KR840000160B1 - Method for the manufacture of a locked material of filament - Google Patents

Abstract

In the manufacture of a padding block of staple fibre material, shch as for upholstery, short fibres of a threedimensional crimped synthetic fibres are pressed into a shaped block and an adhesive is applied. The body is lifted in a general vertical direction and, at the same time, a dielectric heating with high frequency of 1MHz-300GHz is applied to dry the adhesive on the block. The adhesive is distributed evenly and bonds to the fibres.

Description

Manufacturing method of filament lock material

1 is a perspective view of a double stranded filament.

2 is a perspective view of a three-dimensional filament.

3 is a schematic cross-sectional view of an apparatus for producing a filament lock material according to the present invention.

4 is a perspective view of the main part of the apparatus shown in FIG.

Figure 5 is a schematic cross-sectional view showing another embodiment for the manufacture of the filament lock material according to the present invention.

The present invention relates to a method for producing a filament lock material, in particular, to a method for producing a filament lock material in which an adhesive used in a lock material which is a synthetic fiber having a three-dimensional curl and a filament aggregate is uniformly attached.

The present inventors have already found that the filament lock material, which is formed by cutting the filament having three-dimensional curls to a predetermined dimension, is pressed into a predetermined shape while being sponged, and which combines the adhesive points of the filament with an adhesive, has a high rebound elasticity and breathability and excellent cushioning properties. Found. (U.S. Patent No. 4,172,174)

In addition, the filament of the synthetic fiber filament assembly having a three-dimensional curled face, each contact point of the adhesive material is combined with the adhesive material, the filament curl shape of the cushion material is partially oriented and stretched each of the curl filament of various shapes formed It has also been found that the filament lock material formed by forming a portion in a direction to lower the load strength and distributing the fusion portion by the required load strength has a better effect.

These filament-locking materials are compressed by means of a circulating belt and / or roller, rubbing, or the like to form a filament aggregate block having a predetermined multiplicity, and a needle with barbs. Circulating belt traveling in the horizontal direction by spraying adhesive liquid from the top or immersing the filament molded body in the adhesive liquid and then lifting it from the filament molded body raised on the circulating belt running horizontally after needling It is prepared by heating and drying in a phase.

However, when the adhesive is applied to the filament molded body in such a manner, the adhesive adhered to the molded body flows down in the filament molded body until the drying is completed, and in particular, the viscosity decreases due to heating, and thus the flow rate is remarkable, resulting in the obtained filament. In the lock material, the adhesive amount of the adhesive was small at the top and increased toward the bottom, resulting in an extremely non-uniform defect. In addition, the adhesive not only lowers the inside of the molded body but also falls on the circulating belt for transporting the molded body, thereby degrading the belt and degrading workability and causing loss of adhesive.

In addition, in the case of applying the adhesive by the dipping method, when the heating apparatus and the liquid tank are in close proximity, the adhesive liquid in the adhesive liquid tank is also heated by the radiant heat from the heating apparatus, so that the solvent evaporates to change the composition and also the loss of the adhesive.

It is therefore an object of the present invention to provide a method for producing a filament lock material in which an adhesive is uniformly attached. This purpose is to dry the adhesive adhered by dielectric heating while immersing the filament molded body obtained by compression molding synthetic fiber filament single oil having three-dimensional curls into a predetermined shape in the adhesive liquid and raising the molded body in almost vertical direction. It is achieved by the method of the present invention.

Synthetic fibers used in the present invention include polyester, polyamide, polypropylene, etc., but polyester is most preferred, and its thickness is 30-2,000 denier, preferably 50-1,000 denier, and most preferably monofilament. It is a three-dimensional filament that is 100-600 denier. Here, the three-dimensional curl means a wide range of three-dimensional curls such as two-way and three-way curl, but is preferably a three-way three-dimensional curl filament.

For example, by the method and apparatus disclosed in the US Patent No. 4,154,051 by the inventor, the double filament D as shown in FIG. 1 is formed, and then cut into a predetermined dimension and decomposed, as shown in FIG. The same tridirectional three-dimensional filament F is obtained.

The length of the filament after the making is preferably 25 to 200 mm, particularly preferably 60 to 150 mm. The part of the filament F is coiled on the b part in the a part, and the c part is coiled on the d part. However, the e part does not coil over the f part, but coils beneath it. Thus, the filament portions from e to d are two strands or spiral coils. This is commonly referred to as a non-directional spiral, similar to a poor helical telephone cord in which one of the coils is non-oriented relative to the other.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

The filament lock material according to the invention is produced by the apparatus shown in FIGS. 3 to 4.

Synthetic fiber filament F ₁ having a large denier three-dimensional curl shown in FIG. 2 is sent to the sea level machine 16 by a belt conveyor 17 as shown in FIGS. 3 to 4 and filament at exit 44 by wind pressure or the like. It is supplied to supply port 5. The filament F ₁ supplied gradually accumulates in the lower part of the supply port 5 and at the same time reaches the compression section 10 of the molding apparatus 2. The filament aggregate conveyed by the circulating conveyors 6 and 7 has a relationship between the ratio S ₁ / S ₂ (> 1) between the opening area S ₁ of the electrical supply port 5 and the opening area S ₂ of the compression section 10 while passing through the compression section 10. By a predetermined compression ratio (raising density). On the other hand, since the deposition height of the filament F ₁ and the conveying speed of the circulating conveyors 6 and 7 in the supply port 5 affect the density of the compressed filament aggregate F ₂ , the deposition height is detected by the detectors 20a, 20b, and 20c. Control and adjust the feed rate of _{1 and} the feed rate of circulation conveyor 6,7.

The compressed filament aggregate F ₂ is densified by the bar 24 between passing through the densification apparatus 21 as needed, and has a predetermined multiplicity. The filament aggregate block thus compressed usually has a multiplicity of 0.002-0.2 g / cm ³ , preferably 0.05-0.08 g / cm ³ . The press-molded filament aggregate block is conveyed by the conveying apparatuses 28 and 29, immersed in the adhesive liquid 60 in the adhesive liquid tank 30, and then lifted by the other conveying apparatus 31 in a substantially vertical direction. While the aggregate block is pulled up, the flow of the adhesive liquid therefrom is restrained by the surface tension of the liquid itself, while the extra adhesive adhering to the filament molded body F ₃ flows into the molded body. Subsequently, it passes through the high-frequency dielectric heating device 32, and the moisture or solvent of the extremely instantaneous adhesive is evaporated and at the same time hardened to some extent, each contact point of the filaments are combined, and then moved to the conveying devices 42 and 43, and the resulting filament lock material has a predetermined dimension. Is cut into

On the other hand, when the filament molded body is pulled up in the vertical direction, if the molded body may be dispersed, a small amount of adhesive liquid may be spray-dried onto the molded body that runs horizontally before the immersion treatment to perform temporary adhesion.

Typical adhesives include synthetic rubbers such as styrene-butadiene rubber, acrylonitrile-butadiene rubber, chloroprene rubber and urethane rubber, natural rubber, vinyl acetate-based adhesives, cellulose acetate-based adhesives and acrylic adhesives. Used in the form of a solution. The amount of adhesive applied is usually 10-200 g / 100 g filaments, preferably 50-120 g / 100 g filaments, based on the solid content. The filament molded body F ₃ passing through the high-frequency dielectric heating device 32 has a power density sufficient to give the filament molded body by the heat-drying of the adhesive liquid at a high frequency of 1 MHz to 300 GHz, preferably 10 MHz to 30 GHz, that is, 0.1-10 KWh / A power of cm ³ , preferably 0.5-5KWh / cm ³ is applied to heat and remove the moisture and solvent, and the filament interconnection points are combined well.

Therefore, even if the filament molded body F ₃ is raised, it is not cut | disconnected midway by its own weight and adhesive weight.

In some cases, it may be passed through an ordinary drying furnace (not shown), and 10-60 minutes (preferably 15-) at a temperature of 80-200 ° C (preferably 100-150 ° C) by hot air, infrared rays or superheated steam. 40 minutes), then curing is performed and cut into predetermined dimensions by a cutter.

If good resilience is required so that the lock material can be used as a cushioning material, the filament assembly block F ₂ is subjected to a riding device 22 as a ridding device 22 before the adhesive treatment.

Ridling can be done as a predetermined number of pricks with a suitable needle density using a needle having at least one barb at the tip, for example using the apparatus and method disclosed in US Pat. No. 4,172,174.

The needles are determined in diameter and length depending on the purpose, but are generally 1.8-3.6 mm in diameter and 50-2,000 mm in length and typically have 4-12 barbs per needle.

Specifically, for example, the lower surface of the filament aggregate block F ₂ compression molded on the belt conveyor is supported by a flat plate, i.e., a porous plate, a slit plate, a slit conveyor, and the like on the surface facing the plate. The filament assembly block is riddled at an appropriate density by moving up and down the intake openings with or without the slits and the like.

The sediment density varies depending on the intended use of the cushioning material finally obtained and the desired compressive elasticity. The larger the desired compressive elasticity is, the larger the needle spacing becomes, but usually 1-100, preferably 4-50 / 100/100 cm ³ to be.

In addition, the filament may be compressed by a rolling method, a rubbing method, or the like instead of the ridding.

6 is a schematic view showing another embodiment of manufacturing a filament lock material according to the present invention.

Here, the filament supply apparatus 101, the molding apparatus 102, the first adhesive attaching apparatus 103 and the first dielectric heating apparatus 104 are similar to the apparatus shown in FIGS. 3 to 4, and the manufacturing process thereof is also similar. Accordingly, the filament aggregate F ₃ coated with the adhesive agent in the first adhesive attachment device 103 is pulled in a substantially vertical direction in the first dielectric heating apparatus 104 to be dielectrically heated so that the interadhesive points of the filaments in the filament aggregate F ₃ are bonded to each other to perform temporary bonding.

This is sent to the first drying apparatus 153 by the conveying apparatuses 142 and 143, where it is heated to 80-200 ° C. by hot air, infrared rays or the like to complete drying of the adhesive applied to the aggregate F ₄ . The dried aggregate F ₄ is pressed in a steam press apparatus 154 at 100-125 ° C. for 30 seconds-5 minutes, preferably 1-3 minutes, in the presence of steam and then cooled to 20-60 ° C. Pressed filament aggregate F ₅ flows back into the second adhesive attachment device and is applied with a natural rubber adhesive as in the first adhesive attachment device.

The second adhesive-treated filament aggregate F ₆ is pulled in a substantially vertical direction and passes through the second dielectric heating apparatus 156 to remove most of the water or the solvent.

The heated filament aggregate F ₇ is then sent to a second drying apparatus 157 by a conveying device 159-160, such as a circulating conveyor, which is completely dried and then cut into a predetermined dimension by the cutting device 158 to produce a predetermined filament lock material. .

As described above, the filament lock material according to the present invention is attached to the filament molded body obtained by compression molding the opened three-dimensional synthetic fiber filament into a predetermined shape, and then the molded body is pulled in a nearly vertical direction by high frequency. Since the adhesive adhered as dry heating is dried and hardened, the excess adhesive liquid adhered to the molded body in the adhesive liquid tank flows down into the molded body while being pulled almost in the vertical direction. Therefore, only the amount corresponding to the concentration of the adhesive liquid used, the pulling speed of the filament assembly, etc. are uniformly attached to the molded body. Moreover, since the adhesive liquid uniformly attached to the molded body is dielectrically heated by high frequency, it is dried quickly. Therefore, even if the molded body is pulled upward, the amount of the adhesive liquid is small and can be attached only as much as necessary, and there is no fear of being cut or elongated due to the weight of the filament and the weight of the adhesive liquid attached.

Thus, in the present invention, by heating the adhesive filament molded article adhered to the dielectric by high frequency, the solvent in the adhesive liquid, in particular water, is first heated and evaporated without damaging the next synthetic fiber filament, that is, the adhesive medium, that is, rubber, etc. This is heat cured. In addition, since the heating element is a filament assembly, the penetration depth of the high frequency is large, so that the heating is uniformly performed and the loss of the adhesive is reduced.

Therefore, the filament lock material with a uniform adhesive distribution is produced by the method of the present invention.

The present invention will be described in detail with the following examples.

Example 1-7

Twisting 300 denier polyester monofilament to form a total filament of 300,000 denier total filaments of about 60mm three-dimensional filament compression molding, and then needled at a ratio of about 16 bone / 100 cm ² After cutting, 100 parts of natural rubber latex (60% by weight solids) (parts: weight ratio), 1-3 parts of sulfur dispersant, 6-7 parts of zincated agent, dithiocarbamate-based vulcanization accelerator (Noxella-PX) 1-3 Dielectric heating was performed by immersing in a natural rubber adhesive latex consisting of 30 parts by weight and water and pulling it in the vertical direction, irradiating a high frequency of 2540 MHz at a power density of about 1 KWh / cm ³ . The performance conditions and test results of the produced molded articles are shown in Table 1. On the other hand, such dielectric heating was carried out and then post-cured at 120 ° C. for 30 minutes. When the resultant filament lock material was divided into two parts by the length and the density was measured, the values were the same in each of the samples.

Example 8-11

The same procedure as in Example 1-7 was carried out except that styrene-butadiene rubber-based adhesive latex was used. The test conditions and test results are shown in Table 1.

On the other hand, the filament lock material prepared by post-curing at 120 ° C. for 30 minutes after dielectric heating was divided into two parts and the density was measured, respectively. The values were the same in each sample.

[Table 1]

(Note) ※ Weight ratio of adhesive attached to unit weight of filament

[Comparative Example]

The filament molded body as in Example 1 was placed horizontally, sprayed with the same natural rubber adhesive from above, and heated at 130 ° C. for 30 minutes to prepare a filament lock material. The filament lock material (0.05g / cm ^{3 in the} winmill) was divided into two up and down to measure the density of each, the upper side was 0.044g / cm ³ and the lower side was 0.066g / cm ³ . In addition, when the adhesive treatment by the dipping method showed a similar aspect.

Example 12-16

The filament shaped bodies as in Example 1 were immersed in polyurethane emulsions Vondic 1050, Bondic 1030, Bondic 1050, Bondic 1310-B and Hydlan HW-311, and then dielectrically heated at high frequency while being pulled up. Postcure at 100 ° C. for 60 minutes. The filament-locked material was divided into two, and the density was measured. The values were the same in each sample.

Claims (1)

The filament molded body obtained by compression molding a synthetic fiber filament short fiber having three-dimensional curls into a predetermined shape is immersed in an adhesive liquid, and then the adhesive is attached by dielectric heating at a high frequency of 1 MHz to 300 GHz while raising the molded body in a vertical to almost vertical direction. Method for producing a filament lock material characterized in that the drying.

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