JP2005264367A - Pile-forming nonwoven fabric - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a new veloured nonwoven fabric (pile-forming nonwoven fabric) imparting new design effects. <P>SOLUTION: The nonwoven fabric has a veloured design surface (pile design surface) with piles (containing both loops and fuzz) 14 obtained by needle punch processing on one surface of one or a plurality of layers of staple fiber web sheets 12A and 12B. The veloured design surface forms a lattice-like pattern surface with transverse (weft) pile rows 16A and longitudinal (warp) pile rows 16B formed by increasing the pile density into a ridge shape, respectively. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a novel pile-formed nonwoven fabric and a method for producing the same. In particular, the present invention relates to a pile-formed nonwoven fabric suitable as a vehicle floor material and an interior material that require a durability and a soft feeling. In particular, the invention relates to a pile-formed nonwoven fabric suitable for what is called a velor (velvet, velvet) -like nonwoven fabric. Here, a velor-like nonwoven fabric will be described, but the present invention can be applied to a fabric having a pile design surface, not a velor-like design surface.

  Velor (velvet, velvet) -like non-woven fabrics are often used as vehicle floor materials and vehicle interior materials because of their high-class feeling (increase in texture: design), durability, and softness.

  As a velor-like non-woven fabric, there is one in which a pile design surface is formed on at least one surface of a short fiber web sheet by a pile (roller or fluff) by needle punching.

  In addition, with the diversification of design preference, velor-like non-woven fabrics are marketed in which different colored fibers are mixed to make the surface a melange or marbling tone.

  Further, as a design effect, piles are formed in parallel with a width in the width direction at a predetermined pitch, and weft (horizontal) stage velours (also referred to as “tuft strike needles”) are on the market. .

  This weft (horizontal) velor is formed by synchronizing the feed speed (row pitch feed time) of the web sheet (short fibers) and the number of times of needle action (needle machining cycle) during needle punching.

  And with the diversification of the above-mentioned design preferences, there has been a demand for the launch of velor-like non-woven fabric that can provide a novel design effect.

  However, as far as the present inventors know, there is no technology for imparting a novel design effect to a velor-like nonwoven fabric using existing equipment as it is.

Although it does not affect the inventiveness of the present invention, for example, Patent Document 1 exists as a prior art document related to the present invention.
JP-A-6-346356

  In view of the above, an object (object) of the present invention is to provide a novel velor-like nonwoven fabric (pile-formed nonwoven fabric) capable of imparting a novel design effect.

  A further object of the present invention is to provide a method for producing a velor-like non-woven fabric (pile-formed non-woven fabric) that can be produced by using the existing velor-like non-woven fabric (pile-formed non-woven fabric) as it is or almost as it is.

  The velor-like nonwoven fabric (pile-formed nonwoven fabric) of the present invention solves the first problem by the following configuration.

A pile design surface is formed on at least one surface of a short fiber web sheet (hereinafter referred to as “web sheet”) by pile (including both wanna and fluff) by needle punching (hereinafter referred to as “punching”). A pile forming nonwoven fabric comprising:
The pile design surface is a lattice-like pattern surface formed entirely or partially by horizontal (longitudinal) pile rows and vertical (longitudinal) pile rows.

  Thus, the lattice-like pattern surface composed of the horizontal pile rows and the vertical pile rows can impart an unprecedented novel design effect (aesthetics) to the pile-formed nonwoven fabric.

  If the horizontal pile row and the vertical pile row are formed of different color fibers in the above, further increase in the design effect can be expected.

  And the said 2nd subject can be achieved by the following structure.

A method of manufacturing a pile-formed nonwoven fabric by forming a pile design surface with a pile by punching on at least one surface of a web sheet,
A whole-surface implantation board provided with a plurality of linear needle rows orthogonal to the web feed direction at a predetermined pitch, and the needles forming the needle rows are entirely implanted with a shift of 1/2 pitch or less;
A belt-like needle board provided with a plurality of rows of needle rows orthogonal to the web width direction at a predetermined pitch,
A horizontal pile row forming step for forming a horizontal pile row by performing needle processing by synchronizing the feed time of the needle row pitch of the web sheet and the needle machining cycle using the entire surface needle board.
A vertical pile row forming process in which a vertical pile row is formed by using a belt-shaped needle board and shifting the feed time of the needle row pitch from the needle processing cycle (asynchronously).
A grid pattern is formed on the design surface including the steps.

  In the above description, the entire surface needle board is a general-purpose one, and conventional facilities and equipment can be used as they are except for the belt-like needle board.

  In the above configuration, if a strip-shaped needle board is formed by removing needles from the entire surface with a predetermined width / predetermined pitch in the vertical direction, there is no need to prepare a new needle board (needle board). Existing facilities and equipment can be used as they are.

  And in each manufacturing method of the said pile formation nonwoven fabric, after forming one pile row | line | column of one of a vertical pile row | line | column and a horizontal pile row | line by punching on the one surface of the 1st web sheet, A second web sheet formed of fibers different in color from one web sheet can be laminated, and the other pile row can be formed by punching from the second web sheet side.

  The vertical pile row and the horizontal pile row can be formed of different color fibers, and a pile-formed nonwoven fabric having a lattice-shaped design surface with a large design effect can be easily manufactured.

  Hereinafter, one of the best modes (velour-like nonwoven fabric) in the present invention will be described in detail. In the following description, “%” and “part” indicating the blending ratio are mass units unless otherwise specified.

  First, the manufacturing method of the velor-like nonwoven fabric of this embodiment is demonstrated.

  Basically, a velor-like (velvet, velvet) design surface is formed on a pile (roller or fluff) 14 by needle punching (hereinafter referred to as “punching”) on at least one surface of the web sheets 12A and 12B. This is a method for producing a tuned nonwoven fabric.

  As shown in FIG. 1, the velor-like non-woven fabric to be manufactured has a lattice-like pattern surface in which a pile design surface is formed entirely or partially by a horizontal (weft) pile row 16A and a vertical (warp) pile row 16B. It shall be assumed. In the present embodiment, the vertical pile row (longitudinal ridge) 16B and the horizontal pile row (horizontal ridge) 16A are formed of different-colored fibers, with the web sheets 12A and 12B having two layers of different colors. Here, the combination of different colors is any one of dark color / light color, dark color / dark color and light color / light color.

  Moreover, it is desirable from the viewpoint of pile row formation that each pile row (畝) interval S is set to 3 to 15 mm (considering that the needle (punch needle) interval of a general-purpose needle board is 3 to 6 mm. If.)

  Although the fiber (usually short fiber) used for this embodiment changes with application products, either a synthetic fiber or a natural fiber may be sufficient. For example, when it is used as a vehicle interior material, use a polar thermoplastic synthetic fiber excellent in colorability (dyeability) such as polyester (PET) fiber, nylon (PA) fiber, acrylic fiber, rayon fiber, etc. Is desirable. Nonpolar thermoplastic fibers such as polypropylene (PP) fibers can also be used. Of course, in addition to bonding by punching, when adhesive bonding between short fibers is required, the bonding fibers may be mixed at random (5 to 30%).

  The fineness and fiber length of the synthetic fiber vary depending on the applied product and the design pile height, but usually the fineness: about 2 to 30 dtex (desirably 2 to 10 dtex), and the fiber length: 30 to 130 mm (desirably 50 to 100 mm). Select in each range. If the fineness is too small, the productivity of the nonwoven fabric may be reduced.

  The pile height (pile length) h is, for example, 1 to 5 mm. If the pile length is too short or too long, the velour texture is not sufficiently imparted and it is difficult to obtain an appropriate feel (too hard or too soft).

  Then, a full surface needle board 18A and a belt-like needle board 18B having the following configurations are prepared.

Entire Uehari board 18A is straight weft (lateral) needle rows 20 _1, 20 ₂ which is perpendicular to the web feed direction, a plurality columns · · · 20 _n at a predetermined pitch P _A, a needle to form a needle rows The entire needle is implanted with a shift of 1/2 or less of the pitch P _B between the needles. Here, the pitch P _A between the needle rows is, for example, 3 to 8 mm, the pitch P _B between the needles is, for example, 2 to 6 mm, and the deviation amount is random, for example, 0.5 to 2 mm.

In the present embodiment, as shown in FIG. 3, the belt-shaped needle board 18 </ b> B is formed by removing the entire needle board 18 </ b> A with a predetermined width W / predetermined pitch Pd in the vertical direction. That is, (vertical) needle rows 22 ₁ , 22 ₂ ,... 22 _n are formed at a predetermined pitch via the non-needle band 24.

Here, nonwoven fabric (. Including rigidity) required strength and varies by design property, for example, w: 2~6mm, P _d: a 5-12 mm. Even if the needle pulling width w is too large, it only affects the design, and the allowable width is large. On the other hand, if the needle removal width is too small, the needle rows 22 ₁ , 22 ₂ ,... 22 _n are too close to each other, making it difficult to make the vertical pile row into a clear bowl shape.

  The belt-like needle board 18B can be prepared by simply removing the needle from the entire surface needle board 18A, and there is no need to prepare a special needle board. Of course, it is also possible to use a belt-like needle board (not shown) in which needles in a single row or a plurality of rows in the longitudinal direction are needled at a predetermined pitch.

  As the needle (punch needle), a crown needle or a fork needle suitable for pile formation is used.

  And each said needle-planting board 18A, 18B is integrated in a general purpose needle punch machine. The web sheet manufactured using a general-purpose webber is sequentially fed and needle punched, whereby the velor-like nonwoven fabric of this embodiment is subjected to each of the following 1) horizontal pile row forming step and 2) vertical pile row forming step. Produced through a process. Any one of the steps may be performed first.

  In addition, the web sheet is usually a lightly punched product after the cross layer.

  1) A horizontal pile row 16A is formed by performing punching using the entire surface needle-planting board 18A and synchronizing the pitch feed time of the web sheet 12A and the punching cycle (FIG. 4A).

That is, the first punching, with a needle row 20 _1, straight weft pile row next (width) direction one column of the web sheet 12A is formed. In the same line of the lateral pile row in the next punching, by needle rows 20 _2, forms another pile between the pile weft pile rows 16A previously formed. By repeating this, the portion having a high pile density in the horizontal direction is formed in a substantially straight belt shape, and each bowl-shaped horizontal pile row 16A is formed. Here, the horizontal pile row 16A is formed in a straight belt shape (saddle shape) because punching is usually not slightly the same position but slightly shifted even if the pitch feed time and the punching cycle are synchronized. This is because it is punched.

  2) A vertical pile row that forms the vertical pile row 16B by using the belt-like needle board 18B and shifting (asynchronously) the pitch feed time (feed speed) of the web sheets 12A, 12B having the two-layer structure from the needle machining cycle. Formation step (FIG. 4B).

That is, in the first punching process, the vertical needle rows 22 ₁ , 22 ₂ ,... 22 _n punch needles located in the needle row 20 ₁ are spaced in the width direction and staggered pile rows in the vertical direction. Is formed. Next, in the punching process, the vertical needle rows 22 ₁ , 22 ₂ ,... 22 _n located in the needle row 20 ₂ are staggered in the vertical direction in the same manner at positions slightly shifted from the previous pile by the punch needles. A separate pile row is formed. By repeating this, a portion having a high pile density is formed in a straight strip shape in the vertical direction, and a bowl-shaped vertical pile row is formed.

  In the above, the web sheet has a two-layer structure of different colors, but may be a single layer. Further, each of the web sheets 2A and 2B may have a multilayer structure of different colors, and each web sheet may be formed of a random mixture of different color fibers. When it is set as these structures, it becomes possible to provide the bellows-like nonwoven fabric with the design effect from which taste differs.

  In the case of the two-layer configuration, as shown in FIG. 4, after forming one pile row of the horizontal pile row 16A and the vertical pile row 16B on one surface of the first web sheet 12A by needle punching, A second web sheet 12B formed of fibers different from the first web sheet is laminated on the other surface of the sheet 12A, and the other pile row is formed by punching from the second web sheet side 12B.

  3) The laminated web sheet thus formed with the lattice pattern surface is usually subjected to a backing (lining) process by a general-purpose method to obtain a product (pile-formed nonwoven fabric). The backing treatment is performed, for example, by applying an acrylic or SBR emulsion adhesive from the back side and drying by heating (air drying).

  Hereinafter, the present invention will be described in more detail with reference to examples. In the following examples, conversely to the embodiment described above, the horizontal pile row was formed first with a strip-shaped needle board, and the vertical pile row was formed later with a full surface needle board.

<Example 1>
In this example, the following specification was used as the short fiber. Both are commercially available products.

Light short fiber: Light gray (gray) original fiber made of polyester (melting point 230 ° C. or higher) (fineness: 6.6 dtex, cut length: 64 mm)
Dark short fibers: dark original fibers made of high-melting polyester (melting point 230 ° C or higher) (fineness: 6.6 dtex, cut length: 64 mm)
Moreover, the following specification used the whole surface needle board and the strip | belt-shaped needle board, respectively.

Entire needle-planting board: needle pitch 3 mm, row pitch 5 mm, row pitch deviation (random): 0.5-2 mm, fork needle implantation, board size 200 mm (vertical) x 2600 mm (effective width 2200 mm) (horizontal)
Band shaped needle board: A full-surface needle board of the above-mentioned specification, which is formed by needle removal under the conditions of needle removal width w: 3 mm and needle removal pitch P _d : 8.5 mm.

1) A first web sheet having a basis weight of 230 gm ⁻² was prepared using the above-mentioned light-colored short fibers, and then a cocoon ^- shaped vertical pile row was formed using the above-described band-shaped needle board. The vertical pile forming conditions were a feed rate of 2 m · min ⁻¹ and a punching rate of 1000 p · min ⁻¹ .

2) Next, the second web sheet having a basis weight of 230 gm- ² is laminated on the first web sheet using the dark short fibers, and then the entire needle-planting board is formed from the second web sheet side. Used to form a saddle-like horizontal pile row. The formation conditions of the horizontal pile row were a sheet feeding speed: 2 m / min and a punching speed: 400 p · min ⁻¹ . Thereafter, a backing treatment was performed using an SBR adhesive.

  Thus, the manufactured velor-like non-woven fabric of the example has a velor-like design surface in which the ridge-like light-colored horizontal pile row and the dark-colored vertical pile row intersect and are arranged in a lattice shape, and is extremely rich in design. It was.

It is the perspective view (A) which represented the velor-like nonwoven fabric of this invention typically, and a BB arrow arrow background omission sectional drawing. It is a fragmentary top view which shows an example of the whole surface needle board used for this invention. The partial top view which similarly shows an example of a strip shaped needle board. It is a perspective process figure which shows an example of the nonwoven fabric manufacturing method of this invention.

Explanation of symbols

12A (first) web sheet 12B (second) web sheet 14 Pile 16A Horizontal pile row 16B Vertical pile row 18A Full surface needle board 18B Strip needle board 20 ₁ , 20 ₂ ,... 20 _n needle row 22 ₁ , 22 ₂ ... 22 _n needle rows

Claims (5)

A pile design surface is formed on at least one surface of a short fiber web sheet (hereinafter simply referred to as “web sheet”) by pile (including both wanna and fluff) by needle punching (hereinafter simply referred to as “punching”). A pile-formed non-woven fabric,
A pile-formed nonwoven fabric, wherein the pile design surface is a lattice-like pattern surface formed entirely or partially by horizontal (longitudinal) pile rows and longitudinal (longitudinal) pile rows.   The pile-formed nonwoven fabric according to claim 1, wherein the horizontal pile row and the vertical pile row are formed of different color fibers. A method for producing a pile-formed nonwoven fabric by forming a velor-like (velvet, velvet) design surface on a pile (wahna or fluff) by needle punching (hereinafter referred to as “punching”) on at least one surface of a web sheet. ,
A whole-surface implantation board comprising a plurality of linear needle rows orthogonal to the web feed direction at a predetermined pitch, and the needles forming the needle rows are implanted at a pitch of 1/2 pitch or less;
A belt-like needle board provided with a plurality of rows of needle rows parallel to the web feed direction at a predetermined pitch,
A horizontal pile row forming step for forming a horizontal pile row by performing punching by synchronizing the pitch feed time of the web sheet and the needle machining cycle, using the whole surface needle-planting board,
A vertical pile row forming step for forming a vertical pile row by using the belt-shaped needle board and shifting the pitch feed time from the needle processing cycle (asynchronously).
A method for producing a pile-formed non-woven fabric, wherein a pile design surface having a lattice pattern is formed.   4. The method for producing a pile-formed nonwoven fabric according to claim 3, wherein the belt-shaped needle-planting board is formed by punching the whole-surface needle-planting board with a predetermined width / predetermined pitch in the vertical direction. After forming one of the vertical pile row and the horizontal pile row by needle punching on one surface of the first web sheet, fibers different from the first web sheet on the other surface of the first web sheet 5. The method for producing a pile-formed nonwoven fabric according to claim 4, wherein the second web sheet formed in step 1 is laminated and the other pile row group is formed by needle punching from the second web sheet side.

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