JPH02133641A - Production of nonwoven sheet - Google Patents

Production of nonwoven sheet

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Publication number
JPH02133641A
JPH02133641A JP63286118A JP28611888A JPH02133641A JP H02133641 A JPH02133641 A JP H02133641A JP 63286118 A JP63286118 A JP 63286118A JP 28611888 A JP28611888 A JP 28611888A JP H02133641 A JPH02133641 A JP H02133641A
Authority
JP
Japan
Prior art keywords
web layer
shrinkable
fiber web
shrinkable fiber
fibers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
JP63286118A
Other languages
Japanese (ja)
Inventor
Tadashi Miyazaki
正 宮崎
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to JP63286118A priority Critical patent/JPH02133641A/en
Publication of JPH02133641A publication Critical patent/JPH02133641A/en
Pending legal-status Critical Current

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  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

PURPOSE:To obtain a nonwoven sheet excellent in stretchability, drapeability, surface designability, napping suitability, etc., by subjecting a specific nonwoven fabric to specified treatment. CONSTITUTION:A laminate web of a shrinkable fiber web layer and a nonshrinkable fiber web layer without shrinking at a temperature where the above-mentioned shrinkable fiber shrinks is subjected to high-pressure columnar fluid treatment. A film without shrinking at the temperature where the heat- shrinkable fiber shrinks is formed on the nonshrinkable fiber web layer surface of the laminated web having both integrated web layers to shrink the shrinkable fiber web layer. Thereby, a nonwoven fabric having many fine unevennesses on the film surface and creped surface conditions is obtained.

Description

【発明の詳細な説明】[Detailed description of the invention]

【産業上の利用分野] 本発明は、車両用内装材、インテリア用内装十イ。 医療用に布1合成皮革用基布、簡易外衣等に好適に用い
られる不感シートの製造方法に関し2、機能面において
伸縮性、ドレ・−プ性1表面意匠性、起f;i’m性等
に優れた不織シートの製造方法に関するものである。 【従来の技術及び発明が解決しようとする課8】従来よ
り、自動車の車両用内装材等として、不織布に合成樹脂
製フィルムをコーティングやラミ不−1−等の手段で貼
合したシートが用いられている。これは、不織布の持・
つクツション性と合成樹脂製フィルムの持・つ耐摩耗性
を具現したシ・−1・であり、各種の用途に適用しうる
ちのである。 しかしながら、合成樹脂製フィルムは不織布乙こ比べて
、柔軟性及び融通性に劣るため、得られたジ・−トは不
織布の柔軟性及び融通性を発現しえず、ベーパーライク
な風合になってし2まうという欠点があった。また、表
面に合成樹脂装フ、イルムが現れるので、平坦で面白み
のない表面状態を示17、内装材等の装飾的用途に用い
るのには不十分であるという欠点があった。 そこで、本発明者は各種の不織布と合成樹脂製フィルム
とを貼合し種々研究した結果、ある特定の不織布に特定
の処理を施すことにより、不織布の柔軟性及び融通性を
害することなく 11つ表面に装飾的模様を持つ不織シ
ートが得られることを見出し、本発明に到達しまたので
ある。
[Industrial Application Field] The present invention relates to vehicle interior materials and interior materials. Regarding the manufacturing method of an insensitive sheet suitable for use in medical purposes such as cloth 1 for synthetic leather base fabric, simple outerwear, etc. 2. Functionally elasticity, drapability, 1 surface design, and f;i'm property. The present invention relates to a method for producing a nonwoven sheet with excellent properties. [Prior Art and Issue 8 to be Solved by the Invention] Conventionally, sheets made of non-woven fabric and synthetic resin film laminated by means such as coating or laminating have been used as interior materials for automobiles. It is being This is due to the durability of non-woven fabrics.
It is C-1, which embodies the cushioning properties and wear resistance of a synthetic resin film, and can be applied to a variety of applications. However, since synthetic resin films are inferior in flexibility and flexibility compared to non-woven fabrics, the resulting sheet cannot exhibit the flexibility and flexibility of non-woven fabrics and has a vapor-like texture. There was a drawback that it took two hours. In addition, since a synthetic resin coating or film appears on the surface, the surface is flat and uninteresting17, which is disadvantageous in that it is unsatisfactory for use in decorative applications such as interior materials. Therefore, as a result of various studies by laminating various nonwoven fabrics and synthetic resin films, the present inventor has found that by applying a specific treatment to a certain nonwoven fabric, 11 types can be obtained without impairing the flexibility and flexibility of the nonwoven fabric. It was discovered that a nonwoven sheet having a decorative pattern on the surface can be obtained, and the present invention was also achieved.

【課題を解決するための手段及び作用】即ち本発明は、
熱収縮性繊維を含有する収縮性繊維ウェブ層と該熱収縮
性繊維が収縮する温度では実質的に収縮しない非収縮性
繊維ウェブ層とを積層した積層ウェブに高圧柱状流を施
して、該収縮性繊維ウェブ層と該非収縮性繊維ウェブ層
とを一体化し、次いで該非収縮性繊維ウェブ層面に該熱
収縮性繊維が収縮する温度では実質的に収縮しないフィ
ルムを形成した後、該収縮性繊維ウェブ層を収縮させる
ことを特徴とする不織シートの製造方法に関するもので
ある。 本発明においては、まず収縮性魂維ウェブ層と非収縮性
繊維ウェブ層とを積層した積層ウェブを準備する。 収縮性繊維ウェブ層は熱収縮性繊維を含有している。熱
収縮性繊維とは、熱(及び必要により水分)を与えるこ
とにより収縮を発現する繊維である。熱収縮性繊維とし
ては、−1’12に使用されている熱可塑性繊維、特に
高延伸を施した熱可塑性繊維を用いることができる。具
体的には、ポリ塩化ビニル繊維、ポリプロピレン繊維、
高収縮モダクリル繊維、高収縮ポリエステル繊維、ポリ
ビニルアルニ1−ル繊維等を用いることができる。収縮
性繊維ウェブ層中における熱収縮性繊維の割合は、所望
の面積収縮率が得られるように任意に設定しうるが、5
0重駐%程度以上、特に70重量%以上が好ましい、最
も好ましくは、熱収縮性繊維100重景%を用いて収縮
性繊維ウェブ層を形成するのがよい。 収縮性繊維ウェブ層としては、ステーブルファイバーを
集積した繊維フリース、連続フィラメンI・を集積し7
た繊維フリース、或いは編織物等が用いられる。繊維フ
リースとしては、ステーブルファイバー等の構成繊維が
ランダムに集積したランダムフリース又はクロスレ・イ
フリースであってもよいし、構成繊維が一方向に配列し
た一方向性フリースであってもよい。しかし、収縮の発
現を一方向に集中させる方が、収縮効率、生産性及び製
品の中管理等の点から好ましく、従って収縮性繊維ウェ
ブ層としては一方向性繊維フリースを採用するのが好ま
しい。編織物の場合は、経糸及び緯糸の両者とも熱収縮
性繊維よりなる糸を用いてもよいし、経糸又は緯糸のみ
に熱収縮性繊維よりなる糸を用いてもよい。しかし、後
者の編織物の方が収縮の発現を一方向に集中させること
ができるので好ましい。 非収縮性繊維ウェブ層は、前記の収縮性携j11[ウェ
ブ層中の熱収縮性繊維が収縮する温度では実質的に収縮
しないものである。従って、非収縮性繊維ウェブ層を構
成する繊維としては、前記の熱収縮性繊維の収縮温度を
考慮して、任意に決定することができる。従って、熱可
塑性でない天然繊維や再生繊維或いは収縮温度が比較的
高い熱可塑性繊維を用いることができる。また、非収縮
性繊維ウェブ層中には、熱収縮性繊維の収縮温度で非収
縮性繊維ウェブ層が実質的に収縮しない限り、熱融着性
繊維が混入していてもよいし、また熱融着性繊維を10
0重量%用いて非収縮性繊維ウェブ層を形成してもよい
。 非収縮性繊維ウェブ層としては、ステーブルファイバー
を集積した繊維フリース、連続フィラメントを集積した
繊維フリース、或いは編織物等が用いられる。なお、非
収縮性繊維ウェブ層の構成繊維の繊度は細いほど好士U
2い。温度が細いと、収縮性繊維つにブ層が収縮した後
の非収縮性繊維ウェブ層の表面状態が美麗であり、表面
意匠性や起毛適性の面で優れているからである。 収縮性繊維ウェブ層と非収縮性繊維ウェブ層を積層して
積層ウェブを形成する。積層の仕方としては、−枚の収
縮性繊維ウェブ層と一枚の非収縮性繊維ウェブ層とを積
層して二層積層ウェブとしζもよいし、−枚の収縮性ウ
ェブの両面に非収縮性繊維ウェブを積層して三層積層ウ
ェブ等としてもよい。 この積層ウェブに高圧柱状流を施す。高圧柱状流とは、
微細な直径のオリフィス孔を通して高圧で非圧縮性の流
体を噴出させて得られるものである。具体的には、孔径
0.1〜0.2nunのオリフィスから10〜150k
g/c+flの圧力で水を噴出させて得られるものであ
る。この高圧柱状流を積層ウェブに施すと、収縮性繊維
ウェブ層中の熱収縮性繊維等の構成繊維及び非収縮性繊
維ウェブ層中の構成l−維が運動し、隣接する他の構成
繊維と緊密に絡合する。この結果、収縮性繊維ウェブ層
と非収縮性繊維ウェブ層との層間において、各構成繊維
が緊密に絡合し、層間が緊密に接合し一体化したウェブ
が得られる。 次に、この−休出つニブの非収縮性繊維ウェブ層面にフ
ィルムを形成する。フィルムとしては、−膜内に合成樹
脂製フィルムが用いられ、その厚さは50μ程度以下で
あるのが好ましい。フィルムの厚さが50μを超えると
、フィルムの剛性が大きくなって、収縮処理後における
微細な凹凸が発現しにくくなる傾向が生じる。また、こ
のフィルムは熱収縮性繊維が収縮する温度では実質的に
収縮しないものを用いる必要がある。従って、結晶化度
の極めて低い(非晶質)合成樹脂性フィルムや高融点フ
ィルムを用いるのが好ましい。フィルムを非収縮性繊維
ウェブ層面に形成する方法としては、フィルムを非収縮
性繊維ウェブ層面に貼合(ラミネーション)する方法2
合成樹脂の溶液を塗布(コーティング)する方法2合成
樹脂の溶液を噴霧(スプレー)する方法等が用いられる
。 非収縮性繊維ウェブ層面に形成されるフィルムは、無孔
フィルムであってもよいし、有孔フィルムであってもよ
い。また、フィルムとして撥水性フィルム、透ン易防水
性フィルム、ガスバリヤ−性フィルム、菌バリヤー性フ
ィルム、耐薬品性フィルム、隠蔽性フィルム、防汚性フ
ィルム等各種の機能性フィルムを用いることもできる。 フィルム形成後、収縮性繊維ウェブ層に熱く及び必要に
より水分)を与え、熱収縮性繊維を収縮させて収縮性繊
維ウェブ層を収縮させる。この際、非収縮性繊維ウェブ
層及びフィルムは収縮しないので、フィルム表面には微
細な凹凸が発現しクレープ状どなる。収縮性繊維ウェブ
層の面積収縮率は、30%以上が好ましい。面積収縮率
が30%未満であると、収縮の程度が少なく、フィルム
表面に微細な凹凸が発現しにくくなるという傾向を生じ
る。なお、収縮性繊維つJ4ブ層に熱を与える方法とし
ては、乾熱法又は温熱法が採用され、装置としては熱風
オーブン、赤外線ヒーター炉、熱水バス等が採用される
。 このようにして得られた不織シートには、所望の後加工
を施すことができる。例えば、フィルム表面に形成され
た多数の微細な凹凸をブラシ等で擦り或いはもみ加工を
施し、主として凸部を破壊して収縮性繊維ウェブ層中の
構成繊維を起毛させることもできる。
[Means and effects for solving the problems] That is, the present invention has the following features:
High-pressure columnar flow is applied to a laminated web in which a shrinkable fiber web layer containing heat-shrinkable fibers and a non-shrinkable fiber web layer that does not substantially shrink at the temperature at which the heat-shrinkable fibers shrink. After integrating the heat-shrinkable fiber web layer and the non-shrinkable fiber web layer and forming a film that does not substantially shrink at the temperature at which the heat-shrinkable fibers shrink on the surface of the non-shrinkable fiber web layer, the shrinkable fiber web The present invention relates to a method for producing a nonwoven sheet, characterized by shrinking the layers. In the present invention, first, a laminated web in which a contractile fiber web layer and a non-shrinkable fiber web layer are laminated is prepared. The shrinkable fibrous web layer contains heat shrinkable fibers. A heat-shrinkable fiber is a fiber that shrinks by applying heat (and moisture if necessary). As the heat-shrinkable fibers, thermoplastic fibers used in -1'12, particularly highly stretched thermoplastic fibers, can be used. Specifically, polyvinyl chloride fiber, polypropylene fiber,
High shrinkage modacrylic fibers, high shrinkage polyester fibers, polyvinylalnylene fibers, etc. can be used. The proportion of heat-shrinkable fibers in the shrinkable fiber web layer can be arbitrarily set so as to obtain a desired area shrinkage rate, but
The shrinkable fiber web layer is preferably formed using heat-shrinkable fibers of 100% by weight or more, preferably about 0% by weight or more, particularly 70% by weight or more. The shrinkable fiber web layer includes a fiber fleece in which stable fibers are accumulated, and a fiber fleece in which continuous filaments I and 7 are accumulated.
Fiber fleece, knitted fabric, etc. are used. The fiber fleece may be a random fleece or cross-leaf fleece in which constituent fibers such as stable fibers are randomly accumulated, or may be a unidirectional fleece in which constituent fibers are arranged in one direction. However, it is preferable to concentrate the contraction in one direction from the viewpoint of shrinkage efficiency, productivity, and product management, and therefore it is preferable to use a unidirectional fiber fleece as the shrinkable fiber web layer. In the case of knitted fabrics, both the warp and the weft may be made of heat-shrinkable fibers, or only the warp or weft may be made of heat-shrinkable fibers. However, the latter type of knitted fabric is preferable because the contraction can be concentrated in one direction. The non-shrinkable fiber web layer does not substantially shrink at the temperature at which the heat-shrinkable fibers in the web layer shrink. Therefore, the fibers constituting the non-shrinkable fiber web layer can be arbitrarily determined in consideration of the shrinkage temperature of the heat-shrinkable fibers. Therefore, non-thermoplastic natural fibers, recycled fibers, or thermoplastic fibers with a relatively high shrinkage temperature can be used. In addition, heat-fusible fibers may be mixed in the non-shrinkable fiber web layer, as long as the non-shrinkable fiber web layer does not substantially shrink at the shrinkage temperature of the heat-shrinkable fibers. 10 fusible fibers
0% by weight may be used to form a non-shrinkable fibrous web layer. As the non-shrinkable fiber web layer, a fiber fleece in which stable fibers are accumulated, a fiber fleece in which continuous filaments are accumulated, a knitted fabric, or the like is used. Note that the finer the fineness of the constituent fibers of the non-shrinkable fiber web layer, the better
2. This is because when the temperature is low, the surface state of the non-shrinkable fiber web layer after the shrinkable fiber web layer has shrunk is beautiful, and is excellent in terms of surface design and napping suitability. A layer of shrinkable fibrous web and a layer of non-shrinkable fibrous web are laminated to form a laminated web. As for the lamination method, it is possible to laminate - sheets of shrinkable fiber web layer and one sheet of non-shrinkable fiber web layer to form a two-layer laminated web, or it is possible to laminate - sheets of shrinkable fiber web layer and one sheet of non-shrinkable fiber web layer to form a two-layer laminated web. The fiber web may be laminated to form a three-layer laminated web or the like. A high pressure columnar flow is applied to this laminated web. What is high pressure columnar flow?
It is obtained by ejecting a high-pressure, incompressible fluid through an orifice hole with a fine diameter. Specifically, 10 to 150k from an orifice with a hole diameter of 0.1 to 0.2nun.
It is obtained by jetting out water at a pressure of g/c+fl. When this high-pressure columnar flow is applied to the laminated web, the constituent fibers such as the heat-shrinkable fibers in the shrinkable fiber web layer and the constituent fibers in the non-shrinkable fiber web layer move and interact with other neighboring constituent fibers. closely intertwined. As a result, between the shrinkable fiber web layer and the non-shrinkable fiber web layer, the constituent fibers are tightly entangled, and the layers are closely joined to obtain an integrated web. A film is then formed on the surface of the non-shrinkable fibrous web layer of the nib. As the film, a synthetic resin film is used inside the membrane, and the thickness thereof is preferably about 50 μm or less. When the thickness of the film exceeds 50 μm, the rigidity of the film increases, and there is a tendency that fine irregularities are difficult to develop after shrinkage treatment. Further, it is necessary to use a film that does not substantially shrink at the temperature at which heat-shrinkable fibers shrink. Therefore, it is preferable to use a synthetic resin film with extremely low crystallinity (amorphous) or a high melting point film. As a method for forming a film on the non-shrinkable fiber web layer surface, method 2 is to lamination the film on the non-shrinkable fiber web layer surface.
Method 2 of applying (coating) a solution of synthetic resin A method of spraying (spraying) a solution of synthetic resin is used. The film formed on the surface of the non-shrinkable fiber web layer may be a non-porous film or a perforated film. In addition, various functional films such as a water-repellent film, a transparent waterproof film, a gas barrier film, a germ barrier film, a chemical-resistant film, a concealing film, and an antifouling film can also be used as the film. After film formation, heat and optionally moisture are applied to the shrinkable fibrous web layer to shrink the heat shrinkable fibers and cause the shrinkable fibrous web layer to shrink. At this time, since the non-shrinkable fiber web layer and the film do not shrink, the film surface develops fine irregularities and becomes crepe-like. The area shrinkage rate of the shrinkable fiber web layer is preferably 30% or more. When the area shrinkage rate is less than 30%, the degree of shrinkage is small and there is a tendency that fine irregularities are less likely to appear on the film surface. Note that a dry heat method or a hot heat method is used as a method of applying heat to the shrinkable fiber J4 layer, and a hot air oven, an infrared heater furnace, a hot water bath, etc. are used as an apparatus. The nonwoven sheet thus obtained can be subjected to desired post-processing. For example, a large number of fine irregularities formed on the surface of the film may be rubbed or massaged with a brush or the like to mainly destroy the convex portions and raise the constituent fibers in the shrinkable fiber web layer.

【実施例】【Example】

実施例1 熱収縮性繊維として2.0デニール、 51mmのポリ
塩化ビニル繊維70重量%と、1.5デニール、51叩
のレーヨン繊維30重量%とからなる目付15g/n(
の一方向性繊維フリース(収縮性繊維ウェブ層)の上に
、1.0デニール、38(財)のポリエステル繊維10
0重里%からなる目付25g/rdのクロスレイフリー
ス(非収縮性繊維つLブ層)を積層した積層ウェブを作
成した。この積層ウェブに、オリフィス径0.2mm、
オリフィス数1000個/mであるノズルを用いて、非
収縮性繊維ウェブ層側から75kg/ctAの圧力で2
回及び100kg/cfflの圧力で3回、水柱流を施
した。この結果、構成繊維間が緊密に絡合され、収縮性
繊維ウェブ層と非収縮繊維ウェブ層が強固に一体化した
。なお、この時の積層ウェブの移動速度は10m/分で
あった。 得られた一体化つニブから水分を吸引除去した後、非収
縮性繊維ウェブ層面に下記の処理液をフオームコーティ
ング法で塗布し、60゛cで乾燥したところ、非収縮繊
維ウェブ層面に通気性があって且つ耐水圧性及び撥水(
3油性に優れた厚さ10μのフィルムが形成された。処
理液は、ポリアクリレートエラストマーを主体とし、他
に青色顔料、酸化チタン、塩水剤等を含有する合成樹脂
溶液である。 フィルム形成しまた後、150’Cの乾熱オーブン中で
熱処理し、収縮性繊維ウェブ層を経方向にだけ40%収
縮(面積収縮率40%)させ、目付70 g / +d
の不織シートを得た。この不織シー]・は、フィルム面
に微細な凹凸が多数形成されてクレープ状となっていた
。 この不織シートは、塩水性及び細菌バリヤー性であり、
且つ柔軟性及び伸縮性を有して身体へのフィツト性に優
れている。従って、着用感の良好な手術用ガウン基布と
して好適に使用しうるちのであった。 実施例2 熱収縮性繊維し゛C1,5デニール、51Mのポリプロ
ピレン繊維100重¥%からなる目付15g/rdの一
方向性繊維フリース(収縮性繊維ウェブ層)の上に、2
.0デニール、 5fmo+のポリオレフィン系熱融着
性繊維100重量%からなる目付15g/rrfのクロ
スレイフリース(非収縮性繊維ウェブN)を積層し、積
層ウェブを作成した。この積層ウェブに、実施例1と同
一の条件で水柱流を施して、構成繊維間を緊密に絡合さ
せ、収縮性繊維ウェブ層と非収縮繊維ウェブ層を強固に
一体化した。 次に、透湿防水性、耐薬品性、隠蔽性等を有する厚さ2
0μのポリオレフィンフィルムを非収縮繊維ウェブ層面
に重ね、熱カレンダーによってラミネートしてフィルム
を形成した。 フィルムを形成した後、遠赤外線ヒーターを用いて、収
縮性繊維ウェブ層に遠赤外線を照射し、収縮性繊維ウェ
ブ層を経方向にだけ40%収縮(面積収縮率40%)さ
せ、目付83g/rdの不織シートを得た。この不織シ
ートは、フィルム面に微細な凹凸が多数形成されてクレ
ープ状となっていた。 この不織シートは、柔軟性及び伸縮性を有し、身体への
フィツト性に優れており、農薬散布時等の作業着用基布
又はイベント、レジャー等における簡易衣服用基布とし
て好適に使用しうるちのであった。 実施例3 熱収縮性繊維として1.5デニール、51mmの高収縮
性ポリエステル繊維100重量%からなる目付25g/
ボの一方向性繊維フリース(収縮性繊維ウェブ層)の上
に、2.0デニール、 51mmの分割繊維100重品
%からなる目付50g/nfのクロスレイフリース(非
収縮性繊維ウェブ層)を積層し、積層ウェブを作成した
。なお、この分割繊維は、水柱流を施すことによって容
易に12本に分割され、ナイロン繊維及びポリエステル
繊維各々6本づつに分離するものである。 この積層ウェブに、オリフィス径0.2TI8.オリフ
ィス数1000個/mのノズルを用いて、非収縮繊維つ
I7ブ層側から75 kg / clrの圧力で2回及
び100kg / eJの圧力で10回、水柱流を施し
た。この結果、非収縮繊維ウェブ層中の分割繊維が分割
されて極細繊維が得られ、且つこの極細繊維と収縮繊維
ウェブ層中の構成繊維とが緊密に絡合し、収縮性繊維ウ
ェブ層と非収縮繊維ウェブ層が強固に一体化した。なお
、この時の積層ウェブの移動速度は5m/分であった。 また、非収縮繊維ウェブ層は極細繊維を主体とするもの
であるため、緻密で繊細なタッチを有するものであった
。 得られた一体化ウェブを、公知のナイロン繊維。 ポリエステル繊維染色法により染色した。その後、非収
縮繊維ウェブ層面にポリウレタンエラストマーを主体と
する処理液を用いてペーストコーティング法で塗布し、
厚さ10μのフィルムを形成した。 フィルムを形成した後、180°Cの乾熱オーブン中で
熱処理し、収縮性繊維ウェブ層を経方向にだけ50%収
縮(面積収縮率50%)させ、目付150g/ niの
不織シートを得た。この不織シートは、フィルム面に微
細な凹凸が多数形成されてクレープ状となっていた。こ
の不織シートのフィルム面をブラシで軽く擦ると、容易
に均一で豊かな立毛構造のスェード調の起毛シートが得
られ、合成皮革や自動車内装材として好適に使用しうる
ちのであった。 実施例4 まず、熱収縮性繊維として1.5デニール+ 51mm
のポリビニルアルコール繊維100重量%からなる目付
25 g / %の一方向性フリース(収縮性繊維ウェ
ブ層)を準備した。このポリビニルアルコール繊維は、
水中最大収縮率60%(+35°C)である。 次に、緯糸がベージュ色の40番手車糸原着アラミド繊
維糸条で、経糸が20番手8合糸の同様の原着アラミド
繊維糸条で、且つ打ち込み数が緯糸15本/インチ、経
糸8本7/インチの平織物の両面に、ベージュ色の1.
25デニール、 38mo+の原着アラミド繊維100
重量%よりなる目付25g/rrfのクロスレイフリー
スを積層した。この三層構造物を非収縮性繊維ウェブ層
とした。 前記の収縮性繊維ウェブ層上に非収縮性繊維ウェブ層を
積層した積層ウェブに、オリフィス径0゜2mI++、
オリフィス数1000個/mのノズルを用いて、非収縮
性繊維ウェブ側から75kg/cdのm力で3回及び収
縮性繊維ウェブ側から75kg/c”iの圧力で3回、
水柱流を施した。この結果、原着アラミド繊維は平織物
と緊密に絡合され、またポリビニルアルコール繊維は原
着アラミド繊維と緊密に絡合され、収縮性繊維つニブ層
と非数11?i繊維ウェブ層とは強固に一体化した。な
お、この時の積層ウェブの移動速度は5m2/分であっ
た。 得られた一体出つニブから水分を吸引除去した後、非収
縮性繊維ウェブ層面に下記の処理液を用いてスプレーコ
ーティング法で塗布し、60°Cで乾燥したところ、非
収縮性繊維ウェブ層面に厚さ5μの有孔フィルムが形成
された。処理液は、ポリアクリレ−1ヘエラストマーを
主体とし、他に少量の防汚剤、tQ水剤等を含有する合
成樹脂溶液である。 フィルムを形成した後、収縮性繊維ウェブ層を90゛C
の熱水面にフローティングさせて収縮処理を行い、更に
引続いてポリビニルアルコール繊維の溶解除去を行い、
更に脱水乾燥して目付310 g /1dの不織シーl
−を得た。なお、収縮性繊維ウェブ層は経方向にだけ5
0%収縮(面積収縮率50%)した。 このようにして得られた不織シー[−は、太い経糸が波
状に撓むことにより形成された111方向の畝を持ち、
更に畝と畝の間の谷にはポリビニルアルコール繊維の収
縮に起因する微細な凹凸が多数形成されてクレープ状と
なっていた。従−7て、この不織シートは面白みのある
外観を呈すると共に耐炎性を有するので、航空機の内袋
材として好適に使用しうるちのであった。 【発明の効果] 以上説明したように、本発明に係る不織シートの製造方
法は、収縮性繊維うニブ層と、IE収縮性繊維ウェブ層
とよりなる積層ウェブに高圧柱状流を施すことにより得
られた一体化ウェブの非収縮性繊維ウェブ層面にフィル
ムを形成し、その後収縮性繊維ウェブ層を収縮させるも
のであるため、得られた不織シートは、そのフィルム表
面に多数の微細な凹凸を有し2、クレープ状となってお
り、柔軟性、伸縮性、融通性に冨み目、つ面白みのある
表向状態を呈するという効果を奏する。 これが例えば、−・体止ウェブとしてバインダーボンド
タイプのウェブやファイバーボンドタイプのウェブを採
用すると、非収縮性繊維ウェブ層の構成繊維と収縮性繊
維ウェブ層の構成繊維との絡合及び結合が緊密でなく、
収縮性繊維ウェブ層の収縮時に層間で7、り離し、一体
化した不織シートが得られない、また、逆に結合剤(バ
インダー)のIIを多くし7て、構成繊維間の結合を強
固にし、層間II離が生じないようにすると、収縮性繊
維ウェブ層の収縮時に抵抗が大きく充分な収縮が得られ
ない。また、一体止ウェブとしてニードルパンチタイプ
のウェブを用いると、本発明における高圧柱状流を施し
て一体化した場合に比べて、非収縮繊維ウェブ層の表面
の平滑性が劣り、J11収縮性繊維ウェブ層にJ7みの
)青いフィルムを形成することが困難となる。更に、ニ
ードルパンチタイプのウェブを得るには目付100 t
< / n(以上としなげればならず、高圧柱状流を施
して得られるような低[“−1付タイプのウェブは得ら
れにくい。 また、非収縮性繊維ウェブ層を積層・りすに、収縮性m
維ウェブ層に直接フィルムを形成すると、収縮後Jy、
おいてフィルムが全体に波打った状態となり、多数の微
細な凹凸が得られず、クレープ状の不織シー]・が得ら
れない。更に、フィルJ、を形成せずに、収縮性繊維ウ
ェブ層と非収縮性繊維ウェブ層とよりなる積)タウニブ
のみを用いて収縮させると、非収縮性繊維ウェブ層の表
面の構成塾δIWは動きやすいため、その表面に多数の
微細な凹凸が得られにくく、表面の凹凸状態が粗大Qこ
なっでしまう。 即ち、本発明に係る方法によって、多数の微細な凹凸を
持つクレープ状の不織シートが得られ、柔軟性、伸縮性
、融通性に冨み目、つ面白みのある表面状態を呈する不
織シートが得られるのである。 従って、実施例で実証したように、この不織シー(・は
車両用内装材、インテリア用内装材、医療用基布9合成
皮革用基布、簡易外衣等に好適に使用しうるちのである
Example 1 Heat-shrinkable fibers were made of 70% by weight of 2.0 denier, 51 mm polyvinyl chloride fibers and 30% by weight of 1.5 denier, 51% rayon fibers with a basis weight of 15 g/n (
1.0 denier, 38% polyester fiber 10 on top of the unidirectional fiber fleece (shrinkable fiber web layer)
A laminated web was prepared by laminating crosslay fleece (non-shrinkable fiber layer) having a basis weight of 25 g/rd and consisting of 0 weight %. This laminated web has an orifice diameter of 0.2 mm,
Using a nozzle with 1,000 orifices/m, a pressure of 75 kg/ctA was applied from the non-shrinkable fiber web layer side.
Water column flow was applied three times at a pressure of 100 kg/cffl and 100 kg/cffl. As a result, the constituent fibers were tightly entangled, and the shrinkable fiber web layer and the non-shrinkable fiber web layer were firmly integrated. Note that the moving speed of the laminated web at this time was 10 m/min. After removing moisture from the resulting integrated nib, the following treatment solution was applied to the surface of the non-shrinkable fiber web layer using a foam coating method and dried at 60°C, resulting in breathability on the surface of the non-shrinkable fiber web layer. It also has water pressure resistance and water repellency (
3. A 10μ thick film with excellent oiliness was formed. The treatment liquid is a synthetic resin solution that is mainly composed of polyacrylate elastomer and also contains a blue pigment, titanium oxide, a salt water agent, and the like. After forming the film, it was heat-treated in a dry heat oven at 150'C to shrink the shrinkable fiber web layer by 40% only in the warp direction (area shrinkage rate 40%), resulting in a basis weight of 70 g/+d.
A nonwoven sheet was obtained. This non-woven sheet had a crepe-like appearance with many fine irregularities formed on the film surface. This non-woven sheet has saline and bacterial barrier properties,
In addition, it has flexibility and stretchability, and has excellent fit to the body. Therefore, it can be suitably used as a surgical gown base fabric that is comfortable to wear. Example 2 On top of a unidirectional fiber fleece (shrinkable fiber web layer) with a basis weight of 15 g/rd consisting of 100 wt.
.. Crosslay fleece (non-shrinkable fiber web N) having a basis weight of 15 g/rrf and consisting of 100% by weight of 0 denier, 5 fmo+ polyolefin heat-fusible fibers was laminated to create a laminated web. This laminated web was subjected to a water column flow under the same conditions as in Example 1 to tightly entangle the constituent fibers and firmly integrate the shrinkable fiber web layer and the non-shrinkable fiber web layer. Next, the thickness is 2, which has moisture permeability, waterproofness, chemical resistance, concealability, etc.
A 0μ polyolefin film was laid on top of the non-shrink fibrous web layer and laminated by thermal calendaring to form a film. After forming the film, the shrinkable fiber web layer is irradiated with far infrared rays using a far infrared heater to shrink the shrinkable fiber web layer by 40% (area shrinkage rate 40%) only in the warp direction, resulting in a fabric weight of 83 g/ A rd nonwoven sheet was obtained. This nonwoven sheet had a crepe-like shape with many fine irregularities formed on the film surface. This nonwoven sheet has flexibility and stretchability, and has excellent fit to the body, making it suitable for use as a base fabric for work wear such as when spraying pesticides, or as a base fabric for simple clothing at events, leisure activities, etc. It was Uruchino. Example 3 The heat-shrinkable fiber was made of 100% by weight of 1.5 denier, 51 mm highly shrinkable polyester fiber with a basis weight of 25 g/
On top of the unidirectional fiber fleece (shrinkable fiber web layer), a crosslay fleece (non-shrinkable fiber web layer) with a basis weight of 50 g/nf made of 100% by weight of 2.0 denier, 51 mm split fibers is placed. They were laminated to create a laminated web. The split fibers can be easily divided into 12 fibers by applying water column flow, and are separated into 6 each of nylon fibers and polyester fibers. This laminated web has an orifice diameter of 0.2TI8. Using a nozzle with 1000 orifices/m, water column flow was applied from the non-shrinkable fiber I7 layer side twice at a pressure of 75 kg/clr and 10 times at a pressure of 100 kg/eJ. As a result, the split fibers in the non-shrinkable fiber web layer are split to obtain ultrafine fibers, and the ultrafine fibers and the constituent fibers in the shrinkable fiber web layer are tightly entangled, and the shrinkable fiber web layer and the non-shrinkable fiber web layer are tightly entangled. The shrink fiber web layer is firmly integrated. Note that the moving speed of the laminated web at this time was 5 m/min. Furthermore, since the non-shrinkable fiber web layer was mainly composed of ultrafine fibers, it had a dense and delicate touch. The resulting integrated web is made of known nylon fibers. It was dyed using the polyester fiber dyeing method. After that, a treatment liquid mainly composed of polyurethane elastomer is applied to the surface of the non-shrinkable fiber web layer using a paste coating method.
A 10μ thick film was formed. After forming the film, it was heat-treated in a dry heat oven at 180°C to shrink the shrinkable fiber web layer by 50% only in the warp direction (area shrinkage rate 50%) to obtain a nonwoven sheet with a basis weight of 150 g/ni. Ta. This nonwoven sheet had a crepe-like shape with many fine irregularities formed on the film surface. By lightly rubbing the film surface of this nonwoven sheet with a brush, a suede-like raised sheet with a uniform and rich raised structure was easily obtained, and could be suitably used as synthetic leather or automobile interior material. Example 4 First, 1.5 denier + 51 mm as heat-shrinkable fiber
A unidirectional fleece (shrinkable fibrous web layer) having a basis weight of 25 g/% and consisting of 100% by weight of polyvinyl alcohol fibers was prepared. This polyvinyl alcohol fiber is
Maximum shrinkage in water is 60% (+35°C). Next, the weft is a beige-colored 40-count spun-dyed aramid fiber yarn, and the warp is a similar spun-dyed aramid fiber yarn with 20-count 8 ply yarns, and the number of wefts is 15 wefts/inch and 8 warps. Beige 1. on both sides of the 7/inch plain weave.
25 denier, 38mo+ spun dyed aramid fiber 100
Crossray fleece having a basis weight of 25 g/rrf was laminated. This three-layer structure was used as a non-shrinkable fiber web layer. An orifice diameter of 0°2 mI++,
Using a nozzle with 1000 orifices/m, three times from the non-shrinkable fiber web side with a force of 75 kg/c"i and three times from the shrinkable fiber web side with a pressure of 75 kg/c"i.
A water column flow was applied. As a result, the spun-dyed aramid fibers are tightly intertwined with the plain weave, and the polyvinyl alcohol fibers are tightly intertwined with the spun-dyed aramid fibers, and the shrinkable fiber nib layer and the non-number 11? i It was firmly integrated with the fiber web layer. Note that the moving speed of the laminated web at this time was 5 m2/min. After removing water by suction from the obtained integrally protruding nib, the following treatment liquid was applied to the surface of the non-shrinkable fiber web layer using a spray coating method and dried at 60°C. A perforated film with a thickness of 5 μm was formed. The treatment liquid is a synthetic resin solution mainly composed of polyacrylate-1 elastomer and also containing a small amount of an antifouling agent, a tQ water agent, and the like. After forming the film, the shrinkable fiber web layer was heated to 90°C.
Shrinkage treatment is performed by floating on the surface of hot water, and the polyvinyl alcohol fibers are subsequently dissolved and removed.
Further dehydration and drying yields a non-woven seal with a basis weight of 310 g/1d.
I got -. Note that the shrinkable fiber web layer has 5 layers only in the warp direction.
0% shrinkage (area shrinkage rate 50%). The nonwoven sheet [-] thus obtained has 111-direction ridges formed by wavy bending of the thick warp threads,
Further, in the valleys between the ridges, many fine irregularities due to shrinkage of the polyvinyl alcohol fibers were formed, resulting in a crepe-like shape. Therefore, this nonwoven sheet has an interesting appearance and is flame resistant, so it can be suitably used as an inner bag material for an aircraft. [Effects of the Invention] As explained above, the method for producing a nonwoven sheet according to the present invention is achieved by applying high-pressure columnar flow to a laminated web consisting of a shrinkable fiber nib layer and an IE shrinkable fiber web layer. Since a film is formed on the surface of the non-shrinkable fiber web layer of the obtained integrated web and the shrinkable fiber web layer is then shrunk, the obtained nonwoven sheet has many fine irregularities on the film surface. 2, it has a crepe-like shape, and has the effect of exhibiting a surface state with richness in flexibility, elasticity, and flexibility, and a white appearance. For example, when a binder bond type web or a fiber bond type web is used as the anchoring web, the fibers constituting the non-shrinkable fiber web layer and the fibers constituting the shrinkable fiber web layer are tightly entangled and bonded. Not, but
When the shrinkable fiber web layer shrinks, the layers may separate, making it impossible to obtain an integrated nonwoven sheet.In addition, conversely, increasing II of the binder may strengthen the bond between the constituent fibers. If the shrinkable fiber web layer is made so as to prevent separation between the layers, the shrinkable fiber web layer will have a large resistance when shrinking, and sufficient shrinkage will not be obtained. Furthermore, when a needle punch type web is used as the integral fixing web, the surface smoothness of the non-shrinkable fiber web layer is inferior to that of the present invention when the web is integrated by applying high-pressure columnar flow, and the J11 shrinkable fiber web layer is inferior in surface smoothness. It becomes difficult to form a blue film in the J7 layer. Furthermore, to obtain a needle punch type web, the basis weight is 100 t.
< / n (or more), and it is difficult to obtain a low [“-1” type web like that obtained by applying high-pressure columnar flow. Shrinkage m
When a film is formed directly on the fiber web layer, after shrinkage Jy,
In this case, the entire film becomes wavy, many fine irregularities cannot be obtained, and a crepe-like nonwoven sheet cannot be obtained. Furthermore, when shrinking is performed using only the tau nib (product consisting of a shrinkable fiber web layer and a non-shrinkable fiber web layer) without forming a fill J, the surface structure of the non-shrinkable fiber web layer δIW is Since it is easy to move, it is difficult to obtain a large number of fine irregularities on the surface, and the irregularity state of the surface becomes coarse and uneven. That is, by the method according to the present invention, a crepe-like nonwoven sheet having a large number of fine irregularities can be obtained, and the nonwoven sheet exhibits a surface condition that is rich in flexibility, stretchability, and flexibility, and has a smooth surface. is obtained. Therefore, as demonstrated in the examples, this nonwoven sheet can be suitably used for vehicle interior materials, interior interior materials, medical base fabrics, synthetic leather base fabrics, simple outer clothing, etc. .

Claims (1)

【特許請求の範囲】[Claims]  熱収縮性繊維を含有する収縮性繊維ウェブ層と該熱収
縮性繊維が収縮する温度では実質的に収縮しない非収縮
性繊維ウェブ層とを積層した積層ウェブに高圧柱状流を
施して、該収縮性繊維ウェブ層と該非収縮性繊維ウェブ
層とを一体化し、次いで該非収縮性繊維ウェブ層面に該
熱収縮性繊維が収縮する温度では実質的に収縮しないフ
ィルムを形成した後、該収縮性繊維ウェブ層を収縮させ
ることを特徴とする不織シートの製造方法。
High-pressure columnar flow is applied to a laminated web in which a shrinkable fiber web layer containing heat-shrinkable fibers and a non-shrinkable fiber web layer that does not substantially shrink at the temperature at which the heat-shrinkable fibers shrink. After integrating the heat-shrinkable fiber web layer and the non-shrinkable fiber web layer and forming a film that does not substantially shrink at the temperature at which the heat-shrinkable fibers shrink on the surface of the non-shrinkable fiber web layer, the shrinkable fiber web A method for producing a nonwoven sheet, characterized by shrinking the layers.
JP63286118A 1988-11-12 1988-11-12 Production of nonwoven sheet Pending JPH02133641A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP63286118A JPH02133641A (en) 1988-11-12 1988-11-12 Production of nonwoven sheet

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP63286118A JPH02133641A (en) 1988-11-12 1988-11-12 Production of nonwoven sheet

Publications (1)

Publication Number Publication Date
JPH02133641A true JPH02133641A (en) 1990-05-22

Family

ID=17700166

Family Applications (1)

Application Number Title Priority Date Filing Date
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Country Status (1)

Country Link
JP (1) JPH02133641A (en)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH02160962A (en) * 1988-12-13 1990-06-20 Uni Charm Corp Bulky nonwoven fabric and production thereof
JPH09158022A (en) * 1995-12-07 1997-06-17 Daiwabo Co Ltd Bulk nonwoven fabric and its production and female part for hercule's fastener (r)
US6926948B2 (en) 2000-09-22 2005-08-09 Kao Corporation Topsheet for absorbent article
US7303808B2 (en) 2000-10-12 2007-12-04 Kao Corporation Bulky sheet material having three-dimensional protrusions
US7534928B2 (en) 2001-08-10 2009-05-19 Kao Corporation Topsheet for absorbent article
US7569264B2 (en) 2001-12-28 2009-08-04 Kao Corporation Topsheet for absorbent article
US7942992B2 (en) 2002-02-25 2011-05-17 Kao Corporation Bulky sheet material having three-dimensional protrusions
JP2012218437A (en) * 2011-04-06 2012-11-12 Groz Beckert Kg Three-dimensional shaped textile element and method of manufacturing the same

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH02160962A (en) * 1988-12-13 1990-06-20 Uni Charm Corp Bulky nonwoven fabric and production thereof
JPH09158022A (en) * 1995-12-07 1997-06-17 Daiwabo Co Ltd Bulk nonwoven fabric and its production and female part for hercule's fastener (r)
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