JPS6245764A - Nonwoven fabric and its production - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

Detailed Description of the Invention (Industrial Application Field) The present invention relates to a nonwoven fabric and a method for producing the nonwoven fabric, and more particularly to a nonwoven fabric formed from continuous filaments and a method for producing the same, in which the starting material is continuous filaments. The fiber laminated sheet has a weak point 2 in which a weak point is provided on the single fiber surface of the continuous filaments in the surface layer on one or both sides of the fiber laminated sheet, and in some of the weak points, the single fiber is The fabric is cut to form cut ends of the fibers, resulting in a new grooved structure as if short fiber staples were intermixed with it, making it a high-class clothing fabric with excellent flexibility and anti-pilling properties. This article relates to a method for producing a nonwoven fabric and a core nonwoven fabric that can be preferably used as a core nonwoven fabric.

(Prior art) Conventionally, non-woven fabrics began with felt made by utilizing the shrinking properties of wool, and then were made into laminated sheets made of short fiber webs and long fibers such as synthetic fibers that do not have shrinking properties. Many nonwoven fabrics have been proposed in which fibers are entangled by punching or water jet punching using high-pressure water streams.

Depending on the purpose, these nonwoven fabrics may be used as they are or may be impregnated with various binders. In addition, entanglement may be provided by self-adhesion using pressure or heat as a medium.

Here, the former method, which uses a short fiber web as a starting material, has the advantage that the fibers are easily intertwined by needle punching, but it is also possible to form short fiber aggregates into a web using a carding machine. In order to do so, it is inevitably subject to constraints 2 in terms of fiber properties such as fiber fineness and fiber length. That is, fibers having an extremely fine denier and a long fiber length generally have a problem in that defibration is poor and it is difficult to obtain a uniform web. Therefore, this is a major hindrance to realizing weight reduction, flexibility, and uniformity in such nonwoven fabrics, and when a resin coating is particularly provided on the surface of the nonwoven fabric, it is difficult to coat the coating due to nonuniformity. There were problems such as difficulty in achieving high strength. Regarding softening, all fiber raw materials for manufacturing nonwoven fabrics,
One method is to prepare composite fibers exhibiting a sea-island structure in advance, use the fibers to make a non-woven fabric, and then extract the sea components to make ultra-fine fibers, or a splittable composite fiber in the form of laminating different component polymers. Conventional techniques include methods in which the fibers are made into a non-woven fabric and then split or split into fibers, and although the desired results have been obtained, these techniques originally required the complexity and sophistication of the spinneret. However, it is difficult to manage production, and furthermore, it requires a process of elution of sea components or a splitting process, resulting in complicated production management and a significant increase in production costs. There was an unavoidable problem.

On the other hand, when manufacturing nonwoven fabrics using a laminated sheet of long fibers as a starting material using the latter type of direct spinning type known as the so-called spun-nd method, the influence of single fiber fineness is small, and it is generally referred to as ultra-fine. However, it has the advantage that even a fiber sheet made of fibers with a denier of around 0.5 can be easily produced.

Because they are long fibers, there is a limit to how well they can be entangled.2For example, even if strong water jet punching is used to create entanglement, there is a limit to the migration of the fibers, and even the slightest external force can cause the fibers to move. In the end,
A major problem was that nonwoven fabrics using this method could not be successfully applied to clothing applications. As a means to solve such pilling, methods such as impregnating a large amount of binder such as resin or creating strong self-adhesion are generally adopted, but the nonwoven fabric obtained in this way has a noticeable rough and hard feel. In some cases, it becomes a product that has no air permeability, like a rubberized sheet, and emits a characteristic unpleasant sound like a rattling sound. Although it can be used for clothing, it is completely unsuitable for clothing.

(Problems to be Solved by the Invention) In view of the above-mentioned points, the purpose of the present invention is to maintain as much as possible the basic properties of the fiber material constituting the nonwoven fabric, while preventing the occurrence of piling and pilling, which actually becomes a problem with dirt floors. It has the characteristics of light weight, heat retention, excellent drapability, excellent repulsion, and a soft touch feel, all of which are characteristics of nonwoven fabrics.

To provide a new nonwoven fabric for use in high-class clothing that could not be obtained using conventional techniques.

The present invention aims to provide a still novel method for producing nonwoven fabrics.

(Means for Solving the Problems) In order to achieve the above-mentioned objects, the present invention consists of the following configurations.

In other words, the nonwoven fabric of the present invention is a nonwoven fabric formed from at least continuous long fibers, and the fiber surface of the continuous long fibers disposed on one or both surfaces of the nonwoven fabric has a weak point. The fibers are applied in a dispersed manner, and at some of the weak points, the single fibers are cut to form cut ends.
The nonwoven fabric is characterized in that a portion of the fiber cut ends are internally intertwined due to migration within the nonwoven fabric, and a portion is present as fuzz on the surface layer of the nonwoven fabric.

In addition, the method for producing a nonwoven fabric of the present invention includes at least a spinning process, a collecting process for spun fibers, and a fiber entangling process for producing fiber entanglement noise in a fiber sheet formed from the collected fibers. In a fabric manufacturing method, a fiber laminated sheet is pressed with a pressure roller system or a pressure contact plate system having a coarse grain surface with an average roughness of 1 to 5000 μ to create a weak point in the fibers constituting the sheet on one or both sides of the fiber sheet. This is a method for producing a nonwoven fabric, characterized in that the sheet 1 is subjected to a fiber entangling step after being applied.

Preferred embodiments of the nonwoven fabric or the method for producing a nonwoven fabric of the present invention will become clearer in the following description.

(effect) The present invention will be explained in more detail below.

The nonwoven fabric of the present invention has a main chain of polyethylene terephthalate, polyamide, polyacrylonitrile, polyethylene, polypropylene, polysulfide polyimide, polybutylene terephthalate, or the like. It is formed from continuous long fibers made of monopolymer or modified polymer.

As the continuous long fibers, various types can be used, such as ordinary single-component fibers, composite fibers in which single fibers exhibit a sea-island structure, round cross sections like different polymer combinations, and various irregular cross sections. .

The fineness of the continuous filaments is not particularly limited, and can be applied from around 0.01 denier to several tens of denier, but if it is intended for use in general clothing, it should be around 0.05 to 5 denier. It is preferable to set it within the range of , and this may also be determined as appropriate depending on the desired characteristics of the nonwoven fabric.

For example, when using ultrafine fibers and aiming for particular flexibility, sea-island composite fibers should have a single fiber denier within the range of 0.01 to 1.0 after the sea component is eluted.

Furthermore, it is preferable to use splittable composite fibers having a single fiber denier of 0.05 to 5.0 after splitting. For conventional melt spinning of conventional mono- or modified polymers, the denier is preferably within the range of 0.1 to 5 denier. In addition, if the single yarn fineness is 9, for example, 0.01
9. If the fiber size is small, such as ~0.05 denier, the fiber density in the laminated sheet will be high, and the intertwining itself will be improved, resulting in a nonwoven fabric that does not easily flop.9. In addition, since the surface fibers are easily cut even by a minute external force, the occurrence of cracks and pilling is actually extremely small, and from this point of view as well, it can be said to be preferable. On the other hand, when the single fiber fineness is larger, such as over 2 denier, for example, over 5 denier, the rigidity of the single fiber becomes high, so the flexibility tends to be gradually lost.

The nonwoven fabric of the present invention is a nonwoven fabric formed from at least the above-mentioned continuous filaments as starting threads, and the fiber surface of the continuous filaments disposed on one or both surfaces of the nonwoven fabric has weak points. The parts are distributed and given. In a part of the weak point, a single fiber is cut to form a cut end of the fiber, and a part of the cut end of the fiber is internally entangled due to migration inside the nonwoven fabric. Some of it is present as fluff on the surface layer of the nonwoven fabric.

Therefore, the nonwoven fabric of the present invention can be produced by at least a spinning process, a collecting process of spun fibers, and a fiber entangling process of causing fiber entanglement in a fiber sheet formed by the collected fibers. In the method, using a pressure roller system or a pressure contact plate system having a coarse grain surface,
This can be obtained by press-welding a fiber laminated sheet to impart a weak point to the fibers constituting the sheet on one or both sides of the fiber sheet, and then subjecting the sheet to a fiber entangling step.

To explain in more detail about such weak point imparting processing, emery vapor or the like is applied to one or both sides of a laminated sheet in a broad sense (a sheet that has just been assembled, or a sheet that has been subjected to some degree of entanglement or entanglement of fibers after being assembled). Coarse-grained roughhedrons such as emery cloth, or diamonds,
ceramic.

A coarse-grained roughened body coated with a powder of alumina, titanium oxide, glass, etc., or a molded product made of the same, is roughened by forming surface protrusions 2 by puffing, etc., and the like is pressure-bonded. It is preferable that the fibers constituting the sheet have a weak point on one or both sides of the laminated sheet.

The weak point imparting process may be any process as long as it can impart a weak point to the fiber surface.9 Although it is essentially not particularly limited,2 According to the studies of the present inventors, it is convenient to use the above-mentioned rough surface. Further, even in that case, although the actual processing system is not particularly limited, the weak point imparting processing system may be constituted by a pressure roller system or a pressure contact plate system having the coarse-grained surface.

It is practical to apply pressure by the processing system to the fiber laminated sheet flowing along the process.

According to the findings of the present inventors, it is important to have a coarse grain surface with an average roughness of 1 to 5000μ, preferably an average roughness of 50 to 500μ. It is better to keep it within a certain range, and this can be stated correspondingly in the Emery Cross standard.

This corresponds to about +40 to ≠600.

The suppressing load during pressure welding varies depending on the characteristics of the fibers that make up the fiber sheath, and there are some points that cannot be expressed in terms of shear, but if necessary, it is necessary to cut the fiber into fibers in the fiber entangling process after imparting the weak point. The pressing force is set to such an extent that the fibers are cut at at least a portion of the weak point when the force is applied, and conversely, the processing conditions of the fiber entangling step can be determined in this way. There are also things. The present invention is characterized in that the one-weakness imparting is not based on a pulling action as in the case of a napping machine, but rather on imparting scratches to the fiber surface by pressing.

The above-mentioned weak point imparting treatment may be performed after the spinning process - fiber gathering process (this step is a temporarily set nonwoven fabric with substantially no fiber entanglement), or after the spinning process - fiber gathering process - entanglement. It may be carried out after the step (interlacing is temporary entangling), or in the latter method, the entangling step - weak point provision step may be repeated multiple times, or in addition, after the weak point has been provided, resin impregnation may be carried out. It is also possible to take steps such as trying to do this and then adding a weak point again.

After the above weak point imparting treatment, the fiber laminated sheet becomes.

Subjected to fiber entanglement process. In the fiber entangling process, needle punching, water jet punching, etc. can be used as appropriate, but it can be said that water jet punching makes it easier to control product characteristics such as the desired soft feel.

Most preferred. Therefore, it is best to set the pressing load during the pressure welding to such an extent that a weak point that can be easily cut by the water jet punch is provided. Such as by water jet punch or needle punch.

The fluff ends of cut fibers migrate inward from the punched surface, causing entanglement, and at the same time, those that penetrate to the back surface appear as surface fluff, resulting in a nonwoven fabric with raised naps. It is.

The thus obtained nonwoven fabric of the present invention may be used as a product as it is, or may be further subjected to appropriate post-processing to form a final product.

Typical examples of such post-processing include impregnation or coating with a polymeric elastomer.

For example, by impregnating or coating the nonwoven fabric of the present invention with a polyurethane resin, it can be made to have exceptional texture and functional properties. Impregnation with the polyurethane resin can be carried out by either a wet method or a dry method; in the case of the former method, the polyurethane resin generally exhibits a microporous honeycomb structure due to foaming, so it is ideal for achieving a soft texture. Suitable for impregnation or coating processing. In the latter dry method, the solvent is blown away in the air and is suitable for thin film surface coating. Impregnation with a polymeric elastic body (resin) is effective in bonding and elasticity between fibers, preventing residual strain after elongation (elbow pull-out, fold pull-out), and improving durability.

In order to maintain a soft texture, the adhesion amount of these resins should be in the range of 99/1 to 20/80 in weight ratio of resin to nonwoven fabric.
It is preferably within the range of 9515 to 70/30.

When the polymeric elastomer is completely impregnated, if the resin content is 1% or less, the fabric will be highly flexible, but the anti-pilling property and the looseness will tend to be poor. On the other hand, if it exceeds 80%, the anti-build properties and the texture will be at a level that is sufficiently satisfactory for practical use, but the roughness and hardness will increase and the hand will tend to deteriorate significantly.

In addition, calendar press processing is used as other post-processing.

Emboss processing, puff processing (brushed processing), wrinkle processing,
Any one or a plurality of these processes may be performed, or these processes may be performed in combination with the above-mentioned impregnation or coating process of the elastic polymer body. Particularly regarding these processes, calendar press processing is effective in smoothing the surface, imparting gloss, and providing a thin window, and also has a blinding effect, which is effective in further improving heat retention.

In addition, engraving and boss processing are morphologically similar to the surface.

It gives a change (touch, gloss) and is also effective in improving gloss. Also, bread processing (brushed processing).

It is effective in making the hair stand up and making it soft to the touch. In addition, the wrinkle-imparting process produces a wrinkle structure on one surface and has a great effect of improving the fashionability.

The nonwoven fabric of the present invention may also contain short fibers in addition to grooved fibers composed of continuous filaments. It's a trench.
The basis weight is preferably within the range of 10 to 300 g/m.

The nonwoven fabric obtained according to the present invention exhibits an anti-build performance of grade 6 or higher according to the ICI method (after 5 hours), and has excellent anti-build properties. Here, to explain in detail the anti-build property, it is evaluated in five stages using the rcI method, which is commonly used for knitting fabrics as a method for determining pilling.

In addition to this pure pilling evaluation, the presence or absence of peach was evaluated based on the fuzziness of the evaluation fabric. It goes without saying that the occurrence of pilling here is due to the entanglement of fluffs in the initial stage, resulting in minute naps (99) and subsequent slipping of the fibers, which grow from naps to pilling (C pilling). significantly reduced. Since the inter-fiber binding force of non-woven fabrics is extremely small, it is common for pilling to occur in a short period of time. In particular, non-woven fabrics made of long fibers have a weak inter-fiber binding force due to migration compared to those made of short fiber webs, and the long fibers also tear, so once the naps become tangled, the fibers will inevitably slip off, causing pilling. There is a general problem that it is easy to use.

On the other hand, in the present invention, the continuity of the fibers is broken by adding 9 weak points, and in addition, if necessary, the fibers are bonded with resin, thereby making it possible to improve It exhibits excellent effects. Furthermore, even when the fabric is completely impregnated with resin, the amount of resin impregnated can be minimized, and the fabric exhibits a spun touch texture due to fluff, resulting in a fabric with a more natural feel.

By suppressing the amount of resin impregnated in this way, it is possible to obtain a fabric with high breathability and to create comfortable clothing.

To explain the present invention in more detail with reference to the following two drawings, FIG.
It consists of a fiber bundle group 6-a, a cloud-like fiber group 6-b, a loop-shaped migration fiber filter C formed by columnar flow of water jet punching, and holes 3-g formed by the punching. The cloud-like fibers 5-b present in the front and back layers are unstable, and the number of migration fibers 3-c is also extremely small.

FIG. 1 is a schematic diagram showing an example of a nonwoven fabric 5 of the present invention. The difference from FIG. 1 is that the nonwoven fabric has many weak points 3-d on one side and fluff 3-e cut by water jet punching. and end migration fiber 5-
The point is that f is mixed. Figure 5 is the nonwoven fabric 5 in Figure 2.
FIG. 2 is a schematic diagram showing a nonwoven fabric impregnated with a polymeric elastic material (resin) 6, and this figure shows an example in which the middle layer of the shin woven fabric is impregnated with the resin by a wet method.

FIG. 4 is a process schematic diagram showing one embodiment of obtaining the nonwoven fabric 5 of the present invention. First, as shown in FIG. 4A, the continuous filaments 6 spun by the spinning machine 1 are At the same time as the ejector 8 takes the sheet, it is subjected to a stretching action, and is further collided with a collision plate 9.

The fibers are collected on a net conveyor belt 10 to form a fiber laminated sheet 11. Next, the temporarily set nonwoven fabric 1-3, which is the laminated sheet 11, is wound up using the calender roll 12. Next, as shown in FIG. A pre-entangled nonwoven fabric 20i is obtained by performing a pre-entangled treatment.

In FIG. 4B, 15 and 16 are spreading rods, 18 is a net conveyor, 29 is a squeezing roller, and 21 is a winding device.

Further, as shown in FIG. 4C, the above-mentioned pre-entangled nonwoven fabric 20 is pressed by a rough roller 23 and a smooth roller 24 provided on the coarse grain surface to be subjected to weak point imparting processing, resulting in a nine weak point imparted nonwoven fabric 25. be done. Subsequently, the paper is subjected to full-scale entangling processing by an entangling processing device 17 such as a water punching device, and water is squeezed out by a squeezing roller 29.

This is the non-woven fabric 5 of this fabric and is wound up by a winding device 21. 21.22.27.28 shows the spreading rod. In this step, in the confounding process of FIG. 4C, the first
As shown in the figure, first, when the single fibers 6 are cut, the 9 fluff ends 3-e are intertwined.

Note that in the present invention, as described above, the process shown in FIG. 4C may be performed multiple times.

9 As a process of the present invention, it is also possible to perform weak point processing on the temporarily set nonwoven fabric 19 using the weak point imparting devices 23 and 24 without winding it up, and then intertwine it with the entangling processing device 17. It goes without saying that any processing 2, such as buffing, may be incorporated.

FIG. 5 shows a nonwoven fabric that has been subjected to an entangling treatment after improving weak points according to the present invention, and is impregnated with a polymeric elastic body (resin).
Alternatively, the chart shows an example of the process order in which each process is performed using an embossing roller.9 For example, a nonwoven fabric of the present invention that has been puffed and made into a napped nonwoven fabric is subjected to a resin impregnation treatment.

Further, the nonwoven fabric is subjected to the above-mentioned calender pressing and embossing in accordance with the desired nonwoven fabric properties, and then dyed and syllabled as appropriate to produce the final product.

(Example) The present invention will be explained below with reference to Examples.

Example 1 Using a polyamide polymer, a single yarn was spun at high speed to a fineness of 5 denier (the fineness after being taken up by an ejector) and scattered onto a net conveyor belt with a fabric weight of 50 g/m.
' A temporarily set nonwoven fabric was obtained. The total nozzle diameter of the nonwoven fabric is 0.1
4+nm, nozzle pitch 1.1mm, water pressure 40kg/
Preliminary entanglement was performed using a water jet punch under the following conditions. 2. Then, using an emery cloth with a mesh number ≠ 100, weak points were applied twice on each side at a line pressure of 55 mm, and the weak points were again applied using the water jet entangling device. The treated side was treated twice at a water pressure of 60,701 cg/an to cut and entangle the 9 weak points, and then the back side was treated at a water pressure of 60 cg/eI11. The cutting and entangling processing speed was 1.7 m/min. After drying the nonwoven fabric obtained in this way, it is impregnated with a polymer elastic body (resin) at a weight ratio of 78,722 to the greige nonwoven fabric, and then pressed on both sides using a calendar press, and then undergoes a dyeing and finishing process to obtain the desired nonwoven fabric. Obtained. The obtained nonwoven fabric had a soft touch feeling due to fluff, exhibited mild luster, and at the same time exhibited excellent repellency. When this non-woven fabric was compared with a conventional non-woven fabric that was not subjected to the 9-weakness imparting process, the anti-build performance was evaluated over time and the results were as shown in Table 1.

Table 1 (Note)・The numbers in parentheses are visual judgments of momokes, and those in which momokes have appeared (present) and those in which momokes have not appeared (absent).
And so.

・Evaluation method: ICI method.

As shown in Table 1, the products of the present invention were at a level that fully satisfied the practical performance from the early stage to the late stage.

Example 2 Polyethylene terephthalate was spun at high speed with a single fineness of 1°6 denier (after being taken up by an ejector) and scattered onto a net conveyor belt with a fabric weight of 65 g/m'.
A temporarily set laminated sheet was obtained. Using a device that incorporates a weak point imparting device and an interlacing device into the temporary set, for the first processing, emery cross rollers with a mesh number +400 are set up and down, and both sides are treated with a linear pressure of 45 cannon/cII +2. I did it.

Next, the nozzle diameter was 0.14 mm and the nozzle pitch was 1. O
mnr.

The single fibers were cut and entangled by water jet punching at a water pressure of 60/2. Next, it was passed six times through a weak point imparting processing device and a confounding device of the same type. The weak point conditions were the same as the first treatment conditions, and the entangling treatment was performed using the same nozzle specifications with a water pressure of 50 au/am” and 7.
0) cg/mouth 2, 7D bag/country 2. The processing speed is 2
, On/min. After drying the nonwoven fabric thus obtained, it was impregnated with a polymeric elastomer (resin) in a dry process, and then embossed with Silk H and finished with dyeing to obtain a desired fabric. The amount of resin was 80/20 in weight ratio of gray fabric to resin.

The nonwoven fabric thus obtained had a lightness and heat retention feeling different from that of the nine-knit fabric, and was elegant with a soft feel. At the same time, a sample without the 9-weakness imparting treatment was also produced, and the anti-pilling performance over time was evaluated using the rcI method, and good results were obtained in terms of peach resistance and anti-build properties as shown in Table 2.

Table 2 Example 3 The temporarily set laminate obtained in Example 1 was entangled by water jet punching, wet-impregnated with a polymer elastomer (resin), and then the alumina porcelain was puffed. With the roller system with the obtained rough surface, a linear pressure of 17 kg/
-2, followed by water jet punching (nozzle diameter 0.1ff, pitch between nozzles 1.0 mm) and water pressure 60.70.80 kg/cnI2 6 times to rupture the film formed of the polymer elastic material. A nonwoven fabric having very small ventilation holes was obtained.

The amount of resin adhered to the gray non-woven fabric was set at a ratio of 70/30. Furthermore, the entangling treatment conditions before resin impregnation were six treatments at a water pressure of 50.50.85 kg/l'' and a treatment speed of 1.5 m for 7 minutes.

The nonwoven fabric obtained in this example had fine fluff all over its surface, and was soft and highly breathable.

The anti-build property was also grade 4-5 in ICI method after 5 hours and grade 4 in 10 hours, and it was a fabric for high-grade clothing without puckering.

Example 4 Sea component polystyrene, island component polyethylene terephthalate (single fiber denier after sea component removal: 0.1 denier, 3
A single yarn with a denier of 2.8 denier and 24 filaments consisting of 6 islands) was spun at high speed and taken off with an ejector. Next, a laminated sheet with a basis weight of 150 g/m' was collected on a net conveyor belt, a nozzle diameter of 0.21 mm, a pitch between nozzles of 1.2 mm, a water pressure of 404 mm, and a processing speed of 1.8 mm.
All pre-entanglement treatments were carried out at m/min, and then weak point addition and entanglement treatments were carried out alternately. The first weak point process was performed using a roller wrapped with emery cloth with mesh number ≠ 80.

Processing was carried out using a linear pressure of 80 cas/an'' roller pressure, and the nozzle of the water jet punch was the same as in the pre-entangling process, and the water pressure was 65 cas/an2.The residual rate of styrene was 85%. .Next, Metshu number +150
Line pressure 100/
cII+! First, a water jet treatment with a water pressure of 85 V was carried out. At this time, the residual rate of styrene was 68%, and kana cystyrene caused destruction. The fabric was eluted with trichlene (mangle squeezing 6 times), and the eluted nonwoven fabric was coated with resin in a ratio of 74/26, puffed, and then sheared. The nonwoven fabric obtained in this example was extremely densely filled with fibers.

Moreover, it has become a noble item with an ultra-soft touch due to the micro fluff.

On the other hand, as a comparative example, a nonwoven fabric without any weak spots lacked softness, had poor surface smoothness, and was inferior in quality. The results of evaluating the anti-building performance using the ICI method are shown in the table below.

Table 6 As can be seen from these results, 9 products of the present invention are Momoke.

We were able to fabricate a complete set of high-quality non-woven fabrics that were extremely superior in building resistance, and also had flexibility and firmness.

Example 5 Single yarn denier 1.0 denier made of polyamide fiber was taken up by an ejector 9 and then collected by a net conveyor belt. Temporarily set with a basis weight of 60 B/m". Date 40 made of nonwoven fabric and cotton. g 7m” webs were laminated and pre-entangled using a water jet punch (nozzle diameter φ0.14, pitch between nozzles 1° 0-9 water pressure 60
9. Next, the long fiber side is treated twice with a linear pressure of 60 bags/■ using a diamond particle application roller and a rubber roller system with a hardness of 80, and then the above-mentioned entangling device is used again to apply water pressure. The treatment was carried out twice under 65 kg/a-.When the nonwoven fabric was dyed, a fabric with excellent entanglement and a rich natural feel with wavy wrinkles on the cotton side was obtained.The fabric was impregnated with resin. The anti-pilling performance was evaluated using the Seshimezu ICI method.Furthermore, a prototype of this non-woven fabric impregnated with a polymeric elastic material substantially in the middle layer at a ratio of gray fabric weight/resin ratio of 91/9 was fabricated and evaluated. .

The results are shown in Table 4.

Table 4 As shown in Table 4, resin-impregnated metals have an extremely high level that satisfies the practical level.

It can also be seen that even those without the impregnation are at a level that can be used practically.

(Effects of the Invention) According to the above-described nonwoven fabric and nonwoven fabric manufacturing method of the present invention, although the starting material is made of continuous long fibers, it exhibits an effect as if short fiber staples are mixed therein. Moreover, while the basic properties of the fiber materials that make up the non-woven fabric are maintained as much as possible, the occurrence of puckering and pilling is less of a practical problem, and the characteristics of non-woven fabrics such as light weight, heat retention, drapability and repulsion are maintained. It has the characteristics of excellent texture and soft touch. The present invention provides a novel nonwoven fabric for use in high-end clothing, which could not be obtained using conventional techniques, and a method for producing the same.

The effect of imparting weak points in the present invention is as described above, but the secondary effects of imparting weak points will be further described when a composite fiber having a sea-island structure is used.

First, t-1'-jet punching promotes fiber splitting, which makes it easier to elute sea components later.

In conventional elution, the nonwoven fabric structure itself is entangled in fiber bundle units before elution, but in the present invention, it takes on a structure in which ultrafine fiber units are partially entangled after elution, resulting in fiber entanglement. This results in obtaining an excellent nonwoven fabric.

Furthermore, in the present invention, as mentioned above, high entanglement properties are obtained, so even when impregnated with resin, the amount of impregnation is small, and this hardly impairs softness, breathability, etc. This provides a nonwoven fabric suitable for clothing.

[Brief explanation of the drawing]

FIG. 1 is a schematic diagram showing an example of the structure of a nonwoven fabric according to the present invention. FIG. 2 is a schematic diagram showing the structure of a conventional nonwoven fabric obtained by simply subjecting a laminated sheet made of continuous long fibers to high-pressure hydroentangling treatment. FIG. 6 is a schematic diagram showing the structure when the nonwoven fabric of the present invention shown in FIG. 1 is impregnated with an elastic polymer (resin). FIGS. 4A, 4B, and 4C are process schematic diagrams showing one embodiment of a vessel for obtaining a nonwoven fabric according to the present invention. FIG. 5 is a process flowchart of an example of post-processing syllables on the nonwoven fabric of the present invention. 3: Continuous long fiber 6-a: Fiber bundle group 3-d: Weak point 5-e: Fuzz 3-f: Migration fiber at end portion 1: Spinning machine 8: Ejector 10
：Net conveyor belt 17：Water jet punch 23：Roller with rough surface d (bladder, part) Figure 3 I8 Figure 4 B Early Figure 5 Procedural amendment writing method) % formula % 1. Indication of the case 1985 Patent Application No. 185905 2. Name of the invention Non-woven fabric and production of non-woven fabric Method 5: Subject of amendment “Drawings” and “Detailed description of the invention column” 6 of the specification;
Contents of the amendment (1) The intention of the drawing is amended as shown in the attached sheet. (2) In the specification, on page 21, line 8, "Fig. 1" is amended to read "Fig. 2."3> In the specification, page 21, line 12, "Figure 2"
is corrected as "Figure 1".

Claims (13)

[Claims] (1) A nonwoven fabric formed from at least continuous filaments, wherein weak points are distributed and provided on the fiber surface of the continuous filaments disposed on the surface layer of one or both sides of the nonwoven fabric, In a part of the weak point, a single fiber is cut to form a cut end, and a part of the cut fiber end is internally intertwined due to migration inside the nonwoven fabric. A nonwoven fabric characterized in that part exists as fluff on the surface layer of the nonwoven fabric. (2) The nonwoven fabric according to claim (1), characterized in that it is impregnated with or coated with an elastic polymer. (3) Claims (1) or (2), characterized in that the continuous long fibers are polyamide fibers and have a single fiber weave of 0.05 to 5 deniers. non-woven fabric. (4) The continuous long fibers are polyester fibers and have a single fiber fineness of 0.05 to 5 deniers, according to claim (1) or (2). Non-woven fabric. (5) Claims (1) or (2) characterized in that the continuous long fibers are composite synthetic fibers having a sea-island structure or a splittable structure, which is composed of a plurality of components.
) The nonwoven fabric described in item ). (6) Claims (1), (2), and (3) include short fibers as constituent fibers in addition to constituent fibers formed from continuous long fibers. Section, No. (4)
) or (5). (7) Claims (1), (2), (3), ( The nonwoven fabric according to item 4), item (5), or item (6). (8) Claims (1), (2), and (2) have a basis weight of 10 to 300 g/m^2.
The nonwoven fabric according to item 3), item (4), item (5), item (6), or item (7). (9) A method for producing a nonwoven fabric comprising at least a spinning process, a collecting process of spun fibers, and a fiber entangling process of causing fiber entanglement in a fiber sheet formed by the collected fibers, in which an average roughness of 1 After pressing the fiber laminated sheet with a pressure roller system or a pressure plate system having a coarse grain surface of ~5000μ to impart a weak point to the fibers constituting the sheet on one or both sides of the fiber sheet,
A method for producing a nonwoven fabric, which comprises subjecting the sheet to a fiber entangling process. (10) A patent claim characterized in that after the spinning process and the gathering process, a weak point imparting process is performed, and then, as a fiber entangling process, a part of the weak point part is cut off and the fibers are entangled by water jet punching. A method for producing a nonwoven fabric according to item (9). (11) After the spinning process, the collection process, and the fiber entangling process, a weak point imparting process is performed, and then, by performing the entangling process again, a part of the weak part is cut off and the fibers are entangled. A method for producing a nonwoven fabric according to claim (9). (12) Claims (9), (10), or (11) characterized in that after the fiber entangling step, the nonwoven fabric is impregnated with a polymeric elastomer in a wet or dry manner. Method for producing a nonwoven fabric as described in Section 1. (13) After the fiber entanglement step, the nonwoven fabric is subjected to one or more of the following processes: calender press processing, embossing, puff processing, and wrinkle imparting processing as post-processing of the nonwoven fabric. Claim No. 9
), (10), (11), or (12).