JPS604297B2 - Non-woven fabric molded product - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a nonwoven fabric molded article such as a cup for a plunger, and utilizes the difference in melting point of fibers or resins to form at least two layers of fibers and resins that have different melting points. The present invention relates to a flat or curved nonwoven fabric formed by heat-pressing a bulky I-type nonwoven fabric and consisting of two layers: a layer with good texture and touch, and a layer that maintains a compressed and delicate form.

Conventionally, for molded nonwoven fabrics, nonwoven fabrics obtained by spraying or impregnating a bulky or dense fiber web with a thermosetting resin or thermoplastic resin binder, or a mixture of both, are heated using a female and male mold of the desired shape. There is a method of obtaining a nonwoven fabric molded product by pressure molding.

However, if only thermosetting resin is used as the binder,
The curing reaction during molding takes a long time, and the resulting molded product is extremely hard and inflexible, making it unsuitable for clothing applications.
Further, when only thermoplastic resin such as acrylic acid ester is used, a soft texture can be obtained, but there is a problem in shape retention because it does not have appropriate elasticity. Furthermore, when molding a nonwoven fabric obtained using a mixed binder of thermoplastic resin and thermosetting resin, molding is performed by overheating at high temperature, high pressure, or under vacuum pressure, and the molded product is relatively soft and elastic. You get something. However, in all of these methods, bulky or dense non-woven fabrics are sandwiched between female and male molds and compressed by heating and pressurizing them to a uniformly dense layer density. However, it has not been possible to obtain a product that perfectly matches the woman's bust and the texture of woven clothing, and the processing is time-consuming and expensive. The present invention aims to improve the above-mentioned drawbacks and to provide a nonwoven fabric molded product with a feel and curved surface structure ideal mainly for use as a brassiere cup.

In other words, when a molded product is worn as a bra cup, its feel and softness are issues, and the texture and softness are aimed at being those of textiles, and various methods have been tried to achieve softness. However, it has been extremely difficult to obtain molded products, especially molded products with a curved surface structure, that have a soft texture. As a result of intensive research, it was found that when molding a nonwoven fabric, it is effective to divide it into a shape-retaining part and a part that feels good to the touch. Therefore, the present invention provides an upper layer of a bulky and flexible nonwoven fabric made of fibers and a binder having a relatively high melting point, and at least one of the fibers and the binder is made of a material having a lower melting point than the fibers or binder of the upper layer. The lower layer of the bulky nonwoven fabric is laminated and bonded, and heated and pressure molded at a temperature lower than the high melting point fibers or binder but higher than the low melting point fibers or binder to coarsen the density and make it soft. To obtain a molded product for a cup having a coarse and dense two-layer structure, which simultaneously has an upper layer with good texture and a compression-molded dense lower layer necessary for shape retention.

Of course, the main purpose of the present invention is to relate to brassiere cups, but the present invention is not limited thereto, and is suitable for items such as shoulder pads for clothing that require good feel and shape retention. Next, the configuration of the present invention will be explained with reference to the drawings.

In FIG. 1, the lower layer A is a bulky nonwoven fabric made of fibers 1 and a binder 2, and the upper layer B is a bulky flexible nonwoven fabric made of fibers 3 with a relatively high melting point and a binder 4. At least one of the fibers 1 and the binder 2 of the constituent materials of the lower layer A is the constituent material of the upper layer B.
The fibers 3 or the binder 4 have a lower point.
Further, the fibers 3 or the binder 4 of the upper layer B have a melting point higher than that of the fibers 1 or the binder 2 of the lower layer A by 20 qo or more. 5 is a thermoplastic resin adhesive for bonding the lower layer A and the upper layer B together.

Figure 2 shows the laminated nonwoven fabric 9 obtained by sandwiching it between molds and heating and pressurizing it at a temperature higher than the melting point of either the fibers or binder of the lower layer A and lower than the melting point of the fibers or binder of the upper layer B. molded products for pads (non-woven fabric molded products),
The XX cross-sectional view is shown in FIG.

The above-mentioned molded product has a shape-retaining layer 6 that is delicately compression-molded as a lower layer,
It consists of two layers, the top layer being a coarse fluff layer 7 with an excellent texture and density. That is, FIG. 4 shows an enlarged view of the Y-Y cross section of FIG. In the shape-retaining layer 6 which forms a layer with a higher density than that of the layer A, the upper layer b is composed of fibers or a binder having a higher melting point than the layer A, and due to the characteristics of the fibers or binder, it has good resilience, is bulky, and has a coarse density. A fluffy layer 7 with a good texture is formed. In addition, FIG. 5 shows another embodiment of the present invention, which is a molded product in which the a layer is a dense shape-retaining layer 6, and the b and c layers are layers 7 and 8 that maintain texture. You can also do that.

Next, details of the present invention will be explained with reference to examples.

Example 1 Using a polyester fiber with a thickness of 3 denier and a cut length of 38, which has a relatively high melting point (melting point 250 to 260 °C),
After forming a web with a weight of 170 mm using a web forming machine,
A resin binder with a relatively high melting point, which is made by adding a melamine initial condensation resin (melting point 3470) and a catalyst to an emulsion mainly composed of acrylic acid ester as a binder, was applied to one side for 13 minutes.
A bulky, flexible nonwoven fabric with a coarse density is formed by spraying on both sides one by one to form an upper layer B.

Next, a web with a thickness of 3 denier and a cut long grain polyester fiber (melting point (250 to 260°C) and a weight of 120 yen/final was formed, and in the same manner as the upper layer B, a comparative web consisting mainly of acrylic ester was formed. Apply binder liquid with high melting point to one side
Evening: After spraying on both sides one by one to form a bulky nonwoven fabric, upper layer B
As a binder with a lower melting point than the constituent fibers or binders of
Polyethylene resin with an average particle diameter of 15 mm (melting point 100-1
30°C) in a dispersion (containing 1 to 5 parts of dispersant, thickener, antifoaming agent, etc. based on 100 parts of solid polyethylene) and squeezed so that the dry solid resin adhesion amount was 60%. After drying, a bulky nonwoven fabric having a weight of 218 mm and a thickness of 13 and serving as a shape-retaining lower layer A was obtained.

On one side of the bulky nonwoven fabric of the shape-retaining lower layer A, 1.8 nylon resin was dissolved in a mixed solvent of methanol and trichlene.
After spraying a 0% solution and applying it to a dry solid content of 10 minutes, the bulky flexible nonwoven fabric that will become the upper layer B is polymerized and dried and fixed at 50 to 60°C to form an integrated bulky laminate. A nonwoven fabric was obtained.

A modified low-melting point Nion resin (trade name: Platamide 10 porridge) was sprinkled on both sides of the non-woven fabric for 8 days in order to bond it to the compound woven fabric and warp fabric used as the outer material or lining.
The nonwoven fabric base material for molding was completed by heating and melting and adhering.

As a curved molded body, the lining is placed on the forming surface of the dense lower layer A on the male and female molds of the brassiere cup, and the outer material is placed on the rough surface of the upper layer B, and then clamped and fixed so that the thickness after molding becomes 3 sides. When molded at a temperature of 110 to 115q○ under moist heat vacuum, as shown in Figure 6, the front and back sides were the outer fabric 11 and the inner fabric 1.
The convex surface forms a bulky, flexible, and coarse-density fiber layer 12 with a good texture, and the concave surface is compression-molded into a high-density layer with flexibility. A cup for a brassiere was obtained which simultaneously comprises two layers: a layer that retains its shape and a bulky fiber layer that has a good touch and feel. Example 2 Using polyester fibers with a thickness of 3 denier and a cut length of 38 with a relatively high melting point (melting point 250 to 260°C), a bulky and flexible nonwoven fabric with a coarse density was formed in the same manner as in Example 1, and the upper layer was Let it be B.

Next, a polypropylene fiber with a thickness of 3 denier and a length of 76 mm (melting point 165°
o) to form a web with a weight of 120 mm, and a solid amount of acrylic acid ester emulsion as a binder is sprinkled on each side at a rate of 13 mm/pillow on each side, and dried and fixed to produce a bulky non-woven fabric.

Furthermore, the above-mentioned bulky nonwoven fabric was impregnated with acrylic acid ester emulsion, squeezed, and dried so that the amount of resin solid content of the nonwoven fabric was about 60% of the fiber, and the thickness was 11 mm and the weight was 218 mm/cm.
A bulky nonwoven fabric was formed as the shape-retaining lower layer A. On one side of the bulky nonwoven fabric, which is the lower layer A, 8 nylon resin adhesive is applied in the same manner as in Example 1, and the upper and lower layers are laminated and bonded. A bulky laminated nonwoven fabric was formed. Modified low-melting point nylon resin was spread on the front and back surfaces of the above laminated nonwoven fabric in the same manner as in Example 1, and then heat-adhered.Then, it was cut to the required size, put between female and male molds together with the outer material and lining material, fixed with cotton, and heated with moist heat at 120 qo. When molding was carried out, a molded product with a two-layer structure having coarse and dense fiber layers as shown in FIG. 6 was obtained. By adopting the two-layer structure of the present invention, the upper layer, that is, the bulky and flexible fiber layer, is compatible with striped fabrics such as clothes and underwear due to its characteristics, and the lower layer is compression-molded and has a higher density than the upper layer. Because it forms a flexible and elastic shape-retaining layer, it has excellent resilience and mold retention, and brings out the best of both.

In addition, when a bra pad is molded, even if the tip is pressed and indented, the lower layer has excellent resilience and shape retention, so it has a restoring force and easily returns to its original shape. This eliminates the problem of forming square corners in a concave state, which is a drawback of the conventional method. The upper layer of the laminate is thermoformed at a temperature lower than the melting point of its constituent fibers and binder, so it is virtually unaffected by heat or pressure, and therefore has a surface fuzz layer that gives it a very soft feel. vinegar. Furthermore, the nonwoven fabric molded product of the present invention has a simpler and more efficient processing process than conventional sewing processes, and unlike similar pressure molded products, which have a hard texture and are compressed uniformly throughout, they are particularly resistant to wind. It has a good feel and shape retention.

[Brief explanation of the drawing]

Figure 1 is a side view of the nonwoven fabric molded product of the present invention before molding, Figure 2
The figure is a perspective view of a curved molded product showing one embodiment of the present invention.
The figure is a cross-sectional view taken along the line X--X in FIG. 2, FIG. 4 is an enlarged view of the main part of the Y-Y cross-sectional view in FIG. 3, and FIG. 5 is a side view of a nonwoven fabric molded product showing another embodiment of the present invention. FIG. 6 is a sectional view of a brassiere cup using the nonwoven fabric molded product of the present invention. 1... Fiber, 2... Binder, 3... Fiber, 4... Binder, 5... Adhesive, 6
...Shape-retaining layer, 7...Fuzzy layer, 8...
Bulky flexible fiber layer, 9... Laminated nonwoven fabric, 10...
...Nonwoven fabric molded product, 1 1... Outer fabric, 14.
...Lining fabric. Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6

Claims (1)

[Claims] 1 The upper layer is formed of a bulky, flexible nonwoven fabric with a coarse density composed of fibers and a binder with a relatively high melting point, and at least one of the fibers and the binder of the bulky nonwoven fabric forming the lower layer is formed with a high melting point of the upper layer. A laminated nonwoven fabric made of a material with a melting point lower than that of the fibers or binder and whose laminated surfaces are bonded with a thermoplastic resin adhesive is made of a material with a lower melting point than the fibers or binder with a higher melting point. The product is heated and compression molded along the mold at a temperature higher than that of the binder, resulting in a coarse and dense two-layer structure consisting of an upper layer with a coarser density and soft texture, and a denser lower layer that is compression molded to maintain its shape. A nonwoven fabric molded product characterized by: