JPH0921056A - Production of fiber sheet composite - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a fiber sheet composite having good fabric hand, high design properties and a variety of functions. SOLUTION: The first pile layer 2A is formed on the surface of the first fiber sheet 2 by pattern-needling, while the second fiber sheet 3 is laminated on the back surface of the first fiber sheet to effect the pattern-needling thereby forming the second pile layer 3A on the surface of the first fiber sheet 2.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a composite fiber sheet which is excellent in texture, rich in design and has various functions.

[0002]

2. Description of the Related Art A composite fiber sheet having a pile layer on its surface is useful as a floor sheet. Conventionally, in order to manufacture the composite fiber sheet, as shown in FIG.
(2, 13), and the lower fiber sheet (13) as shown by the arrow
Pattern pile needling from the side to form the pile layer (13A) on the surface of the upper fiber sheet (12), or by patterning needling the upper fiber sheet from the back side to form the pile layer on the surface. There has been provided a method of lining the lower fiber sheet on the fiber sheet.

[0003]

In the above-mentioned needling machine for patterning, a needling machine in which a large number of needles for patterning is erected is used. Since the density of the needles is limited, there is a limit to making the pile density of the napped layer of the product correspondingly high, and the piles that make up the napped layer tend to fall down, and the volume feeling is good. I couldn't get a certain product. Further, in the conventional composite fiber sheet, the color of the pile layer (13A) and the fiber sheet (12) below the fiber sheet (12, 13) are made different in order to enhance the design.
However, there is a problem in that the pile layers (13A) have the same color and thus have a monotonous feeling.

[0004]

[Means for Solving the Problems] As a means for solving the above problems, the first fiber sheet (2) is provided with a first pile layer (2A) on the front surface by a first patterned needling from the back surface. ) And then a second fiber sheet (3)
The second pile layer (3A) is formed on the surface of the first fiber sheet (2) by overlapping the back surface of the fiber sheet (2) with a second pattern needling from the back surface, and both fiber sheets are formed.
The present invention provides a method for producing a composite fiber sheet (1) that binds (2,3). In the above manufacturing method, the pile (4) constituting the first pile layer (2A) formed by the first pattern needling and the second pile layer (3A formed by the second pattern needling). Pile (5)
It is desirable to have different positions.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION The fiber sheet of the present invention is a synthetic fiber such as polyester fiber, polyethylene fiber, polypropylene fiber, polyamide fiber, acrylic fiber, urethane fiber, polyvinyl chloride fiber, polyvinylidene chloride fiber, acetate fiber, or pulp. , Natural fibers such as cotton, wool, palm fibers, hemp fibers, and bamboo fibers, inorganic fibers such as glass fibers, carbon fibers, ceramic fibers, or webs such as recycled fibers of the above fibers, or needlepunched nonwoven fabrics, and the above fibers Two or more kinds may be mixed and used.

First fiber sheet (2) and second fiber sheet
Different from (3) or the first fiber sheet (2)
High-quality fiber such as polyamide fiber or acrylic fiber is used for the second fiber, cheap fiber such as polypropylene fiber, polyester fiber, recycled fiber is used for the second fiber sheet (3),
The second fiber sheet (3) is made of a thermoplastic fiber such as polyethylene fiber, polypropylene fiber, or low melting point polyester fiber to impart moldability, or the first fiber sheet (2)
And / or the second fiber sheet (3) may be subjected to flame-retardant treatment, mildew-proof treatment, or the like to have functionality. Furthermore, the pile density of the first pile layer (2A) and the second pile layer (3A) may be changed, or the height of the pile may be changed.

[0007]

In the composite fiber sheet (1) of the present invention, the first fiber sheet (2) is provided with the second pile between the piles (4) of the first pile layer (2A).
The pile density can be increased by interposing the pile (5) of the second pile layer (3A) of the fiber sheet (3). Further, the color and shape of the first pile layer (2A) of the first fiber sheet (2) and the second pile layer (3A) of the second fiber sheet (3) can be made different. Furthermore, the materials of the first fiber sheet (2) and the second fiber sheet (3) are variously changed, or the pile (4) of the first pile layer (2A) and the pile of the second pile layer (3A) are changed.
Diversity can be given to the composite fiber sheet (1) by changing the density, height, etc. of (5) and inserting another sheet (8).

[0008]

EXAMPLE The present invention will be described with reference to an example shown in FIGS. 1 to 4. (2) is a first fiber sheet, and the fiber sheet (2) is a needle punched nonwoven fabric. The fiber sheet
(2) is pulled out from the roll (6), is fed onto the conveyor (12) of the double patterning machine (10) through the guide roller (11), and is fed from the back side by the first patterning needle device (13). Pile on the surface as shown in Figures 2 and 4a by needling
A first pile layer (2A) consisting of (4) is formed. Further, a second fiber sheet having a color different from that of the fiber sheet (2) drawn from the roll (7) on the back surface of the first fiber sheet (2).
Stack (3) through the guide roller (14). The fiber sheet (3) is also a needle-punched nonwoven fabric like the first fiber sheet (2). Then, from the back side of the fiber sheet (3),
A second pile layer (3A) consisting of a pile (5) is formed on the surface of the first fiber sheet (2) by needling with a patterning needle device (15), and both fiber sheets (2, 3) are bonded together. To do. Thus, as shown in FIGS. 3 and 4B, the pile layer (3A) of the second fiber sheet (3) is sandwiched between the piles (4) of the pile layer (2A) of the first fiber sheet (2). Pile of (5)
The composite fiber sheet (1) intervening with is manufactured, but the pile (4) of the first pile layer (2A) is composed of the fibers of the first fiber sheet (2), and the second pile layer (3A). The pile (5) is mainly composed of the fibers of the second fiber sheet (3), and the fibers of the first fiber sheet (2) are mixed with the pile (4) and the pile (4).
The color is different from that of (5), and a spot pattern due to the piles (4,5) is formed on the surface of the composite fiber sheet (1). In this embodiment, the height of the pile (5) is made lower than that of the pile (4),
Since the pile (4) is supported by the pile (5), the pile (4) does not easily fall down, and the texture is extremely good and has a feeling of volume.

For example, the first fiber sheet (2) has a melting point of 200
When high melting point polyester fibers or polyamide fibers having a melting point of ℃ or higher are used and low melting point polyester fibers or polypropylene fibers having a melting point of 200 ℃ or lower are used for the second fiber sheet (3), they are heated after the patterning step. When the second fiber sheet (3) is melt-processed, the roots of the pile (4,5) are reinforced by the melted and solidified material of the fiber sheet (3), the wear resistance is greatly improved, and thermoforming is performed. It is also possible to do.

Further, if high-quality polyamide fiber is used for the first fiber sheet (2) and inexpensive uncolored polyester fiber or recycled fiber is used for the second fiber sheet (3), the composite fiber sheet ( In 1), the pile (4) composed of the fibers of the first fiber sheet (2) is higher than the pile (5) mainly composed of the second fiber sheet (3), so the pile (4 4) becomes more conspicuous, and the raw material cost can be reduced while maintaining a high quality feeling. Furthermore, only the first fiber sheet (2) arranged on the front surface of the composite fiber sheet (1) is subjected to flame retardant treatment, or the second fiber sheet (3) arranged on the back surface.
It is also possible to reduce the treatment cost by applying mildew-proof treatment only to them.

5 to 7 show another embodiment of the present invention. Also in this embodiment, a patterning machine similar to the double patterning machine (10) shown in FIG. 1 is used, but in the case of this embodiment, the patterning machine shown in FIG.
As shown in Fig. 2, the first fibrous sheet (22), which is a needle punched non-woven fabric, is needled from the back side by the first patterning needle device (13) leaving a predetermined portion (flower pattern) and pile (2
Forming a first pile layer (22A) consisting of
The second pile sheet (22A) of the first pile sheet (22A) is formed by stacking a second pile sheet (23), which is a web different in color from the pile sheet (22), on the back surface of the pile sheet (22). ) The second handle needle device (15) for the predetermined part (flower pattern) other than the part where the
By needling from the back side by the second pile which is made of pile (25) and is different from the first pile layer (22A) as shown in FIG.
Forming the pile layer (23A) of the fiber sheet (22,23)
Join both. In this way, as shown in FIG.
Based on the first pile layer (22A) of the fiber sheet (22), and a pile layer different in color from the first pile layer (22A)
A composite fiber sheet (21) having (23A) formed thereon is manufactured.

8 and 9 show still another embodiment of the present invention. In this embodiment, another sheet (8) is interposed between the first fiber sheet (2) and the second fiber sheet (3). The other fibrous sheet (8) is pulled out from the roll (9) and is passed through the roller (16) to the first pattern needle device (13).
The first fibrous sheet (2) needling is superposed on the back surface of the first fibrous sheet (2), and then needling is performed by the second drawing needle device (15). In this way, as shown in FIG. 9, a composite fiber sheet (31) having another sheet (8) interposed between the first fiber sheet (2) and the second fiber sheet (3) is manufactured. As the sheet (8), for example, a fiber nonwoven fabric,
A fiber knitted fabric, a plastic film, an elastomer film, a synthetic rubber film, a metal foil or the like is used, and the sheet (8) reinforces the composite fiber sheet (31) or
(8) is composed of polyethylene fibers, polypropylene fibers, a nonwoven fabric or knitted fabric of thermoplastic fibers such as low melting point polyester fibers, or, for example, polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetate copolymer, Polyvinyl chloride, polyvinylidene chloride, polystyrene, polyvinyl acetate, fluororesin, thermoplastic acrylic resin, thermoplastic polyester, thermoplastic polyamide, thermoplastic urethane resin, acrylonitrile-
When it is made of a thermoplastic such as butadiene-styrene copolymer, the composite fiber sheet (3
Formability is imparted to 1), and the sheet (8) is tricot, spandex knitted fabric, styrene-butadiene-styrene copolymer, styrene-isoprene-styrene copolymer, styrene-hydrogenated polyolefin-styrene copolymer. Elastomer films such as styrene-based thermoplastic elastomers such as butadiene-styrene block copolymers, block copolymers such as styrene-rubber intermediate block-styrene copolymers, acrylic rubber, butyl rubber, silicon rubber, urethane rubber, fluorine Compound rubber, polysulfide rubber, graft rubber, butadiene rubber, isoprene rubber, chloroprene rubber, polyisobutylene rubber, polybutene rubber, isobutene-isoprene rubber, acrylate-butadiene rubber, styrene-butadiene rubber, acrylonitrile-butadiene Rubber, pyridine-butadiene rubber, styrene-isoprene rubber, acrylonitrile-chloroprene rubber, styrene-chloroprene rubber, or other synthetic rubber or natural rubber, the composite fiber sheet (31) has impact resilience in addition to the reinforcing effect. A composite fiber sheet (31) having a very favorable texture is obtained, and when a metal foil is used as the sheet (8), a composite fiber sheet (31) having a heat shielding property is obtained. The sheet (8) may be placed on the back surface of the second fiber sheet (3) after the second fiber sheet (3) is placed on the back surface of the first fiber sheet (2).

The fiber sheets (2, 3) other than those in the above embodiments may both be webs, or the first fiber sheet may be a web and the second fiber sheet may be a needle punched nonwoven fabric.

[0014]

Therefore, according to the present invention, it is possible to easily manufacture a composite fiber sheet having a good texture, a very high designability, and various functions.

[Brief description of drawings]

 1 to 4 show one embodiment of the present invention.

FIG. 1 is an explanatory diagram of a double pattern needling process.

FIG. 2 is a partial cross-sectional view of the first fiber sheet after the first pattern needling.

FIG. 3 is a partial sectional view of a composite fiber sheet.

FIG. 4 a. State diagram after the first pattern needling b. Second state diagram after needling for patterning FIGS. 5 to 7 show another embodiment of the present invention.

FIG. 5 is an explanatory view of a state before needling the second fiber sheet.

FIG. 6 is a partial cross-sectional view of a composite fiber sheet.

FIG. 7 is a partial perspective view of a composite fiber sheet. FIGS. 8 and 9 show still another embodiment of the present invention.

FIG. 8 is an explanatory view of a double pattern needling process.

FIG. 9 is a partial cross-sectional view of a composite fiber sheet.

FIG. 10 is a partial sectional view of a conventional composite fiber sheet.

[Explanation of symbols]

 1,21,31 Composite fiber sheet 2,22,32 First fiber sheet 2A, 22A, 32A First pile layer 3,23,33 Second fiber sheet 3A, 23A, 33A Second pile layer 4, 24 piles 5,25 piles 8 other sheets

Claims (6)

[Claims] 1. A first pile layer is formed on the front surface of a first fiber sheet from the back surface by a first pattern needling.
Then, the second fiber sheet is superposed on the back surface of the first fiber sheet, and the second pile layer is formed on the front surface of the first fiber sheet by the second pattern needling from the back surface and both fiber sheets are bonded together. A method for producing a composite fiber sheet, comprising: 2. The method for producing a composite fiber sheet according to claim 1, wherein the first fiber sheet and the second fiber sheet have different colors. 3. The method for producing a composite fiber sheet according to claim 1, wherein another sheet is further inserted between the first fiber sheet and the second fiber sheet. 4. The method for producing a composite fiber sheet according to claim 1, 2 or 3, wherein another sheet is further inserted into the back surface of the second fiber sheet, and then the second patterned needling is applied. 5. The other sheet is an elastic sheet.
Or the method for producing the composite fiber sheet according to item 4. 6. The position of the pile forming the first pile layer formed by the first pattern needling and the position of the pile forming the second pile layer formed by the second pattern needling are different. The method for producing the composite fiber sheet according to claim 1, 2 or 3 or 4,