JPS5916031B2 - Manufacturing method of needle-punched nonwoven fabric - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a needle-punched nonwoven fabric that can be used for waste materials, and more particularly, to a method for manufacturing a needle-punched nonwoven fabric that has a beautiful image on the surface of the nonwoven fabric.

Conventionally, patterns have been applied to needle-punched nonwoven fabrics by mixing colorless fibers to obtain a marbled texture, or by placing a portion of "wadding" of fibers of different hues on the surface during punching, and then punching from above. There are methods to obtain a cloud-like pattern, but none of these methods allow reproduction of the pattern, and it is difficult to obtain a pattern with arbitrary uniformity.

Another way to obtain a desired pattern is to directly print with a silk screen, but in this case, unless there is a washing process to remove the binder in the subsequent process, the entire culm and the flexible binder are removed. If you do not use it for printing, the texture will deteriorate and you will not be able to obtain a good product.

It is also possible to obtain good-quality needle-punched nonwoven fabrics by printing on nonwoven fabrics using ink containing ordinary dyes using a silk printing machine, developing the color by steaming, and removing the binder in a washing process. However, for thick materials such as those used for flooring, it takes a considerable amount of time to dry after washing, so this is hardly practical, and furthermore, such wet painting processes pose a fundamental problem of pollution. They are intertwined with each other, and the benefits cannot be fully realized.

In order to eliminate the drawbacks of the above-mentioned conventional methods, the present inventors formed a pattern on transfer paper using a completely dry printing process using ink mainly containing sublimation or melt-transferable dyes, and used needles as a base material. We attempted to apply a sublimation transfer method in which punched nonwoven fabric and the transfer paper are brought into close contact with each other and dyed by heating.

However, when applying a transfer pattern to a needle-punched nonwoven fabric using the sublimation transfer method, it is not possible to obtain a nonwoven fabric with sufficient durability unless the material from which the nonwoven fabric is made is ester fiber.

Furthermore, even if the needle-punched non-woven fabric is made of ester fiber, the surface properties of the needle-punched non-woven fabric are not good, so unless a considerable amount of heat and pressure is applied for transfer, the pattern will not be sufficiently transferred and will not remain on the surface. The pattern is mottled with dyed fibers remaining, resulting in an inferior design.

In addition, in order to prevent these defects, if sufficient heat pressure and time are applied during transfer, the pattern will be transferred sufficiently, but
The nonwoven fabric of the base material sag (decreases in thickness) and curls, resulting in a decrease in thickness and change in texture, resulting in a decrease in commercial value.

On the other hand, as a method to eliminate these drawbacks, 100 m
A method of transferring under a reduced pressure of 1HF or less may be considered, but in this case, it is possible to obtain a product with good design properties, but
7 or Japanese Patent Application Laid-Open No. 48-64285, it requires extremely technically difficult and expensive equipment, which increases the cost of the final product and makes it extremely difficult to commercialize needle-punched nonwoven fabrics. Have difficulty.

The present invention eliminates the above-mentioned drawbacks in sublimation transfer painting of needle-punched nonwoven fabrics.The present invention will be described in detail below. A non-woven fabric is prepared by mixing the dyed fibers with a normal needle punch method, and then a transfer paper is formed on which an appropriate image is formed using an ink containing a sublimable or melt-transferable dye. In this method, the image on the transfer paper is transferred to the nonwoven fabric by closely contacting the nonwoven fabric, heating, and applying pressure if necessary, and then, by peeling off the transfer paper, a needle punched nonwoven fabric with an appropriate image formed thereon is obtained.

The undyed fibers that can be used in the present invention include those dyed with sublimation or melt-transferable dyes, and specific examples include fibers of polyester, acrylic, polyamide, etc. It is not limited to.

Since the present invention has the above-mentioned structure, even if the dye does not fully penetrate into the needle-punched nonwoven fabric, since the material is colored, there will be no white areas and a product with sufficient design properties can be obtained.

Furthermore, as mentioned above, since it is not necessary to penetrate the dye deeply, it is possible to obtain a product with good design properties without the need to set transfer conditions at high temperature, high pressure, or for a long time. The product is in good condition with very little scratching.

Furthermore, even if transfer unevenness occurs due to pressure unevenness due to the use of a colored base material, the unevenness becomes extremely less noticeable depending on the pattern.

Furthermore, according to the structure of the present invention, since yarn-dyed fibers and undyed fibers are mixed, the color fastness of the finished product after transfer is currently usually carried out by the sublimation transfer method. It has the same color development and color fastness as dyed fibers, and it is also possible to use acid dyes other than polyester, such as nylon, acrylic, and polyfural, easily and at low cost. Alternatively, yarns that can be dyed with cationic dyes can be used, which is extremely advantageous.

Furthermore, as mentioned above, it is possible to obtain a product with good design properties without applying high temperature and pressure during transfer to penetrate the dye, so it is possible to print 4 and a half joss or 6 jos with a simple device such as an iron. Even large needle-punch carpets can be painted in one spot.

Next, the present invention will be explained according to the steps. The undyed fibers constituting the nonwoven fabric have a denier of 3 to 100, preferably 5 to 50 denier, to give a good finish to the nonwoven fabric.

Furthermore, as the yarn-dyed fibers, heat-resistant nylon fibers, vinylon fibers, acrylic fibers, polyfural fibers, and polyester fibers are desirable.

In particular, nylon can be easily pre-dyed with acid dyes or disperse dyes, and acrylic fibers can be easily pre-dyed with cationic dyes or disperse dyes, which is desirable.

The thickness of the fibers is 3 to 1, similar to the undyed fibers mentioned above.
00 denier, preferably about 5 to 50 denier.

The use of fibers that do not have heat resistance, such as acetate fibers, polyolefin fibers, and polyvinyl chloride fibers, may cause a change in texture and "sagging" (reduction in thickness) during transfer, so the colored fibers used in the present invention undesirable as such.

When heat-resistant natural fibers such as wool, linen, and cotton are yarn-dyed and used as colored fibers, the material (fibers) are not dyed at all during sublimation transfer using disperse dyes in the subsequent process, resulting in a unique taste. It's fun to come out.

The mixing ratio of undyed fibers and yarn-dyed fibers can be 20 to 80 parts by weight of yarn-dyed fibers to 100 parts by weight of undyed fibers, but it is possible to satisfy various fastness requirements after transfer and In order to obtain characteristics as a colored original fabric, the amount of yarn-dyed fiber is preferably 40 to 60 parts by weight.

The base fabric of the needle-punched nonwoven fabric according to the present invention may be any fabric made from synthetic fibers or natural fibers as long as it has heat resistance.

Furthermore, the basis weight should be set depending on the application and is arbitrary.

As the needle punching method, a method for creating a normal needle punched nonwoven fabric may be used.

Also, when coating a backing resin on a nonwoven fabric, it is best to coat it before transfer if a heat-resistant resin is used.
When using a material such as SBR latex that does not have heat resistance, it is desirable to perform resin processing after transfer.

The transfer paper used in the present invention may be a commercially available printing paper for sublimation transfer for polyester cloth, and these are generally nitro-based printing papers that have sublimation or melt transfer properties in the range of 150'C to 200C. Printing is performed using ink containing disperse dyes such as azo, quinophthalone, and anthraquinone by gravure printing, flexo printing, silk printing, or offset printing.

Further, any transfer machine can be used in the present invention as long as it can maintain heat of 150° C. or higher, but any transfer machine that is normally used for fabric transfer can be used as a production machine.

Examples include Nao Printer (product name, manufactured by Naomoto Kogyo Co., Ltd.), Vercumat (product name, manufactured by Kanegiesser AG, West Germany), Transcolorizer (product name, manufactured by Gessner Co., Ltd., USA), and Rolling Strateik (product name, manufactured by Gessner Co., Ltd.).・Manufactured by Lemaire, France), etc.

Example ■) 15 denier stable of Toshi nylon (trade name, manufactured by Toshi) yarn-dyed with C, I Acid Red 89, and tetron (polyester fiber trade name, manufactured by Yondai) 20 denier stave in a weight ratio of 1:l
A nonwoven fabric was prepared using a conventional needle punch method so that the mixture had a basis weight of 40,097 m.

After that, CI D: 5perse Orange
3, CI D:5perseRed15, CI D:
A transfer paper with a gravure pattern printed with an ink containing 15 parts by weight of 5perse Blue 56 per 100 parts by weight of water-based acrylic was overlaid on the nonwoven fabric and heated at 180°C, 60 seconds, 200g/
The dye was transferred to the nonwoven fabric under crA conditions to obtain a painted needle-punched nonwoven fabric with good design and color fastness.

2) 20 denier acrylic stable (manufactured by Mitsubishi Rayon Co., Ltd.) yarn-dyed with CI Ba5ic Blue 3 and the same polyester stable mixed at a weight ratio of 1:2, with a basis weight of 200 g/m A conventional needle-punch nonwoven fabric was prepared so as to have the following properties.

Thereafter, the same steps as in Example 1) were carried out to obtain a painted needle-punched nonwoven fabric having good design and color fastness.

Claims (1)

[Claims] 1. A non-woven fabric is created by mixing heat-resistant yarn-dyed fibers and undyed fibers on a heat-resistant base fabric using a needle pan method, and then a sublimation or melt migration dye is applied. A method for producing a needle-punched nonwoven fabric, which comprises: closely contacting a transfer paper on which an image is appropriately formed with an ink containing the above nonwoven fabric, and carrying out heat transfer.