JP6695077B2 - Laminated nonwoven fabric with uneven pattern - Google Patents
Laminated nonwoven fabric with uneven pattern Download PDFInfo
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- JP6695077B2 JP6695077B2 JP2016119900A JP2016119900A JP6695077B2 JP 6695077 B2 JP6695077 B2 JP 6695077B2 JP 2016119900 A JP2016119900 A JP 2016119900A JP 2016119900 A JP2016119900 A JP 2016119900A JP 6695077 B2 JP6695077 B2 JP 6695077B2
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- 239000004745 nonwoven fabric Substances 0.000 title claims description 104
- 239000000835 fiber Substances 0.000 claims description 139
- 229920000728 polyester Polymers 0.000 claims description 47
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 34
- 238000002844 melting Methods 0.000 claims description 28
- 229920000742 Cotton Polymers 0.000 claims description 17
- 238000004049 embossing Methods 0.000 claims description 14
- 238000000034 method Methods 0.000 claims description 14
- 239000000470 constituent Substances 0.000 claims description 9
- 229920000642 polymer Polymers 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 238000007493 shaping process Methods 0.000 claims description 2
- 230000008018 melting Effects 0.000 description 25
- 238000010521 absorption reaction Methods 0.000 description 10
- 229920001225 polyester resin Polymers 0.000 description 10
- 239000004645 polyester resin Substances 0.000 description 10
- 230000000052 comparative effect Effects 0.000 description 8
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 6
- 239000002131 composite material Substances 0.000 description 6
- 238000002074 melt spinning Methods 0.000 description 5
- 229920001169 thermoplastic Polymers 0.000 description 5
- KKEYFWRCBNTPAC-UHFFFAOYSA-N Terephthalic acid Chemical compound OC(=O)C1=CC=C(C(O)=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-N 0.000 description 4
- 238000002347 injection Methods 0.000 description 4
- 239000007924 injection Substances 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 3
- 229920000297 Rayon Polymers 0.000 description 2
- 229920002678 cellulose Polymers 0.000 description 2
- 239000001913 cellulose Substances 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000002964 rayon Substances 0.000 description 2
- 238000009987 spinning Methods 0.000 description 2
- 229920000433 Lyocell Polymers 0.000 description 1
- OFOBLEOULBTSOW-UHFFFAOYSA-N Malonic acid Chemical compound OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 238000003490 calendering Methods 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 238000007334 copolymerization reaction Methods 0.000 description 1
- 239000003484 crystal nucleating agent Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 150000002009 diols Chemical class 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 230000000877 morphologic effect Effects 0.000 description 1
- 239000005022 packaging material Substances 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- -1 polyethylene terephthalate Polymers 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000007790 scraping Methods 0.000 description 1
- 230000002195 synergetic effect Effects 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
- 239000012209 synthetic fiber Substances 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
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- Treatment Of Fiber Materials (AREA)
- Laminated Bodies (AREA)
- Nonwoven Fabrics (AREA)
Description
本発明は、表裏面ともに凹凸柄模様を有する不織布に関するものである。 The present invention relates to a non-woven fabric having an uneven pattern on both front and back surfaces.
従来より、拭き布等に使用される吸水性に優れた不織布としては、綿繊維やレーヨン繊維等の親水性繊維よりなる不織布が知られている。また、かかる不織布にエンボス加工を施すことにより、凹凸柄模様を付することも行われている。しかしながら、凹凸柄模様を付しても、厚み方向に圧縮することにより、凹凸柄模様が消失しやすいということがあった。凹凸柄模様を消失しにくくするために、不織布自体を剛直にすればよい。しかし、不織布自体を剛直にすると、吸水性が低下するということがあった。 BACKGROUND ART Conventionally, as a non-woven fabric having excellent water absorption used for a wiping cloth, a non-woven fabric made of hydrophilic fibers such as cotton fibers and rayon fibers has been known. In addition, an embossing process is applied to such a non-woven fabric to give an uneven pattern. However, even if a concavo-convex pattern is provided, the concavo-convex pattern may easily disappear by compressing in the thickness direction. The non-woven fabric itself may be made rigid so as to prevent the uneven pattern from disappearing. However, if the non-woven fabric itself is made rigid, the water absorption may decrease.
一方、本発明者は、特殊な横断面形状を持つポリエステル不織布を開発した（特許文献１）。これは、ポリエステル長繊維を構成繊維とする不織布であって、該ポリエステル長繊維の横断面形状が、略Ｙ字の下端で上下左右に連結した
On the other hand, the present inventor has developed a polyester nonwoven fabric having a special cross-sectional shape (Patent Document 1). This is a non-woven fabric having polyester filaments as constituent fibers, and the transverse cross-sectional shape of the polyester filaments is vertically and horizontally connected at the lower end of the approximately Y shape.
形状（以下、「略Ｙ４形状」という。）であることを特徴とするポリエステル不織布というものである。かかるポリエステル不織布は、高剛性であるという特性を持っている。
本発明者は、上記ポリエステル不織布を用いて種々研究を行っていたところ、このポリエステル不織布の表裏面にコットン繊維層を積層すると共に、特定のエンボス加工を施して凹凸柄模様を付与すると、厚み方向に圧縮しても凹凸柄模様が消失しにくいと共に、吸水性の向上した不織布が得られることを見出した。本発明はかかる知見に基づくものである。したがって、本発明の課題は、凹凸柄模様が消失しにくく、しかも吸水性を向上させた不織布を得ることにある。 The present inventor has conducted various studies using the above polyester nonwoven fabric, and when a cotton fiber layer is laminated on the front and back surfaces of this polyester nonwoven fabric, and a specific embossing process is applied to give an uneven pattern pattern, the thickness direction It was found that even when compressed, the uneven pattern is unlikely to disappear and a nonwoven fabric having improved water absorption can be obtained. The present invention is based on such findings. Therefore, an object of the present invention is to obtain a non-woven fabric in which an uneven pattern is less likely to disappear and water absorption is improved.
本発明は、特許文献１記載の長繊維不織布とセルロース系繊維層を組み合わせると共に、特定のエンボス加工を施すことにより、上記課題を解決したものである。 The present invention solves the above-mentioned problems by combining a long-fiber nonwoven fabric described in Patent Document 1 and a cellulosic fiber layer and performing specific embossing.
本発明の要旨は、長繊維不織布の少なくとも片面に短繊維ウェブが積層され、短繊維ウェブの構成繊維が、長繊維不織布の構成繊維に絡み付き交絡することによって積層一体化してなる積層不織布であり、
該長繊維不織布を構成する長繊維の横断面形状が、略Ｙ字の下端で上下左右に連結した形状（略Ｙ４形状）であり、
短繊維ウェブが、セルロース系繊維によって主として構成されているものであり、
積層不織布には、線状の凹凸柄模様が賦形されており、凹凸柄模様は、表面の凸部が裏面の凹部に対応し、表面の凹部が裏面の凸部に対応するものであることを特徴とする凹凸柄模様を有する積層不織布にある。
The gist of the present invention is a laminated nonwoven fabric in which a short fiber web is laminated on at least one surface of a long fiber nonwoven fabric, and the constituent fibers of the short fiber web are laminated and integrated by entangled and entangled with the constituent fibers of the long fiber nonwoven fabric,
The cross-sectional shape of the long fibers constituting the long-fiber nonwoven fabric is a shape in which the lower end of the substantially Y-shape is vertically and horizontally connected (generally Y4 shape),
The short fiber web is mainly composed of cellulosic fibers,
A linear uneven pattern is formed on the laminated nonwoven fabric, and in the uneven pattern, the convex parts on the front surface correspond to the concave parts on the back surface, and the concave parts on the front surface correspond to the convex parts on the back surface. A laminated non-woven fabric having an uneven pattern.
また、本発明の要旨は、長繊維不織布の少なくとも片面に短繊維ウェブが積層して、積層ウェブを形成し、高圧水流を施して、短繊維と長繊維不織布とを交絡させ、次いで、エンボス装置に通して線状の凹凸模様を賦形する方法であって、
該長繊維不織布を構成する長繊維の横断面形状が、略Ｙ字の下端で上下左右に連結した形状（略Ｙ４形状）であり、
短繊維ウェブが、セルロース系繊維によって主として構成されているものであり、
エンボス装置が、一対の凹凸ロールから構成され、一方のロールの凸部が他方のロールの凹部、一方のロールの凹部が他方のロールの凸部に嵌合して回転する装置であることを特徴とする凹凸柄模様を有する積層不織布の製造方法にある。
Further, the gist of the present invention is that a short fiber web is laminated on at least one surface of a long fiber non-woven fabric to form a laminated web, a high-pressure water stream is applied to entangle the short fiber and the long fiber non-woven fabric, and then an embossing device. A method of shaping a linear uneven pattern through the
The cross-sectional shape of the long fibers constituting the long-fiber nonwoven fabric is a shape in which the lower end of the substantially Y-shape is vertically and horizontally connected (generally Y4 shape),
The short fiber web is mainly composed of cellulosic fibers,
The embossing device is composed of a pair of concavo-convex rolls, the convex part of one roll is a concave part of the other roll, and the concave part of one roll is a device that rotates by fitting to the convex part of the other roll. And a method for producing a laminated nonwoven fabric having an uneven pattern.
以下、本発明について詳細に説明する。 Hereinafter, the present invention will be described in detail.
長繊維不織布と短繊維ウェブとは、交絡処理が施されることにより一体化しているものであるが、交絡処理は水流交絡処理であることが好ましい。水流交絡処理は、高圧の液体流を施すものであり、被処理物である繊維を切断する等のダメージを与えることなく交絡させることができるためである。 The long fiber nonwoven fabric and the short fiber web are integrated by being subjected to the entanglement treatment, but the entanglement treatment is preferably hydroentanglement treatment. This is because the hydroentangling treatment is performed by applying a high-pressure liquid flow, and the fibers that are the objects to be treated can be entangled without causing damage such as cutting.
本発明における短繊維ウェブを構成する短繊維としては、水流交絡処理における水流の作用によって、繊維が動き、交絡することができるものであって、その素材としては、コットン、レーヨンやリヨセル等のセルロース系繊維を用いる。セルロース系繊維は、吸水性に優れるため、本発明の積層不織布を拭き布に適用するにあたって好ましい。なお、短繊維ウェブは、セルロース系繊維を主体とするが、ポリエステル系繊維やポリオレフィン系繊維等の合成繊維や、熱バインダー繊維等が少量含まれてもよい。短繊維の繊維長は、交絡性を考慮して、１０〜７０ｍｍ程度がよい。短繊維ウェブの目付は特に限定されず、所望により適宜選択すればよいが、１５〜１００ｇ／ｍ２程度がよい。 As the short fibers constituting the short fiber web in the present invention, the action of the water flow in the water entanglement treatment allows the fibers to move and be entangled, and its material is cotton, rayon or cellulose such as lyocell. A system fiber is used. Cellulose-based fibers are excellent in water absorption and are therefore preferable for applying the laminated nonwoven fabric of the present invention to a wipe. The short fiber web is mainly composed of cellulosic fibers, but may contain a small amount of synthetic fibers such as polyester fibers and polyolefin fibers, and thermal binder fibers. The fiber length of the short fibers is preferably about 10 to 70 mm in consideration of entanglement. The basis weight of the short fiber web is not particularly limited and may be appropriately selected as desired, but is preferably about 15 to 100 g / m 2 .
本発明における長繊維不織布は、その構成繊維の横断面形状に特徴を有するものである。この横断面形状は、図１に示すような略Ｙ字を四個持つものである。そして、略Ｙ字の下端１で上下左右に連結して、図２に示すような略Ｙ４形状となっている。また、中央の略＋字部５と、略＋字部５の各先端に連結された四個の略Ｖ字部６により、高剛性となっている。すなわち、六角形やＹ字等の単なる異形ではなく、剛性の高い略＋字部５と略Ｖ字部６の組み合わせによって、より高剛性となるのである。また、長繊維の繊度を１０デシテックス以上とすることにより、断面形状と太繊度との相乗効果により、より一層高剛性となる。また、略Ｙ字の下端で上下左右に連結することにより、繊維断面の外周において多数の凹部や多数の凸部を有することとなるため、このような長繊維が集積してなる長繊維不織布は嵩高性に優れ、長繊維同士が熱接着等により接合しているものであっても、水流交絡処理の際の水流の透過性にも優れる。なお、長繊維不織布の目付は２０〜８０ｇ／ｍ２の範囲が好ましく、単繊維繊度にもよるが、より好ましくは２０〜５０ｇ／ｍ２である。 The long-fiber nonwoven fabric of the present invention is characterized by the cross-sectional shape of its constituent fibers. This cross-sectional shape has four substantially Y-shapes as shown in FIG. The lower end 1 of the substantially Y-shape is connected vertically and horizontally to form a substantially Y4 shape as shown in FIG. Further, high rigidity is achieved by the substantially + -shaped portion 5 at the center and the four substantially V-shaped portions 6 connected to the respective tips of the substantially + -shaped portion 5. That is, the rigidity is further increased not only by a simple shape such as a hexagon or a Y-shape but also by a combination of the highly rigid substantially + -shaped portion 5 and the substantially V-shaped portion 6. Further, by setting the fineness of the long fibers to 10 decitex or more, the rigidity becomes further higher due to the synergistic effect of the cross-sectional shape and the large fineness. Further, by connecting the lower end of the substantially Y-shape vertically and horizontally, a large number of concave portions and a large number of convex portions are provided on the outer circumference of the fiber cross section. The bulkiness is excellent, and even if the long fibers are joined together by thermal bonding or the like, the permeability of the water flow during the water entanglement treatment is also excellent. The basis weight of the long-fiber nonwoven fabric is preferably in the range of 20 to 80 g / m 2 , and more preferably 20 to 50 g / m 2, although it depends on the fineness of the single fibers.
長繊維不織布は、剛性および形態安定性の観点から、構成繊維同士が熱接着により一体化してなるものが好ましいことから、熱可塑性重合体によって構成される。なかでも、機械的強度に優れ、剛性が付与できることから、ポリエステル系重合体であることが好ましい。ポリエステル系重合体により構成される長繊維（ポリエステル長繊維）は、一種類のポリエステルからなるものでもよいが、低融点ポリエステルと高融点ポリエステルとを組み合わせるのが好ましい。すなわち、ポリエステル長繊維の横断面形状の略Ｖ字部６が低融点ポリエステルで形成され、略＋字部５が高融点ポリエステルで形成された複合型するのが好ましい。複合型ポリエステル長繊維を集積した後、低融点ポリエステルを軟化又は溶融させて固化させることにより、ポリエステル長繊維相互間が低融点ポリエステルによって融着された不織布が得られるからである。 From the viewpoint of rigidity and morphological stability, the long-fiber non-woven fabric is preferably made of a thermoplastic polymer because the constituent fibers are preferably integrated by thermal bonding. Among them, polyester-based polymers are preferable because they have excellent mechanical strength and can impart rigidity. The long fibers (polyester long fibers) formed of the polyester polymer may be made of one kind of polyester, but it is preferable to combine the low melting point polyester and the high melting point polyester. That is, it is preferable to use a composite type in which the substantially V-shaped portion 6 of the cross-sectional shape of the polyester filament is formed of low melting point polyester and the substantially + shaped portion 5 is formed of high melting point polyester. This is because a non-woven fabric in which the polyester long fibers are fused to each other by the low melting point polyester is obtained by softening or melting the low melting point polyester and solidifying it after accumulating the composite type polyester long fibers.
長繊維不織布は、溶融紡糸する際に用いるノズル孔を変更する以外は、従来公知の方法で得られる。すなわち、熱可塑性重合体を溶融紡糸して得られた長繊維を集積して長繊維不織布を製造する方法において、溶融紡糸する際に用いるノズル孔の形状が、Ｙ字の下端で上下左右に連結し、かつ、隣り合うＹ字の／同士及び＼同士が平行である形状（以下、「Ｙ４形」という。）のものを用いるというものである。 The long fiber non-woven fabric can be obtained by a conventionally known method except that the nozzle holes used for melt spinning are changed. That is, in the method for producing a long-fiber nonwoven fabric by accumulating long fibers obtained by melt-spinning a thermoplastic polymer, the shape of the nozzle hole used during melt-spinning is linked vertically and horizontally at the lower end of the Y-shape. In addition, a shape in which adjacent Y-shaped / 's and \' s are parallel to each other (hereinafter, referred to as "Y4 shape") is used.
このノズル孔は、Ｙ字を四個持つものであり、Ｙ字の下端で上下左右に連結して、図３に示すＹ４形となっている。このＹ４形は、隣り合うＹ字の／同士が平行であり、また＼同士が平行となっている。かかるＹ４形のノズル孔に熱可塑性重合体を供給して溶融紡糸することにより、横断面が略Ｙ４形状の長繊維を得ることができるのである。特に、隣り合うＹ字の／同士及び＼同士が平行となっていることにより、四個の凹部２を持つ長繊維を得ることができる。また、略＋字部５と、その各々の先端に設けられた略Ｖ字部６とを持つ長繊維を得ることができる。このように凹部と略Ｖ字部を有することから、Ｖ字部によって汚れの優れたかきとり性を有し、凹部によって汚れの優れた捕集性も有する。 This nozzle hole has four Y-shapes, and the lower end of the Y-shape is connected vertically and horizontally to form a Y4 shape shown in FIG. In this Y4 type, adjacent Y-shaped / 's are parallel to each other and \' s are parallel to each other. By supplying the thermoplastic polymer to the Y4 type nozzle hole and performing melt spinning, it is possible to obtain a long fiber having a substantially Y4 cross section. In particular, long fibers having four recesses 2 can be obtained by arranging adjacent Y-shaped / 's and \' s in parallel. Further, it is possible to obtain a long fiber having a substantially + -shaped portion 5 and a substantially V-shaped portion 6 provided at the tip of each of them. Since the concave portion and the substantially V-shaped portion are provided as described above, the V-shaped portion has excellent scraping property for dirt, and the concave portion also has excellent dirt collecting property.
Ｙ４形のノズル孔に供給する熱可塑性重合体は、一種類であってもよいし、二種類であってもよい。特に、低融点ポリエステル樹脂と高融点ポリエステル樹脂の二種類を用いるのが好ましい。すなわち、低融点ポリエステル樹脂をＹ４形のＶ字部に供給し、高融点ポリエステル樹脂をＹ４形の＋字部に供給するのが好ましい。かかる供給態様で溶融紡糸することにより、略Ｖ字部６が低融点ポリエステルで形成され、略＋字部５が高融点ポリエステルで形成された複合型ポリエステル長繊維が得られる。 The thermoplastic polymer supplied to the Y4 type nozzle hole may be one kind or two kinds. In particular, it is preferable to use two kinds of low melting point polyester resin and high melting point polyester resin. That is, it is preferable that the low melting point polyester resin is supplied to the V-shaped portion of the Y4 type and the high melting point polyester resin is supplied to the + shaped portion of the Y4 type. By performing melt spinning in such a supply mode, a composite polyester continuous fiber in which the substantially V-shaped portion 6 is formed of low melting point polyester and the substantially + shaped portion 5 is formed of high melting point polyester is obtained.
長繊維を得た後、これを集積して一般的に繊維ウェブを形成する。そして、繊維ウェブを少なくとも加熱することにより、長繊維を構成する熱可塑性重合体（二種の重合体によって構成されるときは、低融点の重合体）を軟化又は溶融させ、冷却して固化させることにより、長繊維相互間を熱接着して長繊維不織布を得る。熱接着処理は、熱エンボス加工によって形成される部分的に熱圧着することにより熱接着しているものであっても、また、熱カレンダー加工による熱処理により熱接着しているもの、熱風処理により熱接着しているものでもよい。また、これらの方法を併用したものでもよい。 After obtaining the long fibers, they are collected and generally formed into a fibrous web. Then, by heating at least the fibrous web, the thermoplastic polymer that constitutes the long fibers (a polymer having a low melting point when it is composed of two kinds of polymers) is softened or melted, and is cooled and solidified. Thus, the long fibers are heat-bonded to each other to obtain a long fiber nonwoven fabric. The heat-bonding treatment includes heat-bonding by heat-bonding partially formed by heat-embossing, heat-bonding by heat treatment by heat calendering, heat-bonding by hot-air treatment. It may be glued. Also, a combination of these methods may be used.
本発明において長繊維不織布を構成する長繊維の単繊維繊度は、上述したように剛性を考慮すれば１０デシテックス以上がよい。また、不織布の目付にもよるが、単繊維繊度を１５デシテックス以上とすることにより、長繊維不織布において開孔（繊維が存在しない箇所）の面積比率が大きくなって短繊維が絡み付きやすくなる。単繊維繊度は大きいほど、剛性に優れる傾向にあるが、長繊維不織布を得る際に、延伸可紡性を考慮すれば上限は３０デシテックスとする。また一方で、長繊維の単繊維繊度が大きくなりすぎて、長繊維と短繊維の繊度差が大きくなりすぎると、短繊維ウェブとの一体化の際に短繊維が長繊維に絡みにくくなるため、上限は３０デシテックスがよい。 In the present invention, the single fiber fineness of the long fibers constituting the long fiber nonwoven fabric is preferably 10 decitex or more in consideration of rigidity as described above. Although it depends on the basis weight of the non-woven fabric, by setting the single fiber fineness to 15 decitex or more, the area ratio of the open pores (where the fibers do not exist) in the long-fiber non-woven fabric becomes large, and the short fibers are easily entangled. The larger the single fiber fineness, the more excellent the rigidity tends to be, but the upper limit is set to 30 decitex in consideration of the drawability and spinnability when the long fiber nonwoven fabric is obtained. On the other hand, if the single fiber fineness of the long fibers is too large, and the difference in fineness between the long fibers and the short fibers is too large, the short fibers are less likely to be entangled with the long fibers during integration with the short fiber web. The upper limit is 30 decitex.
本発明の積層不織布は、上記した略Ｙ４形状断面の長繊維からなる不織布の少なくとも片面に短繊維ウェブが積層され、短繊維ウェブの構成繊維同士は交絡一体化しているとともに、長繊維に絡み付くことにより複合化している。 In the laminated nonwoven fabric of the present invention, a short fiber web is laminated on at least one surface of the above-mentioned nonwoven fabric made of long fibers having a substantially Y4 cross section, and constituent fibers of the short fiber web are entangled and integrated with each other and entangled with the long fibers. It is compounded by.
水流交絡処理は、公知の方法により行えばよい。まず、長繊維不織布の上に短繊維ウェブを積層し、この積層物をメッシュ状支持体に担持する。次いで、積層物の短繊維ウェブ側から高圧水流を施し、短繊維ウェブ内の構成繊維同士を交絡させるとともに、短繊維が長繊維に絡み付くことにより一体化させる。この高圧水流は、孔径０．０５〜２．０ｍｍの噴射孔が、噴射孔間隔０．０５〜１０ｍｍで一列又は複数列配置されている噴射装置を用い、水を噴射孔から１．５〜３０ＭＰａの圧力で噴射して得られるものである。そうすると、高圧水流はウェブに衝突して、短繊維に運動エネルギーを与える。この運動エネルギーにより、短繊維ウェブ内の短繊維同士が交絡し、また、短繊維は、長繊維不織布を構成する長繊維に絡む。一体化した積層ウェブには、高圧水流による水分が含まれているので、乾燥して水分を除去する。 The hydroentangling treatment may be performed by a known method. First, a short fiber web is laminated on a long fiber nonwoven fabric, and this laminate is supported on a mesh-shaped support. Then, a high-pressure water stream is applied from the short fiber web side of the laminate to entangle the constituent fibers in the short fiber web, and the short fibers are entangled with the long fibers to be integrated. This high-pressure water flow uses an injection device in which injection holes having a hole diameter of 0.05 to 2.0 mm are arranged in one row or a plurality of rows with an injection hole interval of 0.05 to 10 mm, and water is injected from the injection holes at 1.5 to 30 MPa. It is obtained by injecting at the pressure of. The high pressure water stream then impinges on the web and imparts kinetic energy to the short fibers. By this kinetic energy, the short fibers in the short fiber web are entangled with each other, and the short fibers are entangled with the long fibers constituting the long fiber nonwoven fabric. Since the integrated laminated web contains water due to the high-pressure water stream, it is dried to remove the water.
本発明の積層不織布は、交絡により一体化した状態で、線状の凹凸柄模様が賦形されている。この凹凸模様は、表面の凸部が裏面の凹部に対応し、表面の凹部が裏面の凸部に対応するものである。このような凹凸柄模様を賦形するためには、一対の凹凸ロールから構成されるエンボス装置であって、一方のロールの凸部が他方ロールの凹部に嵌合し、一方のロールの凹部が他方ロールの凸部に嵌合して回転する装置に通すことにより得られる。この一対の回転している凹凸ロール間に、一体化した積層ウェブを通すと、凹凸ロールの周面形状に合致した凹凸柄模様を持つ積層不織布が得られるのである。すなわち、ロールの周面には特定の方向に走行する筋状の凸部と筋状の凹部とが交互に形成されており、これに応じた線状の凹凸が積層不織布に賦形されるのである。ロールの周方向に平行して凹部と凸部が形成してなる凹凸ロールを用いた場合は、積層不織布において、機械方向に平行した線状の凹凸が形成され、ロールの幅方向に平行して凹部と凸部が形成してなる凹凸ロールを用いた場合は、積層不織布において、機械方向と直交する方向に平行して走行してなる線状の凹凸が形成される。また、ロールの幅方向に対して斜行して凹部と凸部が形成してなる(ロールの軸方向に対してらせん状に凹凸が形成されてなる)凹凸ロールを用い、積層不織布面において斜行した線状の凹凸を形成させてもよい。 The laminated nonwoven fabric of the present invention is formed with a linear uneven pattern in a state of being integrated by interlacing. In this uneven pattern, the convex portions on the front surface correspond to the concave portions on the back surface, and the concave portions on the front surface correspond to the convex portions on the back surface. In order to form such a concavo-convex pattern, an embossing device composed of a pair of concavo-convex rolls, in which the convex part of one roll fits into the concave part of the other roll and the concave part of one roll is On the other hand, it is obtained by fitting it into the convex portion of the roll and passing it through a rotating device. By passing an integrated laminated web between the pair of rotating concavo-convex rolls, a laminated nonwoven fabric having a concavo-convex pattern pattern matching the peripheral surface shape of the concavo-convex rolls can be obtained. That is, streaky convex portions and streaky concave portions that travel in a specific direction are alternately formed on the peripheral surface of the roll, and linear irregularities corresponding to this are formed on the laminated nonwoven fabric. is there. When using a concave-convex roll formed by forming concave and convex portions in parallel with the circumferential direction of the roll, in the laminated nonwoven fabric, linear concaves and convexes parallel to the machine direction are formed and parallel to the width direction of the roll. In the case of using the concave-convex roll formed with the concave portion and the convex portion, linear unevenness formed by running parallel to the machine direction is formed in the laminated nonwoven fabric. In addition, a concave-convex roll formed by forming a concave portion and a convex portion obliquely to the width direction of the roll (having irregularities formed in a spiral shape with respect to the axial direction of the roll) is used, and is oblique on the laminated nonwoven fabric surface. You may form the linear unevenness which carried out.
凹凸ロールにおける凹部間及び凸部間のピッチは任意でよいが、一般的には５〜１０ｍｍ程度である。また、凹部の深さ及び凸部の高さも任意でよいが、一般的には０．５〜１．５ｍｍ程度である。エンボス装置に通す際のロール間の線圧も任意であるが、５０〜１００ｋｇｆ／ｃｍ程度であるのが好ましい。一対のエンボスロールは加熱されているのが好ましく、加熱温度は長繊維の融点未満であり、１００〜１７０℃程度が好ましい。 The pitch between the concave portions and the convex portions in the concave-convex roll may be arbitrary, but is generally about 5 to 10 mm. Further, the depth of the concave portion and the height of the convex portion may be arbitrary, but they are generally about 0.5 to 1.5 mm. The linear pressure between the rolls when passing through the embossing device is arbitrary, but is preferably about 50 to 100 kgf / cm. It is preferable that the pair of embossing rolls are heated, and the heating temperature is lower than the melting point of the long fibers, and preferably about 100 to 170 ° C.
凹凸柄模様として賦形する線の形態は、完全に連続してなる線であっても、一部破断してなる破線であってもよい。また、山谷を形成してなるジグザグ状の線であっても、曲線を描く波線であってもよい。 The shape of the line formed as the uneven pattern may be a completely continuous line or a partially broken line. Further, it may be a zigzag line formed by forming a valley or a wavy line that draws a curve.
本発明の積層不織布は、明確な凹凸柄模様を有するものである。長繊維不織布が高剛性であるため、賦形した凹凸柄模様が、押圧した場合でも容易に消失しない。このような積層不織布は、例えば、清掃用の拭き取りシート、トレイマットやドリップシート等の吸水シート、結露吸水シート、フィルター材、包装材等に良好に用いることができる。 The laminated nonwoven fabric of the present invention has a clear pattern of concavo-convex patterns. Since the long-fiber nonwoven fabric has high rigidity, the uneven pattern pattern formed does not easily disappear even when pressed. Such a laminated nonwoven fabric can be favorably used as, for example, a wiping sheet for cleaning, a water absorbing sheet such as a tray mat or a drip sheet, a dew condensation water absorbing sheet, a filter material, a packaging material and the like.
なお、本発明の積層不織布は、長繊維不織布の少なくとも片面に短繊維ウェブを積層してなるが、長繊維不織布を中間層として、その両面に短繊維ウェブを積層し一体化してなるものであってもよい。 The laminated non-woven fabric of the present invention is formed by laminating a short fiber web on at least one side of a long fiber non-woven fabric. May be.
本発明の積層不織布は、高剛性の長繊維不織布の少なくとも片面に吸水性を有するセルロース系繊維を積層したものであり、不織布全体に凹凸柄模様を持つものである。かかる積層不織布は、高剛性の長繊維不織布が中間層に配置されているので、不織布の厚み方向に荷重を掛けても、凹凸柄模様が消失しにくいという効果を奏する。また、嵩高な長繊維不織布が片面に配置されていると共に、表裏面に凹凸柄模様が付されているので、少なくとも片面に存在するセルロース系繊維に吸収された水分は、速やかに拡散するという効果を奏する。 The laminated non-woven fabric of the present invention is a highly rigid long-fiber non-woven fabric laminated with water-absorbing cellulosic fibers on at least one side thereof, and has an uneven pattern on the entire non-woven fabric. In such a laminated non-woven fabric, since a high-rigidity long-fiber non-woven fabric is arranged in the intermediate layer, even if a load is applied in the thickness direction of the non-woven fabric, the uneven pattern pattern is less likely to disappear. In addition, the bulky long-fiber nonwoven fabric is arranged on one side, and since the front and back surfaces are provided with a concavo-convex pattern, the water content absorbed by at least one side of the cellulosic fibers is quickly diffused. Play.
実施例１
［ポリエステル不織布の準備］
ジカルボン酸成分としてテレフタル酸（ＴＰＡ）９２ｍｏｌ％及びイソフタール酸（ＩＰＡ）８ｍｏｌ％を用い、ジオール成分としてエチレングリコール（ＥＧ）１００ｍｏｌ％を用いて共重合し、低融点ポリエステル（相対粘度〔ηｒｅｌ〕１．４４、融点２３０℃）を得た。この低融点ポリエステルに、結晶核剤として４．０質量％の酸化チタンを添加して、低融点ポリエステル樹脂を準備した。一方、ジカルボン酸成分としてテレフタル酸（ＴＰＡ）１００ｍｏｌ％とジオール成分としてエチレングリコール（ＥＧ）１００ｍｏｌ％を用いて共重合し、高融点ポリエステル樹脂（ポリエチレンテレフタレート、相対粘度〔ηｒｅｌ〕１．３８、融点２６０℃）を準備した。そして、図３に示したノズル孔を用い、Ｖ字部に低融点ポリエステル樹脂を供給し、＋字部に高融点ポリエステル樹脂を供給して、紡糸温度２８５℃、単孔吐出量８．３３ｇ／分で溶融紡糸した。なお、低融点ポリエステル樹脂の供給量と高融点ポリエステル樹脂の供給量の重量比は、１：２であった。
Example 1
[Preparation of polyester non-woven fabric]
A low-melting polyester (relative viscosity [ηrel] 1. 44, melting point 230 ° C.). To this low melting point polyester, 4.0% by mass of titanium oxide was added as a crystal nucleating agent to prepare a low melting point polyester resin. On the other hand, 100 mol% of terephthalic acid (TPA) as a dicarboxylic acid component and 100 mol% of ethylene glycol (EG) as a diol component were used for copolymerization to obtain a high melting point polyester resin (polyethylene terephthalate, relative viscosity [ηrel] 1.38, melting point 260). ℃) was prepared. Then, using the nozzle holes shown in FIG. 3, the low melting point polyester resin was supplied to the V-shaped portion, the high melting point polyester resin was supplied to the + shaped portion, the spinning temperature was 285 ° C., and the single hole discharge rate was 8.33 g / Melt spun in minutes. The weight ratio of the supply amount of the low melting point polyester resin and the supply amount of the high melting point polyester resin was 1: 2.
ノズル孔から排出されたフィラメント群を、２ｍ下のエアーサッカー入口に導入し、複合型ポリエステル長繊維の繊度が１７デシテックスとなるように牽引した。エアーサッカー出口から排出された複合型ポリエステル長繊維群を開繊装置にて開繊した後、移動するネット製コンベア上に集積し、繊維ウェブを得た。この繊維ウェブを、表面温度が２１３℃のエンボスロール（各エンボス凸部先端の面積は０．７ｍｍ２で、ロール全面積に対するエンボス凸部の占める面積率は１５％）とフラットロールからなる熱融着装置に導入し、両ロール間の線圧３０ｋｇｆ／ｃｍの条件として、複合型ポリエステル長繊維相互間を低融点成分で熱融着して、目付４０ｇ／ｍ２のポリエステル長繊維不織布を得た。
［コットンウェブの準備］
一方、精練・漂白したコットン繊維（繊維長約２５〜３５ｍｍ）を用いて、大和機工株式会社製のサンプルローラーカード機にて目付３０ｇ／ｍ２のコットンウェブを作成した。
［凹凸模様を持つ不織布の製造］
上記したポリエステル長繊維不織布の片面に、上記したコットンウェブを積層し、２層構造ウェブを作成した。そして、この２層構造ウェブを、１００メッシュのステンレスネット上に載せ、ノズル径０．１３ｍｍ、水圧８．３３ＭＰａの条件で、ポリエステル長繊維不織布の表面に積層されたコットンウェブ側から高圧水流を施して、一体化した２層構造ウェブを得た。
一体化した２層構造ウェブから水分を乾燥除去した後、一対の凹凸ロールに通して、凹凸柄模様を持つ不織布を得た。得られた凹凸柄模様を持つ不織布の目付は８０ｇ／ｍ２であった。ここで、凹凸ロールは、ロールの幅方向に平行して凹部と凸部が交互に形成してなる凹凸ロールであって、ジグザグ線の模様を形成するものである。一方の凹凸ロールには、凹部の幅が３．２ｍｍ、凸部の幅が１．０ｍｍ、凹部及び凸部間のピッチが６．５ｍｍであり、凹部の深さ及び凸部の高さが１．０ｍｍのものである。そして、他方の凹凸ロールは、前記凹凸ロールに嵌合する凹部と凸部を有している。また、一対の凹凸ロールは１４０℃に加熱した状態で、一方の凹部を他方の凸部に、一方の凸部を他方の凹部に噛合させて回転させて、一体化した積層構造ウェブを通した。なお、一対の凹凸ロールの線圧は６６．７ｋｇｆ／ｃｍとした。
The filament group discharged from the nozzle hole was introduced into the inlet of the air sucker 2 m below, and the filament was pulled so that the fineness of the composite polyester filament was 17 decitex. The composite type polyester filaments discharged from the air-sucker outlet were opened with a fiber-opening device and then accumulated on a moving net conveyor to obtain a fiber web. This fibrous web is heat-melted with an embossing roll having a surface temperature of 213 ° C. (the area of the tip of each embossing protrusion is 0.7 mm 2 and the area ratio of the embossing protrusion to the entire area of the roll is 15%) and a flat roll. Introduced into a bonding apparatus, and under the condition of a linear pressure between both rolls of 30 kgf / cm, the composite polyester filaments were heat-fused with a low melting point component to obtain a polyester filament nonwoven fabric with a basis weight of 40 g / m 2 . ..
[Cotton web preparation]
On the other hand, a cotton web having a basis weight of 30 g / m 2 was prepared using a sample roller card machine manufactured by Daiwa Kiko Co., Ltd. using scoured and bleached cotton fibers (fiber length of about 25 to 35 mm).
[Manufacture of non-woven fabric with uneven pattern]
The above-mentioned cotton web was laminated on one surface of the above polyester long-fiber nonwoven fabric to prepare a two-layer structure web. Then, this two-layer structure web was placed on a 100-mesh stainless net, and a high-pressure water stream was applied from the cotton web side laminated on the surface of the polyester long-fiber nonwoven fabric under the conditions of a nozzle diameter of 0.13 mm and a water pressure of 8.33 MPa. To obtain an integrated two-layer structure web.
After water was dried and removed from the integrated two-layer structure web, the web was passed through a pair of uneven rolls to obtain a nonwoven fabric having an uneven pattern. The basis weight of the obtained non-woven fabric having an uneven pattern was 80 g / m 2 . Here, the concavo-convex roll is a concavo-convex roll in which concave portions and convex portions are alternately formed in parallel with the width direction of the roll, and forms a zigzag line pattern. On one concavo-convex roll, the width of the concave portion was 3.2 mm, the width of the convex portion was 1.0 mm, the pitch between the concave portions was 6.5 mm, and the depth of the concave portion and the height of the convex portion were 1 mm. 0.0 mm. The other concavo-convex roll has a concave part and a convex part that fit into the concavo-convex roll. In addition, while the pair of concavo-convex rolls were heated to 140 ° C., one concave portion was meshed with the other convex portion, and one convex portion was meshed with the other concave portion to rotate, and passed through the integrated laminated structure web. .. The linear pressure of the pair of concavo-convex rolls was 66.7 kgf / cm.
比較例１
ポリエステル不織布の目付を７０ｇ／ｍ２に変更する他は、実施例１と同一の方法でポリエステル長繊維不織布を得た。このポリエステル長繊維不織布を、コットンウェブを積層することなく、実施例１で用いた一対の凹凸ロール間に通し、凹凸模様を持つ目付は７８ｇ／ｍ２のポリエステル長繊維不織布を得た。
Comparative Example 1
A polyester continuous fiber nonwoven fabric was obtained in the same manner as in Example 1 except that the basis weight of the polyester nonwoven fabric was changed to 70 g / m 2 . This polyester continuous fiber non-woven fabric was passed between the pair of concavo-convex rolls used in Example 1 without laminating a cotton web, and a polyester continuous fiber non-woven fabric having a concavo-convex pattern and a basis weight of 78 g / m 2 was obtained.
比較例２
ポリエステル長繊維不織布を用いず、かつコットンウェブの目付を７０ｇ／ｍ２に変更する他は、実施例１と同一の方法でコットンウェブを得た。このコットンウェブを、１００メッシュのステンレスネット上に載せ、ノズル径０．１３ｍｍ、水圧８．３３ＭＰａの条件で、高圧水流を施して、コットン不織布を得た。このコットン不織布を、実施例１で用いた一対の凹凸ロール間に通し、凹凸模様を持つ目付は８０ｇ／ｍ２のコットン不織布を得た。
Comparative example 2
A cotton web was obtained in the same manner as in Example 1 except that the polyester continuous fiber non-woven fabric was not used and the basis weight of the cotton web was changed to 70 g / m 2 . This cotton web was placed on a 100-mesh stainless net and subjected to a high-pressure water flow under the conditions of a nozzle diameter of 0.13 mm and a water pressure of 8.33 MPa to obtain a cotton nonwoven fabric. This cotton non-woven fabric was passed between the pair of concavo-convex rolls used in Example 1 to obtain a cotton non-woven fabric having a concavo-convex pattern and a basis weight of 80 g / m 2 .
実施例１で得られた凹凸模様を持つ不織布、比較例１で得られた凹凸模様を持つポリエステル不織布について圧縮歪の試験を行った。また、実施例１、比較例１、２のそれぞれで得られた凹凸模様を持つ不織布について吸水性の試験を行った。圧縮歪の試験は、以下の方法により行った。各試料不織布を平板に挟んで初荷重２０ｇｆ／ｃｍ２を掛けて試料の厚みを測定する。その後、荷重を１０〜１３７ｇｆ／ｃｍ２まで上乗せして増加させ、厚みの減少率を算出した。厚みの減少率は、［（ｔ０−ｔ１）／ｔ０］×１００（％）なる式で算出されるものである。ここで、ｔ０は初荷重２０ｇｆ／ｃｍ２を掛けた時点での試料の厚みであり、ｔ１は荷重を上乗せして増加させたときの試料の厚みである。また、吸水性の試験は、ＪＩＳ Ｌ １９０７に記載のバイレック法により行った。圧縮歪試験の結果を表１に、吸水性試験の結果を表２に示した。 The compressive strain test was conducted on the nonwoven fabric having the uneven pattern obtained in Example 1 and the polyester nonwoven fabric having the uneven pattern obtained in Comparative Example 1. Further, the water absorption test was performed on the nonwoven fabrics having the uneven pattern obtained in each of Example 1 and Comparative Examples 1 and 2. The test for compressive strain was performed by the following method. Each sample nonwoven fabric is sandwiched between flat plates and an initial load of 20 gf / cm 2 is applied to measure the thickness of the sample. After that, the load was increased to 10 to 137 gf / cm 2 and increased, and the reduction rate of the thickness was calculated. The reduction rate of the thickness is calculated by the formula [(t0-t1) / t0] × 100 (%). Here, t0 is the thickness of the sample at the time of applying the initial load of 20 gf / cm 2 , and t1 is the thickness of the sample when the load is increased to increase. The water absorption test was carried out by the Bayrek method described in JIS L1907. The results of the compression strain test are shown in Table 1, and the results of the water absorption test are shown in Table 2.
実施例１、比較例２の結果から分かるように、不織布を厚み方向に圧縮した場合、実施例１に係る方法で得られた不織布は、比較例１に係る方法で得られた不織布に比べて、圧縮されにくく、付された凹凸柄模様が消失しにくいことが分かる。また、不織布を吸水させた場合、実施例１に係る方法で得られた不織布は、比較例１に係る方法で得られた不織布よりも吸水した水が拡散しやすく、また、比較例２に係る方法で得られた不織布よりも吸水性に優れるコットン繊維の含有比率が少ないにもかかわらず、ＭＤ方向においては吸水した水が拡散しやすいことが分かる。 As can be seen from the results of Example 1 and Comparative Example 2, when the non-woven fabric was compressed in the thickness direction, the non-woven fabric obtained by the method according to Example 1 was compared with the non-woven fabric obtained by the method according to Comparative Example 1. It can be seen that it is difficult to compress and the attached uneven pattern is hard to disappear. Further, when the nonwoven fabric is made to absorb water, the nonwoven fabric obtained by the method according to Example 1 is more likely to diffuse the absorbed water than the nonwoven fabric obtained by the method according to Comparative Example 1, and according to Comparative Example 2. It can be seen that the absorbed water is more likely to diffuse in the MD direction, although the content ratio of the cotton fiber, which is more excellent in water absorption than the nonwoven fabric obtained by the method, is small.
１ ポリエステル長繊維の横断面形状である略Ｙ４形状の一つの略Ｙ字の下端
２ 略Ｙ４形状で形成された凹部
３ 略Ｙ４形状で形成された凸部
４ 略Ｙ４形状で形成された小凹部
５ 略Ｙ４形状中の略＋字部
６ 略Ｙ４形状中の略Ｖ字部
1 Lower end of one substantially Y-shape of a substantially Y4 shape which is the cross-sectional shape of a polyester filament 2 Recessed portion formed in a substantially Y4 shape 3 Convex portion formed in a substantially Y4 shape 4 Small recessed portion formed in a substantially Y4 shape 5 Approximately + character portion in substantially Y4 shape 6 Approximate V character portion in substantially Y4 shape
Claims (7)
該長繊維不織布を構成する長繊維の横断面形状が、略Ｙ字の下端で上下左右に連結した
形状（以下、「略Ｙ４形状」という。）であり、
短繊維ウェブが、セルロース系繊維によって主として構成されているものであり、
積層不織布には、線状の凹凸柄模様が賦形されており、凹凸柄模様は、表面の凸部が裏面の凹部に対応し、表面の凹部が裏面の凸部に対応するものであることを特徴とする凹凸柄模様を有する積層不織布。 A short fiber web is laminated on at least one surface of a long fiber non-woven fabric, and the constituent fibers of the short fiber web are laminated non-woven fabrics that are laminated and integrated by entangled and entangled with the constituent fibers of the long fiber non-woven fabric,
The cross-sectional shape of the long fibers constituting the long-fiber non-woven fabric is connected vertically and horizontally at the lower end of the approximately Y shape.
The shape (hereinafter, referred to as “substantially Y4 shape”),
The short fiber web is mainly composed of cellulosic fibers,
A linear uneven pattern is formed on the laminated nonwoven fabric, and in the uneven pattern, the convex parts on the front surface correspond to the concave parts on the back surface, and the concave parts on the front surface correspond to the convex parts on the back surface. Laminated non-woven fabric having an uneven pattern.
該長繊維不織布を構成する長繊維の横断面形状が、略Ｙ字の下端で上下左右に連結した
形状（以下、「略Ｙ４形状」という。）であり、
短繊維ウェブが、セルロース系繊維によって主として構成されているものであり、
エンボス装置が、一対の凹凸ロールから構成され、一方のロールの凸部が他方のロールの凹部、一方のロールの凹部が他方のロールの凸部に嵌合して回転する装置であることを特徴とする凹凸柄模様を有する積層不織布の製造方法。
A short fiber web is laminated on at least one side of a long fiber non-woven fabric to form a laminated web, and a high-pressure water stream is applied to entangle the short fiber and the long fiber non-woven fabric, and then, passed through an embossing device to form a linear uneven pattern. The method of shaping
The cross-sectional shape of the long fibers constituting the long-fiber non-woven fabric is connected vertically and horizontally at the lower end of the approximately Y shape.
The shape (hereinafter, referred to as “substantially Y4 shape”),
The short fiber web is mainly composed of cellulosic fibers,
The embossing device is composed of a pair of concavo-convex rolls, the convex part of one roll is a concave part of the other roll, and the concave part of one roll is a device that rotates by fitting to the convex part of the other roll. And a method for producing a laminated non-woven fabric having an uneven pattern.
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