層が互いに密着するように構成すると、連続繊維間は互いに接合されていないため、畝を形成する繊維層内に、隣の畝を形成する繊維層の繊維の一部分が絡み込む(食い込む)状態が形成され易い。この状態で加熱すると、両畝を構成する繊維層間の熱接着は、両繊維層の接触界面のみにおいて互いの繊維軸の接点のみで熱接着する場合に比べて、強固な熱接着が可能となる。これによって、繰り返し圧縮の耐久性が強化されうる。
The fiber layer obtained by opening (broadening) a bundle of continuous fibers having crimps and extending in one direction used in the present invention has the continuous fibers constituting the fiber layer joined together. Preferably not. For example, it is preferable that a plurality of fusion wires in a direction orthogonal to the length direction of the continuous fibers are not partially joined and integrated (nonwoven fabric).
A fiber layer in which continuous fibers extending in one direction are not joined to each other is folded in a direction in which continuous fibers extend so that wrinkles repeatedly appear on the surface of the fiber layer, and a fiber layer constituting adjacent wrinkles If it is configured to be in close contact with each other, continuous fibers are not joined to each other, and therefore, a state is formed in which a part of the fibers of the fiber layer forming the adjacent wrinkle is entangled (biting) into the fiber layer forming the wrinkle. easy. When heated in this state, the thermal adhesion between the fiber layers constituting both sides becomes stronger than the case where the thermal adhesion is performed only at the contact points of the fiber axes only at the contact interface between the two fiber layers. . Thereby, durability of repeated compression can be enhanced.
<繊維成形体の製造方法>
一方向に延びている連続繊維の束が開繊(拡幅)されてなる繊維層を用いて、畝が繰り返し現れるように折り畳まれた構造を有する繊維成形体を製造するための方法としては、スタフィンボックス内に繊維層を押し込み、折り畳み構造を形成する方法や、プリーツ加工を用いて、折り畳み構造を形成する方法などが挙げられる。
<Method for producing fiber molded body>
As a method for producing a fiber molded body having a structure in which a fold is repeatedly formed using a fiber layer in which a bundle of continuous fibers extending in one direction is opened (widened), Examples thereof include a method of pushing a fiber layer into a fin box to form a folded structure, and a method of forming a folded structure using pleating.
スタフィンボックス内に繊維層を押し込み、折り畳み構造を形成する方法としては、次の方法が例示できる。
1)出口側で繊維層が排出されにくい状態になるように、入口から出口に向かって開口面積が減少する構造を有するボックス内に繊維層を押し込む。繊維層はボックス内に蓄積され、折り畳まれた状態となる。
2)さらに、入口側から繊維層をボックス内に押し込み続けることで、出口側から、折り畳まれた繊維層が排出される。排出される繊維層には、折り畳み構造が付与される。
3)次に、繊維層を繊維成形体とするために、互いに密着している繊維層を接合する。接合する方法は、例えば、連続繊維として熱融着性連続繊維を用いた場合には、例えば、熱風循環式サクションドライヤーを用いて、熱風による熱融着性連続繊維の熱融着によって、互いに密着している繊維層同士を接合すればよい。熱融着性連続繊維としては、熱融着性複合連続繊維が好ましく利用でき、熱融着性複合連続繊維の低融点成分の融点以上、高融点成分の融点未満の温度範囲内の熱風によって接着成形される。
折り畳まれた繊維層の高さは、用いるボックス内の体積により調整すればよい。例えば、ボックス上面の入口側を固定し、出口側を下降できる構造とすることで、ボックス内の体積を変更できる。このとき、体積を小さくすると折り畳み構造を小さくすることができ、逆に体積大きくすると折り畳み構造を大きくすることができる。この製造方法により、畝を形成して繊維成形体の厚み方向に延びる互いに隣り合う畝の繊維層同士が、繊維成形体の厚み方向において互いに密着している繊維成形体を効率よく得ることができるため、好ましい。
その他の繊維成形体の製造方法としては、プリーツ加工などを挙げることができる。繊維成形体の製造方法は、これらに限定されるものではない。
The following method can be exemplified as a method of pushing the fiber layer into the staffin box to form a folded structure.
1) The fiber layer is pushed into a box having a structure in which the opening area decreases from the inlet toward the outlet so that the fiber layer is hardly discharged on the outlet side. The fiber layer accumulates in the box and becomes folded.
2) Further, by continuing to push the fiber layer into the box from the inlet side, the folded fiber layer is discharged from the outlet side. A folded structure is given to the discharged fiber layer.
3) Next, in order to make the fiber layer into a fiber molded body, the fiber layers in close contact with each other are joined. For example, in the case where a heat-fusible continuous fiber is used as the continuous fiber, the bonding method uses, for example, a hot-air circulating suction dryer, and heat-bonding the heat-fusible continuous fiber with hot air to adhere to each other. What is necessary is just to join the fiber layers which are carrying out. As the heat-fusible continuous fiber, a heat-fusible composite continuous fiber can be preferably used, and it is bonded by hot air in a temperature range above the melting point of the low-melting component and below the melting point of the high-melting component. Molded.
What is necessary is just to adjust the height of the folded fiber layer with the volume in the box to be used. For example, the volume in the box can be changed by fixing the inlet side of the upper surface of the box and lowering the outlet side. At this time, when the volume is reduced, the folding structure can be reduced, and conversely, when the volume is increased, the folding structure can be enlarged. By this manufacturing method, it is possible to efficiently obtain a fiber molded body in which the adjacent fiber layers of the ridges extending in the thickness direction of the fiber molded body are in close contact with each other in the thickness direction of the fiber molded body. Therefore, it is preferable.
Examples of other methods for producing a fiber molded body include pleating. The manufacturing method of a fiber molded object is not limited to these.
上記方法によって、一般には、畝が、畝の両側から繊維成形体の厚み方向に延びる繊維層で連続した曲面を形成する繊維成形体を好適に得ることができる。また、こうして得られた繊維成形体の厚み方向の両面から、厚み方向に向けて、平板等で圧し、畝が、繊維成形体の厚み方向に圧縮扁平された形状を有するように加工してもよい。
また、こうして得られた繊維成形体の畝を有する表面側に、種々の刻印紋様を賦形してもよい。刻印紋様は、そのような紋様が刻印された金型等を、必要によって加熱しながら、前記成形体の畝を有する表面側に圧接するなどの方法で得ることができる。
By the above method, generally, a fiber molded body in which the ridge forms a continuous curved surface with fiber layers extending in the thickness direction of the fiber molded body from both sides of the ridge can be suitably obtained. In addition, even if the fiber molded body thus obtained is pressed with a flat plate or the like toward both sides in the thickness direction, the ridges are processed so as to have a shape compressed and flattened in the thickness direction of the fiber molded body. Good.
Moreover, you may shape various stamp patterns on the surface side which has the wrinkles of the fiber molded object obtained in this way. The stamp pattern can be obtained by a method in which a mold or the like on which such a pattern is stamped is pressed against the surface side having the ridges of the molded body while being heated as necessary.
以下、実施例により、本発明をさらに詳細に説明するが、本発明の範囲はこれらに限定されるものではない。 EXAMPLES Hereinafter, although an Example demonstrates this invention further in detail, the scope of the present invention is not limited to these.
本発明の繊維成形体の性能は以下の方法で行った。 The performance of the fiber molded body of the present invention was performed by the following method.
<クッション性の評価法>
10人のパネラーによって、次ぎの評価基準に従い、クッション性を評価した。
◎:反発性があると感じた人数が、8人以上である。
○:反発性があると感じた人数が、5人以上、7人以下である。
×:反発性が有ると感じた人数が、4人以下である。
本評価法において、○または◎の評価となった成形体をクッション性に優れると評価した
<Cushioning evaluation method>
The cushioning properties were evaluated by 10 panelists according to the following evaluation criteria.
A: The number of people who felt resilience was 8 or more.
○: The number of people who felt repulsiveness is 5 or more and 7 or less.
X: The number of persons who felt that there was resilience is 4 or less.
In this evaluation method, it was evaluated that the molded product that was evaluated as ○ or ◎ had excellent cushioning properties.
<柔軟性の評価法>
10人のパネラーによって、次ぎの評価基準に従い、柔軟性を評価した。
◎:柔軟であると感じた人数が、8人以上である。
○:柔軟であると感じた人数が、5人以上、7人以下である。
×:柔軟であると感じた人数が、4人以下である。
本評価法において、○または◎の評価となった繊維成形体を柔軟性に優れると評価した。
<Flexibility evaluation method>
Ten panelists evaluated the flexibility according to the following evaluation criteria.
A: The number of people who felt flexible was 8 or more.
○: The number of people who felt flexible was 5 or more and 7 or less.
X: The number of people who felt flexible was 4 or less.
In this evaluation method, it was evaluated that the fiber molded body evaluated as ○ or ◎ had excellent flexibility.
<繰り返し圧縮の耐久性の評価法>
繊維成形体を100mm×100mmに切り出し、圧縮機を用いて、3kgf/cm2(29.4Pa)の圧力にて10回繰り返し圧縮した後の繊維成形体を用いて、次ぎの評価基準に基づき、評価を行った。評価は、柔軟性の評価を行った10人のパネラーを起用した。
◎:毛羽、リント量がない又は少ないと評価した人数が、8人以上である。
○:毛羽、リント量がない又は少ないと評価した人数が、5人以上7人以下である。
×:毛羽、リント量がない又は少ないと評価した人数が、4人以下である。
本評価法において、○または◎の評価となった繊維成形体を、毛羽立ち、リント量が少なく、繰り返し圧縮の耐久性が良好であると評価した。
<Method for evaluating durability of repeated compression>
Based on the following evaluation criteria, the fiber molded body was cut into 100 mm × 100 mm, and was compressed repeatedly 10 times at a pressure of 3 kgf / cm 2 (29.4 Pa) using a compressor. Evaluation was performed. For the evaluation, ten panelists who evaluated the flexibility were appointed.
(Double-circle): The number of people evaluated that there is little or no amount of fluff and lint is 8 or more.
○: The number of fluff and lint evaluated that there is little or less is 5 or more and 7 or less.
X: The number of persons evaluated that there is no or little amount of fluff and lint is 4 or less.
In this evaluation method, the fiber molded body evaluated as “◯” or “◎” was evaluated as having good fuzzing, small lint amount, and good repeated compression durability.
<(実施例1)サンプルA>
低融点成分がHDPE(高密度ポリエチレン;融点130℃、MI16)であり、高融点成分がPET(ポリエチレンテレフタレート;融点250℃、IV0.68)である、機械捲縮を施し、10〜20山/2.54cmのジグザグ捲縮を持った同心鞘芯型複合繊維(鞘芯比が容量基準で50/50、3.3dtex)が一方向に延びている連続繊維の束を、トウ開繊法で緊張と緩和することによって均―に開繊した。得られた、目付け20g/m2、厚み約1mm、幅約500mmの繊維層を、入口から出口に向かって開口面積が小さくなり、出口の開口部が縦10mm、横500mmであるボックス内に押し込むことにより、ボックス内で折り畳み構造が形成された繊維層を得た。
この折り畳み構造を有した繊維層を、熱風循環式熱処理機を用いて、循環風速1.5m/s、熱風温度130℃、コンベアー速度8.5m/minの条件で熱処理加工を行い、繊維成形体を得た。
得られた繊維成形体は、畝を形成し畝の両側から繊維成形体の厚み方向に延びる繊維層で連続した曲面を形成しており、畝を形成して繊維成形体の厚み方向に延びる互いに隣り合う繊維層が、繊維成形体の厚み方向において、該繊維の低融点成分による熱融着によって接合され互いに密着していた。隣り合う畝の繊維層同士を剥離しようとすると、一方の繊維層の繊維の一部分が、隣り合う他方の繊維層の内部に食い込んで(絡みこんで)熱接着しており、剥離強度の向上に寄与している状況が観察された。
<(Example 1) Sample A>
The low melting point component is HDPE (high density polyethylene; melting point 130 ° C., MI16), and the high melting point component is PET (polyethylene terephthalate; melting point 250 ° C., IV 0.68). A bundle of continuous fibers with a concentric sheath-core type composite fiber having a zigzag crimp of 2.54 cm (sheath core ratio is 50/50, 3.3 dtex on a volume basis) is extended in one direction by the toe opening method. It was opened evenly by tension and relaxation. The obtained fiber layer having a basis weight of 20 g / m 2 , a thickness of about 1 mm, and a width of about 500 mm is pushed into a box whose opening area decreases from the inlet toward the outlet, and the outlet opening is 10 mm long and 500 mm wide. Thus, a fiber layer in which a folded structure was formed in the box was obtained.
The fiber layer having the folded structure is subjected to a heat treatment using a hot air circulating heat treatment machine under conditions of a circulating air speed of 1.5 m / s, a hot air temperature of 130 ° C., and a conveyor speed of 8.5 m / min. Got.
The obtained fiber molded body forms a ridge and forms a continuous curved surface with fiber layers extending from both sides of the ridge in the thickness direction of the fiber molded body, and forms a ridge and extends in the thickness direction of the fiber molded body. Adjacent fiber layers were bonded and adhered to each other in the thickness direction of the fiber molded body by heat fusion using a low melting point component of the fiber. When trying to peel the adjacent fiber layers of the ridges, a part of the fibers of one fiber layer bite into the inside of the other adjacent fiber layer (entangled) and thermally bonded to improve the peel strength. A contributing situation was observed.
<(実施例2)サンプルB>
低融点成分がHDPE(高密度ポリエチレン;融点130℃、MI16)であり、高融点成分がPP(ポリプロピレンホモポリマー;融点160℃、MFR16)である、潜在捲縮性を持った偏心鞘芯型複合繊維(鞘芯比が容量基準で50/50、3.3dtex)のトウを、トウ開繊法で緊張と緩和を与えることによって均―に開繊した。目付け25g/m2、厚み約2.5mm、幅約500mmの繊維束の層を得た以外は、サンプルAの製法に準じて、繊維成形体を得た。繊維成形体を構成する繊維には、10〜15山/2.54cmの螺旋捲縮が発現していた。
得られた繊維成形体は、畝を形成し畝の両側から繊維成形体の厚み方向に延びる繊維層で連続した曲面を形成しており、畝を形成して繊維成形体の厚み方向に延びる互いに隣り合う繊維層が、繊維成形体の厚み方向において、該繊維の低融点成分による熱融着によって接合され互いに密着していた。隣り合う畝の繊維層同士を剥離しようとすると、一方の繊維層の繊維の一部分が、隣り合う他方の繊維層の内部に食い込んで(絡みこんで)熱接着しており、剥離強度が向上していると推定される。
<(Example 2) Sample B>
Eccentric sheath-core composite with latent crimping, whose low melting point component is HDPE (high density polyethylene; melting point 130 ° C., MI16) and whose high melting point component is PP (polypropylene homopolymer; melting point 160 ° C., MFR16). Tows of fibers (sheath core ratio 50/50, 3.3 dtex on a volume basis) were spread evenly by applying tension and relaxation by the tow opening method. A fiber molded body was obtained according to the production method of Sample A, except that a fiber bundle layer having a basis weight of 25 g / m 2 , a thickness of about 2.5 mm, and a width of about 500 mm was obtained. In the fibers constituting the fiber molded body, 10-15 peaks / 2.54 cm of spiral crimps were expressed.
The obtained fiber molded body forms a ridge and forms a continuous curved surface with fiber layers extending from both sides of the ridge in the thickness direction of the fiber molded body, and forms a ridge and extends in the thickness direction of the fiber molded body. Adjacent fiber layers were bonded and adhered to each other in the thickness direction of the fiber molded body by heat fusion using a low melting point component of the fiber. When trying to peel the adjacent heel fiber layers, a part of the fibers of one fiber layer bite into the other adjacent fiber layer (entangled) and thermally bonded, improving the peel strength. It is estimated that
<(比較例1)サンプルC>
低融点成分がHDPE(高密度ポリエチレン;融点130℃、MI16)であり、高融点成分がPET(ポリエチレンテレフタレート;融点250℃、IV0.68)である、機械捲縮を施し、10〜20山/2.54cmのジグザグ捲縮を持った同心鞘芯型の複合短繊維(鞘芯比が容量基準で50/50、3.3dtex×51mm)をカード加工法にて、目付け20g/m2、厚み約1.5mm、幅約500mmの繊維層とした後、サンプルAの方法に準じて、折り畳み構造を有する繊維成形体を得た。
<(Comparative Example 1) Sample C>
The low melting point component is HDPE (high density polyethylene; melting point 130 ° C., MI16), and the high melting point component is PET (polyethylene terephthalate; melting point 250 ° C., IV 0.68). Concentric sheath-core type composite short fiber with a zigzag crimp of 2.54 cm (sheath core ratio is 50/50, 3.3 dtex × 51 mm on a volume basis) by a card processing method, a basis weight of 20 g / m 2 , thickness After forming a fiber layer having a width of about 1.5 mm and a width of about 500 mm, a fiber molded body having a folded structure was obtained according to the method of Sample A.
<(比較例2)サンプルD>
低融点成分がHDPE(高密度ポリエチレン;融点130℃、MI16)であり、高融点成分がPET(ポリエチレンテレフタレート;融点250℃、IV0.68)である、同心鞘芯型複合繊維(鞘芯比が容量基準で50/50)をスパンボンド法にてコンベアー上に集積し、目付け20g/m2、厚み約0.3mm、幅約500mmの繊維層(フリース:2.2dtex)とした後、サンプルAの方法に準じて、折り畳み構造を有する繊維成形体を得た。
<(Comparative Example 2) Sample D>
The low melting point component is HDPE (high density polyethylene; melting point 130 ° C., MI16), and the high melting point component is PET (polyethylene terephthalate; melting point 250 ° C., IV 0.68). 50/50) on the basis of the capacity is accumulated on the conveyor by the spunbond method to obtain a fiber layer (fleece: 2.2 dtex) having a basis weight of 20 g / m 2 , a thickness of about 0.3 mm, and a width of about 500 mm. According to the method, a fiber molded body having a folded structure was obtained.
実施例、比較例の評価結果を表1に示す。 Table 1 shows the evaluation results of Examples and Comparative Examples.
本発明のクッション性を有する繊維成形体は、柔軟性に優れ、圧縮を繰り返した場合であっても、毛羽立ち性が良好で、リントの発生量が少ないことから、例えば、医療分野、自工用、建築分野などに好適に用いることができる。また、本発明の繊維成形体は、折り畳み構造を有することから、垂直反発性が高く、風合いが良好であることから、クッション材等に好適に用いることができる。また、本発明の繊維成形体は、繊維成形体中に空隙が多く、保温性、遮音性に優れることから、保温材、遮音材などに好適に用いることができる。 The fiber molded body having a cushioning property of the present invention is excellent in flexibility, and even when it is repeatedly compressed, it has good fuzzing properties and a small amount of lint. It can be suitably used in the construction field. Further, since the fiber molded body of the present invention has a folded structure, it has high vertical resilience and good texture, and therefore can be suitably used for a cushion material or the like. Moreover, since the fiber molded body of the present invention has many voids in the fiber molded body and is excellent in heat retaining properties and sound insulating properties, it can be suitably used for heat insulating materials, sound insulating materials and the like.
1 繊維成形体
2 畝
3 繊維層
4 繊維成形体の厚み方向
DESCRIPTION OF SYMBOLS 1 Fiber molded object 2 3 3 Fiber layer 4 Thickness direction of fiber molded object
Claims (5)
一方向に延びている連続繊維の束を、トウ開繊法で緊張と緩和することによって均―に開繊し、得られた繊維層を、入口から出口に向かって開口面積が小さくなるボックス内に押し込むことにより、ボックス内で折り畳み構造が形成し、
この折り畳み構造を有した繊維層を、熱風循環式熱処理機を用いて、熱処理加工を行うことで、
繊維成形体は、繊維成形体の表面において、繊維成形体の厚み方向に圧縮扁平化された形状の畝を形成しているか、または、
繊維成形体は、畝を形成し畝の両側から繊維成形体の厚み方向に延びる繊維層で連続した曲面を形成しており、
畝を形成して繊維成形体の厚み方向に延びる互いに隣り合う畝の繊維層が、繊維成形体の厚み方向において互いに密着している繊維成形体の製造方法。 A fiber layer formed by opening a bundle of continuous fibers that have crimps and extend in one direction has a structure that is folded in the direction in which the continuous fibers extend so that wrinkles repeatedly appear on the surface of the fiber layer. A method for producing a fiber molded body comprising:
A bundle of continuous fibers extending in one direction is spread evenly by tension and relaxation by the toe opening method, and the resulting fiber layer is placed in a box with a smaller opening area from the inlet to the outlet. Folds into the box,
By performing a heat treatment on the fiber layer having this folded structure using a hot air circulation heat treatment machine,
The fiber molded body forms, on the surface of the fiber molded body, wrinkles having a shape compressed and flattened in the thickness direction of the fiber molded body, or
The fiber molded body forms a wrinkle and forms a continuous curved surface with fiber layers extending in the thickness direction of the fiber molded body from both sides of the wrinkle,
A method for producing a fiber molded body in which adjacent fiber layers of ridges that form ridges and extend in the thickness direction of the fiber molded body are in close contact with each other in the thickness direction of the fiber molded body.
Priority Applications (6)
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JP2014174719A JP6375781B2 (en) | 2014-08-29 | 2014-08-29 | Cushioned fiber molded body and product obtained using the same |
PCT/JP2015/074152 WO2016031894A1 (en) | 2014-08-29 | 2015-08-27 | Fiber molded article having cushioning property, and product obtained using same |
CN201580057903.6A CN107109744A (en) | 2014-08-29 | 2015-08-27 | Fiber molding with resiliency and use the product obtained by it |
EP15836253.3A EP3187636B1 (en) | 2014-08-29 | 2015-08-27 | Fiber molded article having cushioning property, and product obtained using same |
US15/506,250 US20170241053A1 (en) | 2014-08-29 | 2015-08-27 | Fiber molded article having cushioning property, and product obtained using same |
US16/699,747 US20200102678A1 (en) | 2014-08-29 | 2019-12-02 | Method for producing fiber molded body |
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US6635136B2 (en) * | 2000-03-30 | 2003-10-21 | Kimberly-Clark Worldwide, Inc. | Method for producing materials having z-direction fibers and folds |
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