JPH06257043A - Three-dimensional nonwoven fabric and its production - Google Patents

Abstract

PURPOSE:To obtain uniform three-dimensional nonwoven fabric excellent in tensile strength, shape retainability and compressional resilience by cutting nonwoven fabric with the linear joints as axes into a linearly symmetrical figure bearing continuous radial gussets. CONSTITUTION:Linear joints 2 are first made on nonwoven fabric 1 consisting of a sheet or laminate of nonwoven fabric comprising thermoplastic fibers such as of polyamide, polyester, polyolefin or polyvinyl chloride by a means such as ultrasonic, high-frequency or heat sealing. The nonwoven fabric 1 is then cut with the above linear joints 2 as the axes into a linearly symmetrical figure 3 with radial gussets rectangular to the joints 2 provided continuously in the longer direction, thus obtaining the three-dimensional nonwoven fabric.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention is intended to provide a new material by utilizing a non-woven fabric.

[0002]

2. Description of the Related Art Conventionally, for example, a doll or the like containing a cushion material or stuffed cotton has been manufactured by stuffing cotton or fiber lumps in a bag sewn into a predetermined shape.

[0003]

However, since the stuffed cotton or fiber lumps are free to move, the stuffed product produced in this way is biased during use, or There was a problem that the mold would be broken due to cutting and that it would be time-consuming to stuff the cotton in the manufacturing process.

[0004]

The invention of the present application has a cross-sectional shape which is axisymmetrical about a linear joint portion as an axis, and
Having a cross-sectional shape having radial folds in a cross section orthogonal to this, a three-dimensional nonwoven fabric having a linear joint inside, preferably, the cross-sectional shape having radial folds is continuous in the longitudinal direction. It is manufactured by forming a linear joint portion on one or a plurality of laminated non-woven fabrics and then cutting it into a line-symmetrical shape with the linear joint portion as an axis.

According to the present invention, as shown in FIG. 1, a linear bonding portion 2 is formed on one or a plurality of laminated nonwoven fabrics 1 so that a strong linear compression portion is formed on a nonwoven fabric of a predetermined thickness. By forming and cutting the non-woven fabric along a cutting line 3 having a line-symmetrical shape with the linear joint portion 2 as an axis, the thickness of the non-woven fabric at the cutting location is recovered, and a pleats made of non-woven fabric pieces is formed. A three-dimensional non-woven fabric having a cross-sectional shape that is line-symmetrical about the linear joint portion as an axis and has a radial fold in a cross section orthogonal to the linear joint portion (see FIG. 2). ) Get. In addition to the above-described manufacturing method, as shown in FIG. 3, after laminating one or more non-woven fabrics 4 previously cut into line-symmetrical graphic shapes,
There is also a method of obtaining a three-dimensional nonwoven fabric by forming a linear joining portion 2 on a portion which is a line-symmetrical axis of symmetry.

The material of the non-woven fabric is not particularly limited, but it is desirable that the non-woven fabric is bulky and has a high compression recovery property. The non-woven fabric or the fibrous web is produced by heat-bonding a fibrous web containing adhesive fibers under no pressure or low pressure. Non-woven fabric sprayed with an adhesive, non-woven fabric in which adhesive resin powder is sprinkled on a fibrous web, and heat-treated and bonded under no pressure or low pressure. A non-woven fabric that is temporarily adhered can be suitably used. In addition, a woven fabric, a knitted fabric, a net, a film and the like may be laminated together with the non-woven fabric, if necessary. The linear joint portion 2 may be linear, wavy, solid, broken or dotted. Further, the joint portion can be formed by a sealing means such as a heat seal, an ultrasonic seal, a high frequency seal, an adhesive means by applying an adhesive, or a sewing means such as a sewing machine. In the case of using a sealing means or an adhering means, the width of the above linear joint is 1
-5 mm is preferable. If thermoplastic fibers cannot be used as the constituent fibers of the non-woven fabric, adhesive means or stitching means should be used, but if they can be used, a sealing means can be used to form a joint having a higher tensile strength.

Further, the nonwoven fabric 1 is cut into a line-symmetrical shape with the linear joint 2 as the axis of symmetry. The obtained three-dimensional nonwoven fabric has the shape of a rotating body obtained by rotating this line-symmetrical figure around the axis of symmetry. The shape of the line symmetric figure drawn by the cutting line 3 is not particularly limited, but when it is used as a cushioning material or a cotton stuffing, the purpose of a tree, a ball, a gourd, a mushroom, etc. as shown in FIGS. It is preferable to use a shape obtained by projecting the shape on a plane.

The production by the method of the present invention will be specifically described with reference to an example. One or a plurality of non-woven fabrics containing heat-fusible fibers are stacked, and the laminated thickness (Tcm) has a slit width (Wcm). Set so that 2T ≧ 45/360 × πW. (Depending on the material of the nonwoven fabric, 2T <45
With / 360 × πW, it is difficult to obtain a three-dimensional nonwoven fabric satisfying the physical properties required for the present invention). The set product is continuously sealed (heated, ultrasonic wave, high frequency) or sewn at regular intervals, and then cut into a Wcm width. When the relationship between the laminated thickness and the slit width is 2T <πW, the cross-sectional shape is petal-like as shown in FIG. 7, and when 2T ≧ πW, the cross-sectional shape is as shown in FIG. Is mall shaped (circular)
Becomes At least 20% (preferably 3) on the sealing part
(5%) or more heat-fusible fibers and / or heat-fusible resin (mesh, woven fabrics are also acceptable) have high strength, and
To further increase the strength, a string or wire can be put in the seal portion.

The relationship between the cross-sectional shape of the three-dimensional nonwoven fabric, the laminated thickness (Tcm) and the slit width (Wcm) is as follows. When the linear joint is at the center of the slit width a. When 2T <πW, a gap is created between the folds and the petals open. (2T ≧ (1 / 3πW to 1 / 4π
When W), the petals open uniformly, 2T <(1 / 3π
In the range of W to 1 / 4πW), the petals are likely to open unevenly. ) B. When 2T ≧ πW, the gap between the folds disappears and the fiber layers on the outer peripheral surface are connected to form a molding. Note that (when the thickness Tcm further expands due to compression at the time of sealing, 2T <πW may result in a molding.) Since the slit width W of the three-dimensional nonwoven fabric of the present invention changes as shown in the figure. , Depending on the position, the cross section may have a petal shape or a mall shape. However, when the maximum slit width W _MAX is 2T ≧ πW _MAX , there is no space between the folds at any position.

As a joining method, when the nonwoven fabric itself contains an adhesive component, a sealing means such as ultrasonic sealing, high frequency sealing, heat sealing or the like is preferable. Since the shape of the sealing portion is continuous, the strength is improved. To do. In addition, it is also possible to seal it discontinuously. The seal width may be any width, but a width of 1 to 5 mm is preferable, and a wider width is preferable for obtaining strength. Further, in order to reinforce the strength, a string-like material, a mesh or a woven or knitted material may be put in the seal part or the entire surface. When a thermoplastic fiber is used as an adhesive component in the non-woven fabric, it is desirable that the non-woven fabric is composed mainly of polyolefin, polyester, polyamide, polyvinylidene chloride and acrylic fiber. In the case of vinylon or polyvinyl alcohol fiber, it can be sealed by moist heat and pressure. The direction of the seal may be either vertical or horizontal. The ratio of these thermoplastic fibers varies depending on the required tensile strength, flexibility, or the width of the seal portion, the thickness of the seal portion, and the type of fibers involved in the adhesion in the laminated nonwoven fabric. It is desirable that the fiber ratio involved in the above is at least 20 wt% or more, preferably 40 wt% or more. Even if the content is less than 20 wt%, a seal can be obtained, but it is not suitable for applications where tensile strength and shape retention are strongly required. However, these problems can be solved in the case of sealing with a hot melt adhesive and in the case of inserting a string-like material or a mesh knitted fabric as a reinforcing material. Also,
Adhesive means may be used as an adhesive for forming the linear joint, and in this case, an adhesive (for example, ethylene and ethylene copolymer, copolyamide, copolyester, polypropylene, vinyl acetate copolymer, Cellulose derivative, acrylic resin, polyurethane)
The base material may be compressed (press-fitted) while being compressed.

The material obtained by the invention of this application has the following uses, for example, depending on its function. For polishing and brushes, scrubbing brushes, loofahs, car wash brushes, household scrubbing brushes, carriers for immobilizing microorganisms for water purification, artificial seaweed and artificial soil, and filters for liquid filters, air conditioning filters, vacuum cleaners. Of the filter, as the drain material, a water conduit, a civil engineering drain material, as the water absorbing material, a water absorbing pad, a dew condensation preventing material, and as the oil absorbing material, an oil catcher, an oil fence,
Oil absorbing material, heat insulating cotton as a heat insulating material, substitute for rope wrapped around wood, sound absorbing material for absorbing sound in duct, shock absorbing material for protector, gym mat, etc., cushion material As stuffed cotton in the shape of wood, mushrooms, rugby balls, kokeshi dolls, zabuton, pillows, back support,
In addition, it is used as a doll stuffed toy in the form of three-dimensional picture books, trees, mushrooms, rugby balls, kokeshi dolls, deodorant molds in shoes, malls, cushion blocks instead of bamboo swords, etc.

[0012] To further describe the use and the material and shape of the material, those used for water purification and carrier for immobilizing microorganisms are BOC and CO in rivers, lakes and marshes.
D, a useful microorganism immobilizing material for the purpose of reducing nitrogen and phosphorus,
Since it will be a fishing reef and artificial seaweed, it is desirable that the shape should open like a petal. This is to increase the chance of contact with microorganisms in water, dissolved O ₂ , and nutrient sources, and the diameter of the cross section is preferably 3 to 12 cm. If it is larger than 3 cm, the contact area increases, and if it is smaller than 12 cm, water easily penetrates into the inside. The fiber composition is preferably a single or composite system of thermoplastic fibers such as polyolefin, polyester, polyamide, polyvinyl chloride and polyvinylidene chloride. Non-thermoplastic fibers such as viscose rayon and cotton may be included for the purpose of imparting hydrophilicity or a carbon source. The average fineness of the structure (fineness) of the non-woven fabric is 1
0 denier or more is preferable, and if the fineness is too small, clogging may occur. The apparent density of the nonwoven fabric before sealing is preferably 0.2 g / cm ³ or less from the viewpoint of clogging.
The non-woven fabric may be a non-woven fabric bonded by fibers or a non-woven fabric bonded by a binder, and may be subjected to a polymer treatment or an ion exchange treatment for increasing the amount of immobilized microorganisms. The number of laminated sheets is appropriately 3 to 6 (the number of petals is 6 to 12), and the thickness of one sheet is preferably about 3 to 15 mm. Also,
If you want to reduce the thickness of one petal, reduce the number of petals, and open it evenly, layer a thin, dense, wide non-woven fabric 4 and a thick, elastic, narrow non-woven fabric 5 alternately. Can be achieved by sealing. When it is used as a scrubbing tool or an abrasive, cushioning properties, impact resilience, and wear resistance (particularly in the slit cross section) are required, so it is preferable that the end faces of the fibers are exposed. As for the shape, the structure that the gap between the petals is not so open,
A good structure is one in which the petals are stuck together to form a mall. Further, the slit may be meandered to form an uneven shape like a gourd. As the fiber composition, polyamide, polyester, polyolefin, vinyl chloride or the like is used, and one having high rigidity is preferable. As the non-woven fabric structure, in order to improve wear resistance, it is preferable to use an adhesive agent in addition to the adhesion by the heat-sealing fiber. The adhesive component (including adhesive fiber) is 30
% Or more, and the fineness varies depending on rough polishing and finish polishing, but 0.1 denier to 100 denier is preferable, and an abrasive (for example, carborundum) may also be applied (attached). When used as a mall for Christmas decorations, clothing (seal is desirable to sew. Compress and sew on sewing machine) and accessories, tactile feeling is important and there is no gap between folds and folds. Is preferred. The fiber composition is polyamide, polyester, acrylic, polyolefin, rayon,
Cotton, etc. are used, and the structure of the non-woven fabric is 0.1
12 denier and fine, high crimp fiber,
Using latent crimped fiber, softness of volume and touch,
It is good to have heat retention. Especially when it is used as a cotton pad for dolls and cushions, it can be made of wood, balls, gourds,
Since it can be made into a desired rotational shape such as mushrooms, the dolls and cushions produced using this can be easily deformed, are soft and have excellent compression recovery properties, and are very useful.

[0013]

【Example】

Example 1 A basis weight 20 made of Chisso ES fiber (fineness 20 denier)
0 g / m ² , thickness 8 mm, apparent density 0.025 g / c
Five m ³ heat-bonded nonwoven fabrics are laminated and ultrasonically sealed in a line. Next, as shown in FIG. 4, a circular slit having a radius of 4 cm is slit so that the seal portion becomes the axis of symmetry. In this way, a spherical three-dimensional non-woven fabric is formed in which folds having a radius of about 4 cm and a cross section of 10 sheets are formed, the folds are close to each other near the center of the axis of symmetry, and the folds are open near the upper and lower portions of the axis of symmetry. Form. It is effective to use this string-shaped nonwoven fabric as a carrier for purifying biofilms of ponds, lakes, rivers, seas, industrial wastewater, and a carrier for immobilizing useful microorganisms.

Example 2 A non-woven fabric was prepared by adhering a halogenated benzyl 4-vinylpyridine-styrene copolymer as a polymer for adsorbing microorganisms to the non-woven fabric base used in Example 1 and then producing Example 1.
The spherical three-dimensional nonwoven fabric produced in the same manner as above has an excellent ability to adsorb microorganisms and is useful as a carrier for immobilizing microorganisms.

Example 3 An acrylic adhesive is applied to a web of polyamide fibers having a fineness of 30 denier to prepare a nonwoven fabric having a fiber / binder = 60/40, a basis weight of 350 g / m ² and a thickness of 15 mm.
After laminating 8 sheets of this non-woven fabric and sealing them linearly using an ultrasonic welder, a maximum width of 5 with the sealing part as the axis of symmetry
Slit into a gourd shape as shown in FIG. The cross section of the laminated non-woven fabric spreads out in a circle and becomes a gourd-like material that is rich in elasticity and has no gap between the non-woven fabrics. This gourd-like three-dimensional nonwoven fabric is useful as a substitute for loofah for rubbing the body, and as a scrubbing brush for bath cleaning when wrapped around a hand.

Example 4 300 g / m ² in unit weight of 6 denier, a high crimp type core-sheath type composite fiber comprising polyethylene terephthalate as a core component and polybutylene terephthalate as a sheath component,
A 25 mm thick non-woven fabric is prepared. After laminating 4 sheets of this non-woven fabric and compressing it to form a linear suture line with a sewing machine, slitting it into a mushroom shape with a maximum width of 6 cm with the suture line as the axis of symmetry as shown in FIG. The non-woven fabric piece recovers its thickness in the center to form a mushroom-shaped three-dimensional non-woven fabric with no gaps between the pleats made of the non-woven fabric pieces. This mushroom-shaped three-dimensional nonwoven fabric has a soft touch and a rich cushioning property, and is useful as a filling, a decoration for Christmas, a cushioning material for clothing, and the like.

[0017]

EFFECTS OF THE INVENTION The invention of the present application has excellent tensile strength due to the presence of a linear joint, has no unevenness of cotton or cotton breakage, is excellent in shape retention, does not lose its shape, and has a good feel. Since a product excellent in compression recovery can be easily formed into a desired shape, it is possible to provide materials having many uses in a shape suitable for use, and development of new products can be expected in various fields.

[Brief description of drawings]

FIG. 1 is a diagram showing an example of a process for producing a three-dimensional nonwoven fabric of the invention of the present application.

FIG. 2 is a diagram showing a three-dimensional nonwoven fabric of the invention of this application.

FIG. 3 is a diagram showing the state of another example of the process for producing the three-dimensional nonwoven fabric of the present invention.

FIG. 4 is a diagram showing a state of a manufacturing process of the spherical three-dimensional nonwoven fabric of the present invention.

FIG. 5 is a diagram showing a state of a process for producing a gourd-shaped three-dimensional nonwoven fabric of the present invention.

FIG. 6 is a view showing a state of a process of manufacturing a mushroom-shaped three-dimensional nonwoven fabric of the invention of the present application.

FIG. 7 is a cross-sectional view showing an example of a petal-shaped cross section of the invention of this application.

FIG. 8 is a sectional shape (circular shape) of the invention of this application.
Sectional view showing an example of

[Simple explanation of symbols]

 1 Non-woven fabric 2 Linear joint 3 Cutting line of symmetrical line shape

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[Submission date] May 11, 1993

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Claims (3)

[Claims] 1. A solid having a cross-sectional shape that is line-symmetrical about a linear joint portion as an axis, has a cross-sectional shape that has radial folds in a cross section orthogonal to this, and has a linear joint portion inside. Shaped non-woven fabric. 2. The three-dimensional nonwoven fabric according to claim 1, wherein the cross-sectional shape having radial pleats is continuous in the longitudinal direction. 3. A non-woven fabric obtained by laminating one sheet or a plurality of sheets,
A method for producing a three-dimensional nonwoven fabric, which comprises forming a linear joint and then cutting it into a line-symmetrical shape with the linear joint as an axis.