JPH11269750A - Needle punched laminate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a bulky and high-strength needle punched shrinkable laminate scarcely causing falling off of a fibrous web. SOLUTION: This needle punched shrinkable laminate is obtained by superimposing a fibrous web 3 on the surface of a base fabric 2 comprising flat yarns having heat shrinkability, carrying out interlacing treatment for passing the fibrous web 3 through the base fabric 2 according to a needle punching method, then thermally shrinking needle through-holes by heat treatment and thereby tightening the fibrous web 3 to the surface of the base fabric 2. The laminate is used as a cleaning sheet or a cushioning packaging sheet.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a needle punch laminate, and more particularly to a needle punch laminate, in which a fiber web is tightened to a base cloth without using an adhesive, so that it can be effectively used as a cleaning sheet or a cushioning packaging sheet. The present invention relates to a needle punch laminate that can be used.

[0002]

2. Description of the Related Art Hitherto, a large number of laminates have been used in which a woven fabric or a nonwoven fabric is used as a base fabric as a cleaning sheet or a cushioning packaging sheet, and a fiber web is laminated on the surface thereof. As a method of manufacturing such a laminate, there is a method of bonding the fiber web to the base fabric by using an adhesive or a method such as heat welding. However, when the fiber web is bonded to the base fabric, the degree of freedom of the fiber web is increased. Thus, there is a problem that the flexibility of the laminate is lost and the cushioning property is reduced, and the cleaning sheet deteriorates in retention of dusts. In order to solve such a problem, a method of intertwining and integrating a fiber web with a base fabric by a spunlace method or a needle punch method is often used, but in the spunlace method, a high-pressure water flow or the like is used. There is a problem that the fiber web is crushed and the apparent bulk specific gravity is reduced.In addition, in the needle punch method, the fiber web is a short fiber, or when the fiber density is low, the degree of entanglement is weak, There has been a problem that the fibers fall off.

[0003]

SUMMARY OF THE INVENTION In view of the above circumstances, an object of the present invention is to provide a needle punch laminate which is bulky, has high strength, and in which a fiber web laminated on a base fabric is less likely to fall off.

[0004]

According to the present invention, a fiber web is laminated on the surface of a base fabric composed of heat-shrinkable flat yarn, and a part of the fiber web is projected to the back surface of the base fabric by needle punching. In the entangled state, by performing heat treatment and shrinking the through hole of the base fabric by the needle,
A needle punch laminate comprising a fiber web fastened to a base fabric.

[0005] The above-mentioned needle punch laminate is suitably used as a cleaning sheet or a cushioning packaging sheet.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The configuration of the present invention will be described below in detail. FIG. 1 shows a schematic cross section of a needle punch laminate of the present invention.

Among the laminates of the present invention, the synthetic resin used for the flat yarn serving as the base fabric is selected from those which have good moldability and which sufficiently shrink by the subsequent heat treatment. And polyolefin-based resins such as propylene-ethylene copolymer, high-density polyethylene, linear low-density polyethylene, and low-density polyethylene.

The flat yarn can be formed by melt-extruding a raw resin with an extruder, forming a film by a T-die method or an inflation method, slitting the film, and then hot-stretching. The thermal stretching here is performed at a temperature lower than the melting point of the raw material resin and higher than the softening point. The stretching ratio is preferably 3 to 15 times, more preferably 5 to 10 times.
The thickness of the obtained flat yarn is 20 to 50 μm, and the fineness of the flat yarn is preferably 100 to 2000 denier, more preferably 500 to 1200 denier.

It is important that the flat yarn has heat shrinkability. The degree of heat shrinkage is determined by the relationship between the heating temperature and the heating time, but in the present invention, the through-hole formed by the needle described later is narrowed, and the fiber web existing in the hole can be tightened, and the flat yarn or the fiber web can be tightened. It is necessary to set a temperature that does not cause thermal deterioration, and it is preferable that the thermal shrinkage is 30% or more,
It is more preferably at least 50%, further preferably at least 60%.

The configuration of the flat yarn is not limited to a single layer, but may be a multilayer composite flat yarn in which an outer layer made of a low melting polymer is laminated on both surfaces of an intermediate layer made of a high melting polymer.

Using the flat yarn, a base fabric is formed by a known weaving knitting method. The weaving organization is plain weave, twill weave, leno weave, etc., and the knitting method may be either horizontal knitting or vertical knitting, specifically tricot knitting,
The Miranese edition, the Russell edition, and the like. Among these, a plain woven fabric having a good balance of shrinkage and capable of easily obtaining a tight base fabric is preferable. In the case of this woven fabric, the driving density of the flat yarn is preferably from 3 to 20 yarns / inch, and the weft spacing is preferably small, depending on the fineness of the flat yarn used. By using such a tight base cloth, the needle web is heat-treated while penetrating the flat yarn while holding the fiber web at the time of needle punching, which will be described later. It is tightly tightened and has an effect of preventing the thread from coming off.

One or both surfaces of the base fabric can be coated and laminated with low-density polyethylene or the like to be used as a laminate sheet. Laminate layer thickness is 10-30μ
m is preferable.

Next, the fiber web used in the laminate of the present invention is a fibrous material generally referred to as a fiber, and may be a heat-shrinkable fiber or a non-heat-shrinkable fiber. Weldable fibers may be used. Specifically, synthetic fibers such as polyester, polyamide, polyolefin, and acrylic, or composite fibers thereof, semi-synthetic fibers such as acetate, regenerated fibers such as cupra and rayon, and natural fibers such as cotton, silk, and wool. Any of these may be used, or a blend thereof may be used.

The single fiber fineness of the fiber web is preferably 0.1 to 30 denier, more preferably 0.5 to 6 denier. If the thickness is less than 0.1 denier, the web formability decreases,
If the denier is larger than 30 denier, the degree of entanglement is not sufficient, and the flexibility of the laminate is reduced. In particular, the retention of dust for cleaning is deteriorated.

[0015] The fiber web may be a fiber web formed by using a known carding machine and formed of short fibers or long fibers, or a nonwoven fabric such as a spunbonded nonwoven fabric or a meltblown nonwoven fabric. There may be.

The basis weight of the fiber web is 10 to 200
preferably ^{g / m 2, 50~100g / m} 2 is more preferable. If the basis weight is less than 10 g / m ² , the degree of entanglement is weak and the fibers are likely to fall off. If the basis weight is more than 200 g / m ² , it becomes bulky and it is difficult to achieve the object of the present invention.

Such a fiber web is entangled by a needle punch method from the fiber web side in a state of being laid on the surface of the base fabric to form a laminate. The lamination structure of the fiber web may be lamination on one side or lamination on both sides of the base fabric, and may be selected depending on the application.

[0018] is preferably carried out in a range entangling treatment is needle density by the needle punch method is 20 to 300 present / cm ^2, and more preferably 50 to 150 present / cm ^2. If the needle density is less than 20 needles / cm ² , the degree of entanglement is weak and the fiber web is liable to peel off. If the needle density exceeds 300 needles / cm ² , the base fabric is greatly damaged by the needles, which is not preferable.

After the entanglement treatment, the laminate is heat-treated to thermally shrink the base fabric, and the fiber web penetrating the base fabric is tightened to prevent the yarn from coming off. The heat treatment temperature is within the range of the heat shrinkage temperature of the resin constituting the used flat yarn. For example, in the case of polyethylene, it is preferably in the range of 90 to 130 ° C, and in the case of polypropylene, it is preferably in the range of 110 to 150 ° C. As the heat treatment method, any method such as a hot roll, a hot plate, an infrared ray, and a hot air oven can be adopted. Among them, the hot air oven method is preferable in terms of high-speed productivity and stability.

[0020]

EXAMPLES Example 1: Linear low density polyethylene (MF)
R = 2.0 g / 10 min., Density = 0.924 g / c
Using m ³ ), a film was formed by an inflation method, cooled, slit, and then stretched 6.8 times to obtain a flat yarn with a fineness of 1000 d. This flat yarn had a heat shrinkage at 61 ° C. of 61%. The flat yarn was used as the warp yarn, and a plain weave flat yarn cloth was obtained at a driving density of 16 × 16 yarns / inch by a throughr weaving machine to obtain a base cloth.

On the other hand, a mixture of 50% by weight of a polyester short fiber having a denier of 3 denier and 6 denier was carded to form a fibrous web having a basis weight of 50 g / m ² , and the fibrous web was laminated on one surface of the base fabric previously formed. , Needle density 5
Needle punching was performed at 0 needles / m ² , and the fiber web and the base fabric were entangled and integrated.

Next, the fiber web was passed through a hot air oven set at 110 ° C. to thermally shrink the flat yarn cloth, thereby performing a yarn pull-out preventing treatment for tightening the fiber web. When this needle punch laminate was used as a packaging sheet for furniture, it had excellent cushioning properties and was suitable.

Example 2 The procedure of Example 1 was repeated except that the fiber web was laminated on both sides of the base fabric. When this needle-punched laminate was used as a cleaning sheet, there was no thread coming off and the dust-retaining property was excellent.

Comparative Example: The same operation as in Example 2 was performed except that the heat treatment for developing the heat shrinkage of the flat yarn cloth was not performed after the needle punching treatment. When this needle punched laminate was used as a cleaning sheet, the fiber web was often peeled and dropped off, and was unsuitable as a cleaning sheet.

[0025]

As described above, according to the present invention, a fiber web is entangled with a base fabric made of a heat-shrinkable flat yarn by a needle punch method, and the through-hole is heat-shrinked by a heat treatment. Because it is a laminated body that tightens the fiber web, it is bulky, high-strength, has little falling off of the fiber web, is flexible and has excellent cushioning properties, and particularly has a good dust retention cleaning sheet or cushioning property. It can be effective as a good packaging sheet.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view of a needle punch laminate of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Needle punch laminated body 2 Base cloth 3 Fiber web 4 Needle punch

Claims (3)

[Claims] 1. A state in which a fiber web is laminated on the surface of a base fabric composed of a heat-shrinkable flat yarn, and a part of the fiber web is projected and entangled with the back surface of the base fabric by needle punching. A needle punch laminate, wherein a fiber web is tightened to the base fabric by performing heat treatment to shrink the through holes of the base fabric formed by the needles. 2. The needle punch laminate according to claim 1, which is used as a cleaning sheet. 3. The needle punched laminate according to claim 1, which is used as a cushioning packaging sheet.